description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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FIELD OF THE INVENTION
[0001] The present invention relates to a selective hydrogenation catalyst and the preparation thereof. The catalyst is suitable for the selective hydrogenation of medium or low distillate oil, especially for the first stage selective hydrogenation of pyrolysis gasoline distillate.
BACKGROUND OF THE INVENTION
[0002] Pyrolysis gasoline is a byproduct C 5 -200° C. during the preparation of ethylene, the yield of which is above 50% to 80% of ethylene production capacity, wherein the amount of aromatics is more than 50%, making the pyrolysis gasoline an important source for aromatics. The pyrolysis gasoline also comprises highly unsaturated hydrocarbons such as diolefin, styrene and the like that are convertible to corresponding monoolefin via selective hydrogenation and act as the starting material for extracting aromatics. Recently, ethylene industry has been largely developed and the ethylene production capacity is improved yearly, leading to substantial increasing of the yield of pyrolysis gasoline that is an important byproduct of ethylene. The hydrogenation technique focusing on the hydrogenation catalyst of pyrolysis gasoline is an important branch in the field of hydrogenation and plays a critical role in the post-treatment of preparation of ethylene by steam cracking.
[0003] Currently in industry, the catalyst for the first stage selective hydrogenation of pyrolysis gasoline mainly comprises platinum and palladium catalysts, with the majority being palladium-based catalysts. Palladium-based catalysts are advantageous to have low start temperature, high hydrogenation activity, large feed capacity, long lifetime and so on. However, in part of the feed for hydrogenation apparatus of pyrolysis gasoline, the amount of water and arsenic is in excess, and the distillate is too heavy, and the hydrogenation load is too large, leading to the low stability and short lifetime of the current catalysts in industry process.
[0004] CN 200410061031 reports a palladium-alumina catalyst, and the preparation thereof. The application relates to using Al 2 O 3 calcinated at elevated temperature and precoated with proper amount of alkaline earth metal oxide as a carrier, and impregnating the carrier with 0.15% to 0.24% of palladium to produce the catalyst. CN 1175931C reports supported palladium-alumina catalysts for hydrogen peroxide production by anthraquinone route and the preparation thereof. The application relates to using Al 2 O 3 calcinated at 900 to 1000° C. and precoated with proper amount of rare earth oxide as a carrier, and impregnating the carrier with 0.15% to 0.25% of palladium to produce the catalyst. CN 85100761A discloses a fiber carrier catalyst for selective hydrogenation of diolefin which is the distillate of pyrolysis gasoline, characterized in the use of η-Al 2 O 3 porous fibrous carrier having a specific surface area of 20 to 150 m 2 /g and a pore volume of 0.1 to 0.3 ml/g. The catalyst has a high initial activity, but the pore volume is too small. When the content of colloid, water and arsenic in the feed for pyrolysis gasoline hydrogenation apparatus is in excess, the pores on the catalyst are readily coked and blocked, which influences the hydrogenation stability of the catalyst.
[0005] An excellent selective hydrogenation catalyst should have high hydrogenation activity and good selectivity, and more importantly, it should have good stability. That is, the catalyst should be water-resistant and colloid-resistant, so as to extend the lifetime of the catalyst.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to provide a new selective hydrogenation catalyst especially suitable for pyrolysis gasoline, and the preparation thereof. The present catalyst has good water-resistant and colloid-resistant property, and also has ability against high load and oil change as well as higher hydrogenation stability.
[0007] The selective hydrogenation catalyst according to the present invention, with alumina as carrier, and metal palladium as active component that supported on the surface of the carrier in an egg-shell form, characterized in that based on the total weight of the catalyst, it comprises:
[0008] 0.2 to 0.5 wt % Pd as active component,
[0009] 2 to 8 wt % lanthanum and/or cerium as aids, and
[0010] 2 to 8 wt % alkaline earth metal,
[0011] wherein said catalyst has a shell thickness of 0.07 to 0.15 mm, a specific surface area of 70 to 150 m 2 /g and a pore volume of 0.3 to 0.6 ml/g, and the crystal form of the carrier may be θ form or θ, α mixed form mainly composed of θ form. The catalyst is useful in diolefin selective hydrogenation of medium or low distillate oil, in particular, in the first-stage selective hydrogenation process of pyrolysis gasoline distillate.
[0012] The alumina carrier in the present invention may be prepared by conventional method. For example, during the preparation of carrier, the alumina powder and water are kneaded and extruded, then dried at 40 to 120° C., and calcinated at 300 to 600° C. for 4 to 6 hours.
[0013] The catalyst according to the present invention is prepared by the most common impregnation process, that is, the addition of active component is accomplished by impregnation process. The present invention also provides the best preparation process for the present catalyst: alkaline earth metal, lanthanum and/or cerium are preferably added prior to palladium, especially prior to the formation of alumina in θ form or in θ, α mixed form, leading to better improvement of acidity, activity and stability of the carrier.
[0014] The present invention also provides a specific preparation process for the present catalyst: the soluble salts of alkaline earth metal, lanthanum and/or cerium nitrates are dissolved in water to form a solution, and then the carrier is impregnated with the said solution, dried at 40 to 120° C., and calcinated at 900 to 1100° C. for 4 to 6 hours to obtain alumina carrier in θ form or in θ,α mixed form comprising alkaline earth metal elements, lanthanum and/or cerium. The impregnation loading of metal palladium is the same as the impregnation technique of common shell catalyst, that is, the alumina carrier in θ form or in θ,α mixed form is first pre-impregnated with a liquid miscible with a salt solution containing noble metal palladium, and then the pre-impregnated alumina carrier in θ form or in θ,α mixed form is impregnated with the salt solution containing noble metal palladium. Thereafter the resultant impregnated alumina carrier is washed, dried and calcinated at 350 to 500° C. for 2 to 4 hours to obtain the catalyst product.
[0015] The most common liquid which is used for pre-impregnating the alumina carrier in θ form or in θ,α mixed form and is miscible with a salt solution containing noble metal palladium is deionized water.
[0016] The catalyst according to the present invention may be prepared by another process: soluble salts of alkaline earth metal, lanthanum and/or cerium are added into water to dissolve, and then alumina powder is added into the solution, kneaded followed by extrusion, dried at 40 to 120° C., and calcinate at 900 to 1100° C. for 4 to 6 hours. Then the carrier is impregnated with palladium. The impregnation of palladium is accomplished using general impregnation methods, as described above.
[0017] It is not limited that the catalyst according to the present invention is obtained by the preparation process described herein. The catalyst product according to the present invention may be used after reduction with hydrogen in the reactor.
[0018] Pd as active component in the catalyst is in the amount of 0.2-0.5 wt %, preferably, 0.2-0.4 wt %. Too low amount of Pd will lead to the hydrogenation activity of catalyst too low. Contrarily, too high amount of Pd will lead to the initial activity of catalyst too high.
[0019] The addition of lanthanum and/or cerium into the catalyst according to the present invention may inhibit the growth of Al 2 O 3 crystalline during the calcination at elevated temperature, increase the dispersion of Pd, increase the surface basicity of the carrier, and improve the hydrogenation activity and stability of the catalyst. The amount of lanthanum and/or cerium in the catalyst is 2 to 8 wt %, preferably 2 to 6 wt %. The effect of lanthanum and/or cerium is not significant when their content is too low, and the activity of the catalyst would be influenced when their content is too high. The rare earth metal may be one or two of lanthanum and cerium, preferably is cerium.
[0020] In one aspect, after the addition of alkaline earth metal into the catalyst according to the present invention, the surface acidity of the catalyst may be regulated by calcination at elevated temperature, and the colloid-resistance property of the catalyst during the hydrogenation may be improved. In another aspect, the incorporated alkaline earth metal together with lanthanum and/or cerium may have a synergy effect with alumina, prevent the loss of the specific surface area of the alumina carrier, and improve the thermal stability and chemical stability of the alumina carrier. The content of the alkaline earth metal in the catalyst is 2 to 8 wt %, preferably 3 to 6 wt %. The effect of the alkaline earth metal is not significant when its content is too low, and the activity of the catalyst would be influenced when its content is too high. The alkaline earth metal may be one or more of Mg, Ba, Sr and the like, preferably is Mg.
[0021] The catalyst according to the present invention may comprise other components such as one or more of Ag, K and the like, in addition to the required components, the content of the other components being generally 0 to 0.2 wt %, preferably 0.4 to 1.7 wt %.
[0022] The carrier of the catalyst according to the present invention is alumina in θ form or in θ,α mixed form characterized in proper specific surface area and pore distribution, good activity and stability, which is better than alumina carriers in other crystallization form. When the alumina in θ,α mixed form mainly composed of θ form is used, it is preferable to have less than 15% of α form and 80 to 120 m 2 /g of specific surface area.
[0023] The Al 2 O 3 powder used in the catalyst according to the present invention may be commercial available alumina powder, such as those obtained by nitric acid method or carbon dioxide method. The shape of the alumina carrier is not particularly limited in the present invention, it may be in sphere or extruded strip form.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Source of starting materials and analysis method:
[0025] Alumina powder: available from Shandong Taiguang Company Limited
[0026] Alumina carrier: extruded strip
Example 1
[0027] 180 ml water was added to 300 g alumina powder, which was then kneaded and extruded, dried in air at 120° C. and calcinated at 560° C. for 4 hours. Then 76.5 g magnesium nitrate and 28.7 g lanthanum nitrate were dissolved in water and impregnated onto the carrier, dried in air at 120° C. and calcinated at 1020° C. for 4 hours to produce Al 2 O 3 carrier.
[0028] 5.25 g palladium chloride powder having a palladium content of not less than 59% was weighed and added into 200 ml water, followed by the addition of hydrochloric acid. After dissolution, the solution was diluted to 1.2 L with deionized water. The pH value was adjusted depending on the thickness of the shell needed. 1.0 kg carrier product was weighed, and deionized water was added to impregnate the carrier. The water was filtered off. The prepared palladium chloride solution was poured onto the carrier, and the mixture was heated to boil under stirring. After 20 minutes, the solution was filtered, dried at 120° C. in air and calcinated at 480° C. for 4 hours, thereby obtaining the catalyst.
Comparative Example 1
[0029] 180 ml water was added to 300 g alumina powder, which was then kneaded and extruded, dried at 120° C. in air and calcinated at 540° C. for 4 hours. Then 76.5 g magnesium nitrate was dissolved in water and impregnated onto the carrier, dried at 120° C. in air and calcinated at 1020° C. for 4 hours to produce Al 2 O 3 carrier.
[0030] The preparation of the catalyst is similar to that of Example 1.
Comparative Example 2
[0031] 180 ml water was added to 300 g alumina powder, which was then kneaded and extruded, dried at 120° C. in air and calcinated at 540° C. for 4 hours. Then 28.7 g lanthanum nitrate was dissolved in water and impregnated onto the carrier, dried at 120° C. in air and calcinated at 1020° C. for 4 hours to produce Al 2 O 3 carrier.
[0032] The preparation of the catalyst is similar to that of Example 1.
Comparative Example 3
[0033] 180 ml water was added to 300 g alumina powder, which was then kneaded and extruded, dried at 120° C. in air and calcinated at 540° C. for 4 hours. Then 45.2 g cerium nitrate was dissolved in water and impregnated onto the carrier, dried at 120° C. in air and calcinated at 1020° C. for 4 hours to produce Al 2 O 3 carrier.
[0034] The preparation of the catalyst is similar to that of Example 1.
Example 2
[0035] 180 ml water was added to 300 g alumina powder, which was then kneaded and extruded, dried at 120° C. in air and calcinated at 540° C. for 4 hours. Then 100.7 g magnesium nitrate and 34.5 g cerium nitrate were dissolved in water and impregnated onto the carrier, dried at 120° C. in air and calcinated at 1030° C. for 4 hours to produce Al 2 O 3 carrier in θ form.
[0036] 5.6 g palladium chloride powder having a palladium content of not less than 59% was weighed and added into 200 ml water, followed by the addition of hydrochloric acid. After dissolution, the solution was diluted to 1.2 L with deionized water. The pH value was adjusted depending on the thickness of the shell needed. 1.0 kg carrier product was weighed, and deionized water was added to impregnate the carrier. The water was filtered off. The prepared palladium chloride solution was poured onto the carrier, and the mixture was heated to boil under stirring. After 20 minutes, the solution was filtered, dried at 120° C. in air and calcinated at 450° C. for 4 hours to produce the catalyst.
Comparative Example 4
[0037] 180 ml water was added to 300 g alumina powder, which was then kneaded and extruded, dried at 120° C. in air and calcinated at 560° C. for 4 hours. Then 69.7 g magnesium nitrate and 34.5 g cerium nitrate were dissolved in water and impregnated onto the carrier, dried at 120° C. in air and calcinated at 850° C. for 4 hours to produce Al 2 O 3 carrier in δ form.
[0038] The preparation of the catalyst is similar to that of Example 2.
Example 3
[0039] 102.5 g magnesium nitrate, 20.1 g cerium nitrate and 19.4 g lanthanum nitrate were dissolved in water and added into 300 g alumina powder. The mixture was kneaded and extruded, dried at 120° C. in air and calcinated at 1050° C. for 4 hours to produce Al 2 O 3 carrier in θ form.
[0040] 5.07 g palladium chloride powder having a palladium content of not less than 59% was weighed and added into 200 ml water, followed by the addition of hydrochloric acid. After dissolution, the solution was diluted to 1.1 L with deionized water. The pH value was adjusted depending on the thickness of the shell needed. 1.0 kg carrier product was weighed, and deionized water was added to impregnate the carrier. The water was filtered off. The prepared palladium chloride solution was poured onto the carrier, and the mixture was heated to boil under stirring. After 20 minutes, the solution was filtered, dried at 120° C. in air and calcinated at 460° C. for 4 hours to produce the catalyst.
Example 4
[0041] Selective hydrogenation catalyst carrier for medium or low distillate supplied by Shandong Taiguang Company Limited is used and calcinated at 500° C. for 4 hours. Then 162.9 g magnesium nitrate, 38.6 g cerium nitrate and 1.8 g silver nitrate were dissolved in water and impregnated onto the carrier, dried at 120° C. in air and calcinated at 1050° C. for 4 hours to produce Al 2 O 3 carrier in θ form.
[0042] 5.95 g palladium chloride powder having a palladium content of not less than 59% was weighed and added into 200 ml water, followed by the addition of hydrochloric acid. After dissolution, the solution was diluted to 1.2 L with deionized water. The pH value was adjusted depending on the thickness of the shell needed. 1.0 kg carrier product was weighed, and deionized water was added to impregnate the carrier. The water was filtered off. The prepared palladium chloride solution was poured onto the carrier, and the mixture was heated to boil under stirring. After 20 minutes, the solution was filtered, dried at 120° C. in air and calcinated at 460° C. for 4 hours to produce the catalyst.
Example 5
[0043] 180 ml water was added to 300 g alumina powder, which was then kneaded and extruded, dried at 120° C. in air and calcinated at 560° C. for 4 hours. Then 13.1 g barium nitrate, 9.1 g strontium nitrate and 34.5 g cerium nitrate were dissolved in water and impregnated onto the carrier, dried at 120° C. in air and calcinated at 1000° C. for 4 hours to produce Al 2 O 3 carrier in θ form.
[0044] 4.72 g palladium chloride powder having a palladium content of not less than 59% was weighed and added into 200 ml water, followed by the addition of hydrochloric acid. After dissolution, the solution was diluted to 580 ml with deionized water. The pH value was adjusted depending on the thickness of the shell needed. 1.0 kg carrier product was weighed, and deionized water was added to impregnate the carrier. The water was filtered off. The prepared palladium chloride solution was poured onto the carrier, and the mixture was heated to boil under stirring. After 20 minutes, the solution was filtered, dried at 120° C. in air and calcinated at 470° C. for 4 hours to produce the catalyst.
Example 6
[0045] 180 ml water was added to 300 g alumina powder, which was then kneaded and extruded, dried at 120° C. in air and calcinated at 560° C. for 4 hours. Then 30.5 g strontium nitrate and 45.52 g lanthanum nitrate were dissolved in water and impregnated onto the carrier, dried at 120° C. in air and calcinated at 1050° C. for 4 hours to produce Al 2 O 3 carrier in θ,α mixed form.
[0046] 5.78 g palladium chloride powder having a palladium content of not less than 59% was weighed and added into 200 ml water, followed by the addition of hydrochloric acid. After dissolution, the solution was diluted to 590 ml with deionized water. The pH value was adjusted depending on the thickness of the shell needed. 1.0 kg carrier product was weighed, impregnated with the prepared palladium chloride solution, dried at 120° C. in air and calcinated at 450° C. for 4 hours to produce the catalyst.
Comparative Example 5
[0047] 180 ml water was added to 300 g alumina powder, which was then kneaded and extruded, dried at 120° C. in air and calcinated at 560° C. for 4 hours. Then 7.6 g potassium nitrate and 2.1 g silver nitrate were dissolved in water and impregnated onto the carrier, dried at 120° C. in air and calcinated at 980° C. for 4 hours to produce Al 2 O 3 carrier in θ form.
[0048] The preparation of the catalyst is similar to that of Example 6.
INDUSTRY APPLICABILITY
[0049] Oil for evaluation: available from Lanzhou Chemical Company
[0000]
TABLE 1
Properties of the hydrogenation feed oil (C 5 -C 9 )
Iodine
Diolefin ×
Sulfur
Colloid ×
Water
Arsenic
value × 10 −2
10 −2
Distillation
content
10 −2
content
Density
content
Color
(g/g)
(g/g)
range (° C.)
(ppm)
(mg/ml)
(ppm)
(g/ml)
(ppb)
Yellow
171.3
33.7
45-205
96
13.0
650
0.815
36
[0050] Apparatus for evaluation: 100 ml adiabatic bed hydrogenation apparatus
[0051] Analysis Method
[0052] specific surface area: BET method
[0053] Pore volume: BET method
[0054] Diolefin: Diolefin value of oil is determined by malic anhydride method and is expressed as g iodine/100 g oil
[0055] Iodine value: Iodine value of oil is determined by iodine chloride method and is expressed as g iodine/100 g oil
[0056] The physical properties of the catalysts of examples and comparative examples are shown in Table 2.
[0000]
TABLE 2
Physical properties of the catalyst samples of Examples 1-6 and Comparative examples 1-5
Comp.
Comp.
Comp.
Comp.
Comp.
example
example
example
example
example
Ex. 1
1
2
3
Ex. 2
4
Ex. 3
Ex. 4
Ex. 5
Ex. 6
5
Crystallization
θ
θ
θ, α
θ
θ
δ
θ
θ
θ
θ, α
θ
form of the
mixed
mixed
carrier
form
form
α < 5%
α < 10%
Dimension
Φ2.8-3.0 × 3-8 trifolium-shaped
Specific
93
90
92
95
96
103
105
94
102
91
104
surface area
(m 2 /g)
Pore volume
0.47
0.46
0.47
0.47
0.46
0.49
0.45
0.47
0.44
0.48
0.46
(ml/g)
Pd content
0.30
0.30
0.30
0.30
0.32
0.32
0.29
0.34
0.27
0.33
0.30
(%)
Shell
0.08
0.10
0.09
0.09
0.08
0.15
0.07
0.11
0.07
0.10
0.13
thickness
(mm)
K content (%)
/
/
/
/
/
/
/
/
/
/
1.3
Mg content
3.1
3.2
/
/
3.9
2.7
3.9
6.1
/
/
/
(%)
Ba content
/
/
/
/
/
/
/
/
2.9
/
/
(%)
Sr content (%)
/
/
/
/
/
/
/
/
1.5
5.1
/
La content
3.9
/
4.2
/
/
/
2.5
/
/
5.9
/
(%)
Ce content
/
/
6.4
4.6
4.6
2.6
4.9
4.7
/
/
(%)
Ag content
/
/
/
/
/
/
/
0.45
/
/
0.6
(%)
[0057] C 5 -C 9 distillate of pyrolysis oil is used as the feed, and the property thereof is shown in Table 1. The catalysts of Example 1-6 and Comparative example 1-5 were evaluated. The evaluation was carried out on 100 ml adiabatic bed hydrogenation apparatus. The catalysts were first reduced under hydrogen at 110° C. for 10 hours. After cooling to 40° C., the feed oil was fed. The reaction condition: reaction pressure 2.8 MPa, inlet temperature 40° C., fresh feed oil rate 3.5 h −1 , volume ratio of hydrogen to oil 200:1 (based on fresh oil). The evaluation was carried out for 200 hours. And the iodine value and diolefin of the products were analyzed every 6 hours. The average data of the iodine value and diolefin of the product for each catalyst during the 200-hour evaluation are shown in Table 3.
[0000]
TABLE 3
The average data of 200-hour evaluation for catalysts of examples and comparative examples
Comp.
Comp.
Comp.
Comp.
Comp.
Ex.
example
example
example
Ex.
example
Ex.
Ex.
Ex.
Ex.
example
1
1
2
3
2
4
3
4
5
6
5
Product
Diolefin
1.01
1.18
1.22
1.82
1.02
0.98
1.05
2.01
1.34
1.15
1.87
oil
value g
iodine/100 g
oil
Iodine
42.6
44.2
45.3
45.3
41.5
41.2
43.7
42.8
44.8
45.1
45.6
value g
iodine/100 g
oil
After reacting for 200
7.5
7.8
9.8
9.9
7.2
12.6
7.4
8.8
7.5
7.9
10.1
hours, the colloid
content on the
catalyst %
[0058] The catalyst sample of Example 2 was performed 1000 hour long period evaluation. The evaluation was carried out on 100 ml adiabatic bed hydrogenation apparatus. The catalysts were first reduced under hydrogen at 106° C. for 10 hours. After cooling to 45° C., the feed oil was fed. The reaction condition: reaction pressure 2.8 MPa, inlet temperature ˜45° C., fresh feed oil rate 3.5 h −1 , volume ratio of hydrogen to oil 200:1 (based on fresh oil). The property of the hydrogenation feed oil (C 5 -C 9 ) is shown in Table 1. The iodine value and diolefin of the product were evaluated for each 12 hours. The average analysis data in each 200 hours were obtained and the evaluation results are shown in Table 4. During the 1000-hour operation time of feeding the feed, the iodine value and diolefin value of the hydrogenation product maintained at low level, which indicates that the catalyst of Example 2 is suitable for the relatively worse hydrogenation feed having a diolefin value of 33.7 g iodine/100 g oil, iodine value of 171 g iodine/100 g oil, water amount of 650 ppm, arsenic amount of 36 ppb and colloid amount of 13 mg/100 ml. The catalyst has an ability against impurities such as colloid, water, arsenic and the like, and a good stability as well as good hydrogenation activity.
[0000]
TABLE 4
1000-hour evaluation data for catalysts
of Example 2 and Comparative Example 4
Hydrogenation product index
Catalyst of Example 2
Catalyst of Comparative example 4
Cumulative
Diolefin
Iodine
Diolefin
Iodine
operation
10 −2
value × 10 −2
10 −2
value × 10 −2
time (h)
(g/g)
(g/g)
(g/g)
(g/g)
200
0.8
42.5
0.8
40.9
400
1.0
44.8
1.1
45.8
600
1.2
48.6
1.8
47.3
800
1.4
50.2
2.5
48.1
1000
1.6
52.7
2.8
50.2
[0059] The hydrogenation catalyst according to the present invention has good hydrogenation performance, especially under the condition that the hydrogenation feed contains a small quantity of water and colloid, the catalyst still has good hydrogenation activity and stability. The catalyst is suitable for the selective hydrogenation of medium or low distillate oil, especially for the first stage selective hydrogenation of pyrolysis gasoline. | A selective hydrogenation catalyst, with alumina as carrier, and palladium as active component that distributed on the surface of the carrier in an egg-shell form, characterized in that: provided that the catalyst is weighed 100%, it comprises 0.2-0.5 wt % active component Pd, 2-8 wt % aids lanthanum and/or cerium, and 2-8 wt % alkaline earth metal. The specific surface area of the catalyst is 70-150 m2/g, the pore volume is 0.3-0.6 ml/g, and the crystal form of the carrier may be θ form or θ, α mixed form mainly composed of θ form. The catalyst is suitable for the selective hydrogenation of medium or low distillate oil, especially for the first stage selective hydrogenation of pyrolysis gasoline. The catalyst has good hydrogenation performance, and can keep good hydrogenation activity and stability especially under the condition that the feed contains a small quantity of water, and the content of colloid, arsenic, and diolefin is higher. | 2 |
TECHNICAL FIELD OF THE INVENTION
This invention relates to improved designs of work-coils used in electromagnetic forming. More specifically, the invention relates to coil designs wherein the current is split one or more times, or reversed in coil direction, thereby creating work-coils that are less prone to mechanical failure and create electromagnetic pressure distributions that are better suited for forming sheet metal. This invention has a variety of applications including forming large conductive sheet metal, such as that which may be used in automobile manufacture.
BACKGROUND OF THE INVENTION
Electromagnetic forming is a method of forming sheet metal or thin walled tubes that is based on placing a work-coil in close proximity to the metal to be formed and running a brief, high intensity current pulse through the coil. If the metal to be formed is sufficiently conductive the change in magnetic field produced by the coil will produce eddy currents in the work piece. These currents also have associated with them a magnetic field that is repulsive to that of the coil. This natural electromagnetic repulsion is capable of producing very large pressures that can accelerate the work piece at high velocities (typically 10-200 meters/second). This acceleration is produced without making physical contact to the work piece. The electrical current pulse is usually generated by the discharge of a capacitor bank. This field has been developed by many individuals and companies and is widely used for the forming and assembly of tubular and sheet work pieces. Several excellent reviews of the field are available, including Moon, F. C., Magneto-Solid Mechanics, ASTME, High Velocity Forming of Metals, revised edition (1968); Plum, M. M., Electromagnetic Forming, Metals Handbook, Maxwell Laboratories, Inc., pp. 644-653; and Belyy, I. V., Fertik, S. M. and Khimenko, L. T., Electromagnetic Metal Forming Handbook, Khar'kov State University, Khar'kov, USSR (1977) (Translation from Russian by M. M. Altoynova 1996), all of which are hereby incorporated herein by reference. Examples of prior art patents involving electromagnetic forming include U.S. Pat. No. 4,947,667 to Gunkel et al., U.S. Pat. No. 4,531,393 to Weir aet al., U.S. Pat. No. 5,353,617 to Cherian et al., U.S. Pat. No. 3,998,081 to Hansen et al., U.S. Pat. No. 5,331,832 to Cherian et al., U.S. Pat. No. 5,457,977 to Wilson, U.S. Pat. No. 4,619,127 to Sano et al., U.S. Pat. No. 4,473,862 to Hill, U.S. Pat. No. 4,151,640 to McDermott et al. and U.S. Pat. No. 5,016,457 to Richardson et al., all of which are hereby incorporated herein by reference.
Electromagnetic forming can be carried out on a wide range of materials and geometries within some fundamental constraints. First, the material must be sufficiently electrically conductive to exclude the electromagnetic field of the workcoil. The physics of this interaction have been well characterized.
Another key constraint is coil strength. Generally equal and opposing external forces will exist on the work-coil and work piece. In addition, the current that runs through the coil can induce large internal transient forces that are separate with the repulsion from the work piece. These can also lead to coil failure. In the development of electromagnetic forming coils the issue of robustness has generally been addressed by wrapping what is often called a `field-shaper` with many windings of coil from the power source. The main mechanical forces are transmitted through the massive field shaper which accepts the pressure from the work piece acceleration. This concept is used to make the `wafer coils` which are generally acknowledged to produce the highest pressures from production coils designed for thousands to hundreds of thousands of operations without a rebuilding procedure. In many other designs the deformation of the work coil or fracture of insulation and arcing usually causes the coils to fail after a number of operations. That number is set roughly by the construction of the coil and the average energy of the operations performed.
To date, all of the coils that have been reported to have been used for electromagnetic forming typically have had roughly cylindrical symmetry, such as shown in schematic form in FIG. 1. FIG. 1 shows a standard unidirectional coil through which the current pulse is passed from the positive pole 11 to the negative pole 12. The coil 10 is supplied with a current pulse from a power source which typically is a simple bank of capacitors with appropriate charging circuitry and discharge bus work, as is well-known in the art (not shown).
The most common such coils are those based on simple solinoidal windings used for the expansion or compression of tubes. Less common, but still abundantly mentioned in the literature, are `pancake coils` that use a flat spiral geometry. Such coils are commonly used to form bulge-like features in flat metal sheets. These coils do suffer from limited strength and as a result of this a number of specialized coils using massive field shapers have been developed and are taught in the art. Both field shaper geometry and the standard flat spiral geometry are limited in that the magnetic pressure drops to zero at the center of the actuator.
As shown in FIG. 1A, a cross-section along line 1A--1A of FIG. 1, the magnetic field produced in the work-force area has a area of weakness in the center of the work-force area. Careful analyses have been performed on the flat spiral coil (G. Fenton, N. Takatsu, M. Kato, K. Sato and T. Tobe, JSME International Journal, 31, 142 (1988)) which show that the magnetic pressure is actually a maximum at the outer edge of the coil. This is a distinct disadvantage in most practical cases as the maximum displacement and force are generally desired at the center of work-force area adjacent the coil.
Secondly, such a geometry is disadvantageous because all of these coils are typically based on circular symmetry. This makes it very difficult to envision ways to form many shapes such as those including elongated features or those with complicated shapes which may be extended from the plane of the work piece.
Accordingly, it is desirable to be able to produce electromagnetic actuators that can provide maximum force and displacement and force at the center of the actuator coil, and which can be produced in robust arrangements that resist and maximize mechanical stress in the forming operation. It is also desirable to provide an actuator that produces a relatively uninterrupted magnetic field over the region where forming is desired.
It is also advantageous to be able to produce electromagnetic actuators that can be conveniently applied to the formation of elongated metal pieces, as well as the formation of other metal shapes of a wide variety of geometries.
It is also an object of the present invention to eliminate some of the drawbacks in the prior art by allowing one to tailor the spatial distribution of pressure more effectively and by permitting the building of stronger, more robust coils (i.e., typically of thicker conduit cross-section) to balance internal magnetic forces.
The present invention also has as its goal to allow one to produce electromagnetic actuators that provide more uniform force distribution and/or force distribution that are tailored to suit the geometry of the component being formed.
The present invention also allows such actuators to be more easily incorporated into, and used with, molds, forming dies and tool bodies.
In view of the following disclosure, other advantages of the invention, and the solution to other problems using the invention, may become apparent to one of ordinary skill in the art.
SUMMARY OF THE INVENTION
One of the key features of the present invention is the use of a electrical conduit arrangement that allows for the tailoring of the magnetic field so as to provide for the greater amount of force to be brought to bear generally in the center of the work force area. The present invention provides for such capability by providing for a single central current conduit for forming longitudinally extending work pieces. The present invention also provides for the splitting, and/or direction (or curvature) reversal, of the electrical current pulse one or more times to likewise tailor the magnetic field of the work-coil or forming actuator.
While the prior art was based on the use of concentric, unidirectional coils, the present invention makes possible the production of electromagnetic actuators that may be tailored to a wide variety of geometries, including elongated shapes. The principal benefit of such pulse splitting (and/or direction reversal) is that the actuator may produce a work-force distribution in the work-force area (that area served by the actuator) that concentrated or otherwise arranged about the center (for actuators of relatively equilateral geometry such as multi-coil or polygonal geometries) or about its longitudinal axis for elongate actuators or about some other feature direction (where maximum force is desired in a particular region). The actuators of the present invention do not have the disadvantages associated with prior art actuators such as centrally discontinuous work-force distributions, such as those brought about by concentric, unidirectional coils of the prior art.
Generally speaking, the magnetic field produced by actuators of the present invention is relatively stronger in the relative center portion of the work-force area than in the relative side portions of the work-force area. In this regard, reference to "relative center" and "relative sides" is intended in a general sense, intending to refer to the magnetic field produced by actuators of the present invention, whether the actuator has one or several degrees of symmetry. Also, one may wish to maximize field strength at the interior of the coil but not at the center. The central current conduit and the at least two return current conduits may form a substantially symmetrical or asymmetrical work-force area, although the size and shape of the work-force area may be determined according to the desires of the operator and the requirements of the work piece to be formed, as shown by the examples provided herein.
In accordance with the present invention, there is disclosed several variations of the present invention, methods of its use, and metal pieces formed using the inventive apparatus and method in their many embodiments.
One of the most fundamental embodiments of the present invention includes an apparatus for forming a metal work piece, said apparatus comprising:
(a) an electromagnetic actuator comprising a central current conduit, said central current conduit adapted to conduct a current pulse, and extending longitudinally so as to conduct a current pulse along a linear or arcuate path, and a return current conduit adapted to conduct said current pulse to an electrical ground; and
(b) a current power source adapted to produce a current pulse through said electromagnetic actuator so as to produce a magnetic field.
The central conduit may be in the form of a mold body defining a mold shape against which the metal work piece is deformed.
The current pulse may be guided along a linear or arcuate path in order to conform to the desired final or intermediate shape of the metal work piece to be form. Typically, if an arcuate path is used, it will be of an arc of 180 degrees or less, although greater arcs less than 360 degrees may be used.
The apparatus may additionally include a work piece holder adapted to hold the metal work piece alongside the central current conduit and in such proximity to the central current conduit such that the magnetic field causes the deformation of said metal work piece. The work piece holder may also comprise a mold body defining a mold shape against which the metal work piece is deformed. The work piece holder can be a mold body comprising a first half adapted to fit along a first side of the actuator so as to hold the metal work piece between the actuator and the first half, and a second half adapted to fit along a second side of the actuator opposite the first side.
The present invention also includes a method of forming a metal work piece using the actuator of the present invention as summarized herein. The method generally comprises steps:
(a) obtaining a metal work piece having an original shape;
(b) disposing the metal work piece in the work force area of an electronic actuator, said actuator comprising:
(i) an electromagnetic actuator comprising a central current conduit, the central current conduit adapted to conduct a current pulse, and extending longitudinally so as to conduct a current pulse along a linear or arcuate path, and a return current conduit adapted to conduct the current pulse to an electrical ground; and
(ii) a current power source adapted to produce a current pulse through the electromagnetic actuator so as to produce a magnetic field; and
(c) causing a current pulse to pass through the actuator, the current being sufficient to produce a magnetic field of sufficient strength to deform the metal work piece from the original shape to another shape.
The present invention also includes a metal work piece formed from an original shape into another shape in accordance with the method of the present invention as summarized herein.
The apparatus of another embodiment of the present invention includes an apparatus for forming a metal work piece which features a split current conduit, and which comprises: (a) an electromagnetic actuator comprising a central current conduit, the central current conduit adapted to conduct a current pulse, and adapted to divide the current pulse so as to provide a divided current pulse, and a return current conduit adapted to conduct the divided current pulse to an electrical ground; and (b) a current power source adapted to produce a current pulse through the electromagnetic actuator so as to produce a magnetic field.
The cross-section of the current conduit used in the present invention may be of any geometrical shape, as exemplified in the accompanying figures and description. The invention is thus not limited to any particular geometrical shape of the cross-section, and may be selected from any desired shape such as flat, round, square or other polygonal or irregular shapes. Also, the return path may be fabricated from a monolithic section (such as a die) that encompasses both sides of the conduit.
The apparatus of the present invention may also have a central current conduit and at least two return current conduits which have at least one of the following characteristics: (1) the central current conduit and the at least two return current conduits are substantially co-planar, (2) the at least two return current conduits form substantially planar coils in which each may have multiple windings, (3) the central current conduit and the at least two return current conduits are linear and substantially co-planar, (4) the central current conduit and the at least two return current conduits are linear, substantially co-planar and parallel, and (5) the central current conduit and the at least two return current conduits are curvilinear and substantially parallel. The central current conduit and the at least two return current conduits may form an elongate work-force area having a longitudinal axis extending substantially parallel to the central current conduit.
As one alternative, the central current conduit may also be adapted to divide the current pulse by being in the form of a mold body defining a mold shape against which the metal work piece is deformed. Such mold body may be in the form of mated male and female mold body portions.
The actuators of the present invention may have the central current conduit and the two or more return current conduits that form either a substantially symmetrical work-force area or an asymmetrical work-force area.
The power source may be selected from any power source capable of providing a current pulse of sufficient strength and duration to induce a work-force appropriate to form the work piece into the desired shape. Such parameters are well known to those skilled in the art, and capacitor banks used in such actuators are well-known in the art. Examples include current pulses in the range of 5KA-100KA amps for times in the range of 1-100 milliseconds. For instance, the current power source may be in the form of a charged capacitor bank.
The apparatus of the present invention may also have a work piece holder to hold the work piece during forming. Such a work piece holder may be in the form of a female mold body or a male mold body defining a mold shape against which, or into which, the metal work piece is deformed. The apparatus may also have a work piece holder which comprises a first half adapted to fit along a third side of the actuator (where the return conduits are on respective first and second sides) so as to hold the metal work piece between the actuator and the first half, and a second half adapted to fit along a fourth side of the actuator opposite the third side.
Any of the actuators of the present invention described herein may also be used with an apparatus for forming a metal work piece into a target shape, the apparatus comprising: (a) a male mold portion having a mold side and a back side; (b) a female mold portion having a mold side and a back side; the mold side of the male mold portion and the mold side of the female mold portion adapted to mate incompletely so as to deform a work piece disposed therebetween so as to form the work piece into a precursor shape, leaving at least one precursor area of the work piece to be finally formed; (c) at least one electromagnetic actuator disposed on one of the mold portions and opposite the at least one precursor area; and (d) a current power source adapted to produce a current pulse through the at least one electromagnetic actuator, so as to produce a magnetic field in the at least one precursor area so as to deform the at least one precursor area into a target shape.
Any of the actuators of the present invention described herein may be used with the methods of the present invention.
The present invention includes a method of forming a metal work piece comprising the steps of: (a) obtaining a metal work piece, the work piece having an original shape; (b) disposing the metal work piece in the work force area of an electronic actuator, the actuator comprising:
(i) an electromagnetic actuator comprising a central current conduit, the central current conduit adapted to conduct a current pulse, and adapted to divide the current pulse so as to provide a divided current pulse, and at least two return current conduits adapted to conduct the divided current pulse to an electrical ground; and
(ii) a current power source adapted to produce a current pulse through the electromagnetic actuator, so as to produce a magnetic field in a work force area on the third side of the central current conduit;
(c) causing a current pulse to pass through the actuator, sufficient to produce a magnetic field of sufficient strength to deform the metal work piece from the original shape to another shape.
In another embodiment, the present invention includes a method of forming a metal work piece comprising the steps: (a) obtaining a metal work piece, the work piece having an original shape; (b) disposing the metal work piece in the work force area of an electronic actuator, the actuator comprising:
(i) an electromagnetic actuator comprising a central current conduit, the central current conduit adapted to conduct a current pulse in a first current direction and having first and second sides, and a third side perpendicular to a direction between the first and second sides, the central current conduit divided into at least two return current conduits, at least one of the at least two return current conduits extending along a first and second side of the central current conduit and adapted to conduct the current pulse in a second direction to an electrical ground; and
(ii) a current power source adapted to produce a current pulse through the actuator, so as to produce a magnetic field in the work force area on the third side of the central current conduit;
(c) causing a current pulse to pass through the actuator, sufficient to produce a magnetic field of sufficient strength to deform the metal work piece from the original shape to another shape.
Such methods may be used in another method, that being a method of forming a metal work piece into a target shape, the method comprising the steps:
(a) obtaining a metal work piece, the work piece having an original shape;
(b) disposing the metal work piece in a mold comprising an electronic actuator, the mold comprising:
(i) a male mold portion having a mold side and a back side;
(ii) a female mold portion having a mold side and a back side;
the mold side of the male mold portion and the mold side of the female mold portion adapted to mate incompletely so as to deform a work piece disposed therebetween so as to form the work piece into a precursor shape, leaving at least one precursor area of the work piece to be finally formed so as to complete the target shape;
(iii) at least one electromagnetic actuator disposed on one of the mold portions and opposite the at least one precursor area; and
(iv) a current power source adapted to produce a current pulse through the at least one electromagnetic actuator, so as to produce a magnetic field in the at least one precursor area so as to deform the at least one precursor area into a target shape;
(c) closing the mold sides upon the metal work piece so as to form the work piece into the precursor shape; and
(d) causing a current pulse to pass through the actuator, sufficient to produce a magnetic field of sufficient strength to deform the metal work piece from the precursor shape to the target shape.
In yet another embodiment of the present invention there is included an apparatus for forming a metal work piece, the apparatus comprising:
(a) an electromagnetic actuator comprising a current conduit, the current conduit defining a current path having a shape, the shape comprising:
(i) a current pulse origin;
(ii) a first current coil portion coiling outward from the current pulse origin, the first current coil portion coiling in a first direction;
(iii) a direction reversing portion; and
(iv) a second coil portion coiling inward to an electrical ground;
such that the direction of the current pulse carried by the direction reversing portion and those portions of the first and second coil portions that intersect a line connecting the current pulse origin and the electrical ground, are substantially parallel; and
(b) a current power source adapted to produce a current pulse through the electromagnetic actuator, so as to produce a magnetic field.
The present invention also includes a method of forming a metal work piece, the method comprising the steps:
(a) obtaining a metal work piece, the work piece having an original shape;
(b) disposing the metal work piece in the work force area of an electronic actuator, the actuator comprising:
(i) an electromagnetic actuator comprising a current conduit, the current conduit defining a current path having a shape, the shape comprising:
(1) a current pulse origin;
(2) a first current coil portion coiling outward from the current pulse origin, the first current coil portion coiling in a first direction;
(3) a direction reversing portion; and
(4) a second coil portion coiling inward to an electrical ground;
such that the direction of the current pulse carried by the direction reversing portion and those portions of the first and second coil portions that intersect a line connecting the current pulse origin and the electrical ground, are substantially parallel; and
(ii) a current power source adapted to produce a current pulse through the electromagnetic actuator, so as to produce a magnetic field; and
(c) causing a current pulse to pass through the actuator, sufficient to produce a magnetic field of sufficient strength to deform the metal work piece from the original shape to another shape.
It will be understood from the examples of the present invention given below that the actuator coils of the present invention may be of any geometry generally described herein. Accordingly, the actuator coils of the present invention may be of any regular or irregular geometry, such as forming such shapes as circular, ovoid, polygonal spirals. In accordance with the present invention, the actuator coils of the present invention may also be in the form that includes branching of multiple coils, as shown in the examples. Also, the coils may be confined to a plane, or their outward surface may be singly or doubly curved, or be even more complex, as desired.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the plan view of an actuator coil in accordance with the prior art.
FIG. 1A is a cross-section elevation of the coil shown in FIG. 1 shown juxtaposed with a workpiece, in accordance with the prior art.
FIG. 2 is a plan view of an actuator coil in accordance with one embodiment of the present invention.
FIG. 2A is a cross-section of the actuator coil of FIG. 2 shown juxtaposed with a workpiece and a forming die.
FIG. 3 is plan view of another actuator coil in accordance with another embodiment of the present invention.
FIG. 3A is a cross-section of the actuator coil in accordance with FIG. 3 shown juxtaposed with a work piece.
FIG. 3B is plan view of another actuator coil in accordance with another embodiment of the present invention.
FIG. 4 is a plan view of yet another actuator coil in accordance with another embodiment of the present invention.
FIG. 4A is a plan view of yet another actuator coil in accordance with another embodiment of the present invention.
FIG. 5 is a plan view of yet another actuator coil in accordance with another embodiment of the present invention.
FIG. 5A is a plan view of yet another actuator coil in accordance with another embodiment of the present invention.
FIG. 6 is a plan view of yet another actuator coil in accordance with another embodiment of the present invention.
FIG. 7 is a computer-generated simulation of a sheet forming problem.
FIG. 8 shows a profile of a deforming sheet metal work piece.
FIG. 9 shows a schematic of a hybrid matched tool electromagnetic forming apparatus with which actuator coils of the present invention may be used.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the foregoing summary, the following presents several examples of actuators of various geometries which are considered to be the best modes of the invention for the embodiments they represent.
Three example applications of the patent electromagnetic forming actuator have been built and tested for experimental purposes.
FIG. 2 shows a plan view of an actuator in accordance with one embodiment of the present invention.
FIG. 2 shows schematically the primary or simplest geometry for an actuator 20 of the present invention, consisting of three straight prismatic bar conductors of the same cross section, i.e., 0.375 by 0.750 inch. FIG. 2 shows central conduit 21 which is split to form return conduits 22 and 23 substantially parallel thereto. The conduits 21, 22 and 23 are mounted co-planar on the 0.375 inch sides and parallel on the 0.750 inch sides with a 0.375 inch separation between conductors. The structural and electrical connection is made at one end of the assembly by a through bolt using separation spacers of the same bar stock (not shown). The other end of the assembly is connected by right angle conductor pieces, to the double buss bar of Maxwell-Magneform 48KJ capacitor bank (not shown). The longer center conduit 21 is connected to the positive buss and the two shorter return conduits 22 and 23 are connected to the negative buss. Current direction is indicated by arrows 24 and the polarity indicated by the plus (+) and minus (-) signs. The total assembly length is approximately twenty (20) inches. The central twelve inches of the actuator is surrounded on three sides by an aluminum support channel (not shown) which reacts to the repulsive forces generated between the conducting bars of the actuator. The support channel is insulated from the actuator by 0.125 inch thick polycarbonate sheet. The top side of the actuator is flush with the top of the support channel assembly and covered by a 0.010 inch thick sheet of Mylar to insulate the actuator assembly from the work piece sheet which is placed atop the assembly. In this embodiment, the form tool for the test is then positioned on the test sheet centrally over the actuator assembly and weighted down with several heavy, one inch thick rubber pads prior to discharging the capacitor bank. It is also possible to incorporate such an actuator into a mold body by using a central conduit and a single return conduit in the form of a conductive body that is insulated from, but surrounds the central conduit on two or three adjacent sides, leaving a side to face the work force area. In such an embodiment, the current pulse is "split" by being diffused into the mass of the single return conduit in at least two divergent directions, ultimately returning to the negative bus.
FIG. 2A shows a cross-sectional view of the actuator 20 taken along line 2A--2A of FIG. 2. FIG. 2A shows a cross section of central conduit 21 and return conduits 22 and 23. FIG. 2A also shows a general indication of the magnetic force distribution as indicated by magnetic flux lines 25. The density of the flux line is related to the local electromagnetic force. FIG. 2A shows that the maximum displacement would not be effected in a work piece 26 as reflected by the magnetic force lines 25 when attempting to deform the work piece 26 as indicated by dotted lines 27. FIG. 2 also shows die 28 against which the work piece 26 may be formed (as may be the case with any of the embodiments of the present invention shown in the drawings).
An alternative embodiment, a coil assembly similar in construction to that of FIG. 2 is constructed, except that its working length is forty inches, has a face width of 1.5 inches and is curved in a plane perpendicular to the working face, to form a 120 degree included angle with a six inch radius at the angle apex. The coil is mounted in a plywood housing consisting of a sandwich of four thicknesses of 0.75 inch (nominal) finish grade interior plywood which is contoured to match the coils curvature. The coil is supported by the two center sheets of plywood which also react the primary pressure pulse generated by the coil. The two outer plywood sheets extend up along the sides of the outer coil conductors to react the separation forces between the three coil conductor and are contoured to be approximately flush with the working face of the coil assembly. The plywood sheets held together by several through bolts which also provide clamping pressure to secure the coil assembly in the channel formed by the shorter center sheets and longer outer sheets of plywood. The form tool is clamped in similar way in a plywood laminate assembly which forms a conjugate to the coil holder. The coil holder and tool holder are held together during forming by four threaded tie rods, nuts and simple, straight angle iron tie brackets. The assembled coil half and tool half form a rectangular plywood block approximately 24 by 36 inches and 3 inches thick. This experimental electromagnetic forming tool accepts a 40 inch long aluminum strip up to 6 inches thick and forms it into a 120 degree angle bracket with an integral stiffening rib along the center. The center rib has a cross-sectional shape defined by the form tool mounted in the upper plywood housing. Both stretch ribs (outside of the bracket) and compression ribs (inside of the bracket) can be formed by selecting the proper plywood halves to mount the coil and the form tool.
FIG. 3 shows actuator coil 30 which has central conduit 31 which splits into two return conduits 32 and 33 which form inward turning coils. These coils may be co-planar with the return conduit and preferably are co-planar with the exception that the straight portions extending from the interior of each coil toward the negative (-) pole are shown as extending below the plane of the coils of the return conduits 32 and 33. The conduit 31 is connected to the positive bus and the return conduits 32 and 33 are connected to the negative bus. Current direction is indicated by arrows 34. It will be understood that FIG. 3 is merely an example of the geometry that could be used in such return conduit coils. Other geometries may include oval, ovoid, polygonal or irregular shapes, even without regard to the symmetry of the return conduit coils, according to the original and desired intermediate or final shape of the work piece, and the corresponding requirements of the shape and dimensions of the magnetic field to be applied. See FIG. 3B as an example.
FIG. 3A shows a cross-section taken along 3A--3A of FIG. 3. This Figure shows central conduit 31 and portions of return conduits 32 and 33. The magnetic field produced in the work-force area is indicated by general magnetic field lines 35. FIG. 3A shows that the maximum magnetic force would be effected in a work piece 36 when attempting to deform the work piece 36 as indicated by dotted lines 37. As in FIG. 1A and 2A, FIG. 3A indicates the direction of current flow by a single dot to indicate current flow out of the plane of the paper as presented to the reader while an asterisk design (*) indicates current flow into the plane of the drawing as viewed by the reader. Also, the work force area is that area generally perpendicular to the plane defined by the dotted lines and above (or below, as the case may be) the actuator indicated by the position of the work pieces in these Figures.
FIG. 3B shows a variation of the actuator coil shown in FIG. 3, the embodiment of FIG. 3B showing a quadralateral geometry in the return conduit coils.
FIG. 3B shows actuator coil 130 which has central conduit 131 which splits into two return conduits 132 and 133 which form inward turning quadralateral coils. These coils may be co-planar with the return conduit and preferably are co-planar. The conduit 131 is connected to the positive bus and the return conduits 132 and 133 are connected to the negative bus. Current direction is indicated by arrows 134.
FIG. 4 shows yet another alternative embodiment of a geometry of an actuator coil in accordance with the present invention. FIG. 4 shows an actuator coil 40 comprising central conduit 41 which is split twice to form return conduit coils 42, 43, 42a and 43a. In this embodiment all four return coils are shown as being co-planar with the straight portions extending toward the negative bus from the interior of each coil extending below the plane of the four return coils. Such an embodiment gives a greater work force area but maintains high magnetic pressures through the central portion of the work force area similar to the field shown in FIG. 3A as described above.
FIG. 4a shows a variation of the accuator coil arrangement shown in FIG. 4. in accordance with the present invention. FIG. 4a shows an actuator coil 140 comprising central conduit 41 which is split only once to form return conduit coils 142, 143, 142a and 143a in a series, connected by serial conduits 145 and 146 which connect, respectively, the centers of coil pairs 142 and 142a, and 143 and 143a. Serial conduits 145 and 146 as shown extend below the plane of the conduit coils. In this embodiment all four coils are shown as being co-planar, with coils 142a and 143a having straight portions extending toward the negative bus from their exterior and extending in the plane of the four return coils.
Yet another coil follows the fundamental principle of the present invention, that of splitting the pulse current in order to generate a magnetic field having a central high flux area. Such a coil is shown in plan view in FIG. 5. In this embodiment, the work piece is to be formed so as to have an asymmetric bulge (depending upon the energy input), and having an approximately isosceles triangular plan with two 6 inch edges 54 and 55 and one 7 inch edge 56. The coil for this shape was constrained to lie entirely within the plan view of the bulge. The coil 50 was cut in one piece from a 0.375 inch thick copper plate. The central conduit 51 of the coil is about 0.500 inch wide and bisects the angle between the 6.0 inch edges 52 and 53 starting at the 7.0 inch edge. Just short of the apex the conductor branches, forming separate legs running parallel to each 6.0 inch plan edge. At the 7.0 inch plan edge the return conduits 52 and 53 return the current pulse back toward the central conduit along a line parallel to the 7.0 inch edge. The legs reach about 0.375 inch from the central conduit 51 and then turn parallel to it. Each return conduit essentially forms a 270 degree coil within itself maintaining a 0.375 spacing from the outer loop.
The input and output leads are brazed at the ends of the branch legs and start of the central leg and are perpendicular to the plane of the coil. The coil was imbedded into a 3.0 inch thick layered plywood base 58 such that the face of the coil was flush with the top plywood sheet surface and the brazed lead bars extended from the bottom. Four straight legs supported the coil-base assembly at the proper height above the buss bars to allow unstrained connection of the lead bars to the busses with bolted angle bracket connectors. A female form tool (not shown) was positioned and secured by two tie rods running through the assembly outside of the test blank nesting area. The tie rods also provided the work piece clamping force required to restrain sheet draw-in and flange wrinkling.
The apparatus of the present invention was tested using the coils described above with a female form tool (die). The die, made from a polymer composite material, reproduced a corner of an automobile inner door panel stamping that had proved to be very difficult to form by conventional methods, The test corner part was successfully formed in 0.8 mm (0.032 inch) thick 6111-T4 aluminum with a discharge energy through the coil of 24.0 kilo-joules (kilowatt-sec). The maximum sheet displacement height from the flat blank surface was approximately 29 mm at which point the sheet experienced biaxial tension strain of 0.165 major and 0.104 minor. Spring-back of the part was qualitatively observed to be within acceptable limits for general automotive stampings.
Another embodiment of the present invention shown in FIG. 5a is similar in overall geometric shape as that shown in FIG. 5. However, the embodiment shown in FIG. 5a features a split conduit to form coils each having a trigonal shape. This embodiment follows one of the fundamental principles of the present invention, that of splitting the pulse current in order to generate a magnetic field having a central high flux area. In this embodiment, the work piece is to be formed so as to have an asymmetric bulge (depending upon the energy input), and having an approximately isosceles triangular plan with two 6 inch edges 154 and 155 and one 8 inch edge 156. The coil for this shape was constrained to lie entirely within the plan view of the bulge. The coil 150 was cut in one piece from a 0.375 inch thick copper plate. The central conduit 151 of the coil is about 0.500 inch wide and bisects the angle between the 6.0 inch edges 152 and 153 starting at the 8.0 inch edge. Just short of the apex the conductor branches forming separate legs running parallel to each 6.0 inch plan edge, and then form trigonal coils on either side of the central conduit 151. The legs extend away from the central conduit 151 and then coil toward it.
The input and output leads are brazed at the ends of the branch legs and start of the central leg and are perpendicular to the plane of the coil. The coil was imbedded into a 3.0 inch thick layered plywood base 158 such that the face of the coil was flush with the top plywood sheet surface and the brazed lead bars extended from the bottom. Four straight legs supported the coil-base assembly at the proper height above the buss bars to allow unstrained connection of the lead bars to the busses with bolted angle bracket connectors. A female form tool (not shown) was positioned and secured by two tie rods running through the assembly outside of the test blank nesting area. The tie rods also provided the work piece clamping force required to restrain sheet draw-in and flange wrinkling.
FIG. 6 shows still another coil 60 following another fundamental principle of the present invention, that of reversing the direction of the pulse current in the plane of the actuator coil in order to generate a magnetic field having a central high flux area. The piece to be formed by this actuator coil was to have an asymmetric bulge, 1.5 inches high and having an approximately equilateral triangular plan with 6 inch edges 61 and 62, with one side further bordering upon the longest side of a trapezoidal shape having a long side of about 6 inches, a shorter opposing side 63 of about 4 inches and lateral sides 64 and 65 of about 2 inches. The coil was constrained to lie entirely within the plan view of the bulge. The coil was cut in one piece from a 0.375 inch thick high strength aluminum plate. As can be appreciated from FIG. 6, this coil provides that the pulse (indicated by the directional arrows) running through those portions of the coil intersecting a line 66 between the input lead 67 and the output lead 68 are substantially parallel, causing there to be generated a magnetic field having a high flux in this central area (i.e., one that is substantially uninterrupted by zones having little or no flux).
The input and output leads are brazed at the ends of the branch legs and start of the central leg and are perpendicular to the plane of the coil. The coil was imbedded into a 3.0 inch thick layered plywood base 69 (as may any actuator coil of the present invention) such that the face of the coil was flush with the top plywood sheet surface and the brazed lead bars extended from the bottom. Four straight legs supported the coil-base assembly at the proper height above the buss bars to allow unstrained connection of the lead bars to the busses with bolted angle bracket connectors. A female form tool (not shown) was positioned and secured by two tie rods running through the assemble outside of the test blank nesting area. The tie rods also provided the work piece clamping force required to restrain sheet draw-in and flange wrinkling.
To illustrate the advantages of the present invention over the prior art, the stresses in electromagnetic forming and the velocity vs. Time profiles have been accurately predicted for expanding ring experiments using solenoid coils. Computer codes that can model more complex two dimensional problems are also available. CALE, a "C" language based code, originally developed at Lawrence Livermore National Laboratory as an astrophysics code, is now being used to model these forming processes and the subsequent material response. FIG. 7 shows an example of a CALE simulation of a sheet forming problem. A flat spiral coil is used to form a clamped metal sheet. The irregular lines indicate lines of magnetic flux around the current-carrying elements (shown in cross section) in the simulation. Two views from the simulation are shown as they would be at 90 and 300 microseconds. It is observed that the deformation begins at the edges of the sheet and progresses towards the center. The predicted time-profile of the deformation agrees with the profiled obtained with a high speed camera in a real experiment reported by others under similar conditions. CALE accurately simulates the trajectory and profile of the deforming sheet metal work piece. This simulation demonstrates that the maximum force from the traditional prior art coil is at its periphery. With the coils of the present invention, the maximum force region may be brought to bear on the center of the work piece.
FIG. 8 shows a profile of the sheet through the deformation process simulated in FIG. 7.
Though there are no fundamental limitations to the size of the parts that can be made by electromagnetic forming in accordance with the present invention, larger parts require more energy which translates into larger capacitor banks and higher initial capital expenditure. As a result, hybrid forming processes are also being considered where electromagnetic and electrohydraulic forming may be used in such a hybrid process. Accordingly, the present invention may also be used in a matched tool set with electromagnetic coils built into sharp corners and other difficult-to-form contours, to form such parts. The matched tools would form the parts of the work piece which can be easily formed at low velocities using mechanical energy from the press. This semi-formed work piece would then be subjected to high rate forming with the electromagnetic coils to complete the forming operation. A schematic of such a process is shown in FIG. 9.
FIG. 9 shows hybrid matched tool-electromagnetic forming apparatus 90 including capacitor bank 91, inner ram 92, outer ram 93 with blank holder and die 94 (on press bolster 100. Stage 1 punch 95 partially forms work piece 96 leaving one or more portions partially formed. The actuator coils of the present invention, such as 97, powered by coaxial power distribution lines 99, may then be applied to fill out the remaining portions (indicated by voids such as 98), to reach the final desired shape of the work piece. Similarly, a quasi static, fluid pressure process with an electrical discharge in the fluid at the end of the pressure cycle to form the sharp comers and bends could represent another embodiment of the hybrid method of making difficult parts.
Industrial Applicability
Actuators of the present invention may find application in many industries that involve the formation of shaped metal pieces, such as in the making of parts for the automobile industry aerospace and the boat manufacture industry. Other applications may be found in the making of specially shaped parts in wide variety of other industries as well.
In view of the foregoing disclosure, it will be within the ability of one of ordinary skill in the art to make modifications to the present invention, such as through equivalent alternative mechanical arrangements and/or the integration or separation of component parts, without departing from the spirit of the invention as reflected in the appended claims. | One of the key features of the present invention is the use of a electrical conduit arrangement that allows for the tailoring of the magnetic field so as to provide for the greater amount of force to be brought to bear generally in the center of the work force area. The present invention provides for such capability by providing for a single central current conduit for forming longitudinally extending work pieces. The present invention also provides for the splitting, and/or direction (or curvature) reversal, of the electrical current pulse one or more times to likewise tailor the magnetic field of the work-coil or forming actuator. | 8 |
TECHNICAL FIELD
The present invention relates to an apparatus for monitoring optical signal-to-noise ratio of optical signals in wavelength-division-multiplexing (WDM) optical transmission system, and more particularly, to an apparatus for monitoring optical signal-to-noise ratio of each optical signal by measuring noise signal occurring when an optical signal is detected through de-multiplexing optical signals at each channel in wavelength-division-multiplexing (WDM) optical transmission system.
BACKGROUND OF THE INVENTION
Wavelength-division-multiplexing (WDM) optical transmission system is a system that transmits several transmission lasers with different wavelengths from each other by multiplexing them in an optical fiber.
By using the system, there is an advantage to significantly increase transmission capacities per optical fiber, even though each laser operates with relatively low transmission rate.
It is necessary to use an optical fiber amplifier for amplifying optical signals so as to increase transmission range in these systems. However, due to amplified spontaneous emission (ASE) light, occurring when the optical fiber amplifier amplifies optical signals, optical signal-to-noise ratios of the optical signals are deteriorated and therefore, that causes performance degradation of total system.
That is to say, as optical signal-to-noise ratio of an optical signal is directly related to the performance of system, the performance of wavelength-division-multiplexing (WDM) optical transmission system can be measured by monitoring optical signal-to-noise ratio. Also, more effective maintenance of a system is achieved by comprehending precise performance of the system.
Especially, in the case of all optical transmission networks, which is expanded wavelength-division-multiplexing (WDM) optical transmission system, due to different optical signal-to-noise ratio of an optical signal at each channel, the monitoring of optical signal-to-noise ratio for each optical signal is indispensable.
Conventional method for monitoring optical signal-to-noise ratio of an optical signal was using optical spectrum analyzer with rotating diffraction grating.
Even though these optical spectrum analyzers have advantages of wide measurement range and high accuracy, there is disadvantage of additional installation cost in wavelength-division-multiplexing (WDM) optical transmission system caused by high volume and high cost.
Several methods for monitoring wavelength-division-multiplexing (WDM) optical signal-to-noise ratio of an optical signal, while complementing the disadvantage, have been proposed.
First, there is one technique of “Signal Monitoring Apparatus for Wavelength-division-multiplexed Optical Communication” [U.S. Pat. No. 5,796,479], which was issued for a patent by Dennis Derickson and Roger Lee Jungerman and registered.
This method separates wavelength-division-multiplexing (WDM) optical signals, which are incident upon via an optical fiber by using diffraction grating, at each wavelength and then monitors optical signal-to-noise ratio of the optical signal by using photo diode array.
However, this method has problems of low accuracy in measurement and instability of optical spatial alignment on account of spatial distance between the optical fiber and the diffraction grating.
Next, another technique was described in a paper entitled “A High-Performance Optical Spectrum Monitor with High-Speed Measuring Time for WDM Optical Networks” written by K. Otsuka, Y. Sampei, Y. Tachikawa, N. Fukushima, and T. Chikama, in “97 European Conference on Optical Communication, pp. 147-150, 1997”. As this method also used a diffraction grating and photo diode array, there were problems of instability in optical spatial alignment and low accuracy in measurement.
Next, another technique was described in a paper entitled “High Resolution Fiber Grating Optical Network Monitor” written by Chris Koeppen, Jefferson L. Wagner, Thomas A. Strasser, and John KeMarco, in “National Fiber Optic Engineers Conference '98, Sep. 14-17, 1998”. This method used a blazed bragg grating and photo diode array.
However, this method had problems of not having precise measurement result of optical signal-to-noise ratio of an optical signal unless spatial alignment between the blazed bragg grating and photo diode array is stable.
Besides, there is method for monitoring optical signal-to-noise ratio of an optical signal by using Fabry-Perot Filter.
However, these methods for monitoring optical signal-to-noise ratio of an optical signal are useful only when optical signal-to-noise ratios are nearly same and the characteristic of amplified spontaneous emission (ASE) light, occurring from optical amplifier, is flat. Particularly, in the case of all optical transmission network, which is expanded wavelength-division-multiplexing (WDM) optical transmission system, as each channel is added/dropped by an optical add-drop multiplexer, transmission range at each channel is different from each other.
Therefore, the intensities of amplified spontaneous emission (ASE) lights, which are occurring from optical amplifier, are different from each other and as a result, optical signal-to-noise ratio at each channel is different.
FIG. 1 shows optical spectrums in wavelength-division-multiplexing (WDM) optical transmission network, after passing several optical add-drop multiplexers. Referring to FIG. 1, it is known that the spectrums of optical noises, occurring from optical amplifier, does not have flat characteristics by arrayed waveguide grating within optical add-drop multiplexer and optical signal-to-noise ratio at each channel is different from each other.
Moreover, as the optical signal is distorted by optical filter such as array waveguide grating, core device of optical add-drop multiplexer, these conventional methods have problem of impossibility in the measurement of optical signal-to-noise ratio.
FIG. 2 A and FIG. 2B show optical spectrums measured by optical spectrum analyzer with resolution of 0.05 nm after passing an optical signal with 25 dB of optical signal-to-noise ratio through wavelength-division-multiplexing optical add-drop multiplexer.
In the FIG. 2A is capable of monitoring optical signal-to-noise ratio when passing through optical add-drop multiplexer with passband of 1.1 nm. However, FIG. 2B is difficult to monitor optical signal-to-noise ratio when passing through optical add-drop multiplexer with passband of 0.3 nm.
Due to the low resolution, the measurement of optical signal-to-noise ratio is impossible in the case of FIG. 2B, which is impossible to be measured by optical spectrum analyzer with high resolution. Therefore, new method for monitoring optical signal-to-noise ratio, which is also applicable to wavelength-division-multiplexing (WDM) optical transmission network, is indispensable.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an apparatus for monitoring optical signal-to-noise ratio in wavelength-division-multiplexing optical transmission system, in which maintenance and management of system can be effectively performed by de-multiplexing the optical signal of each channel in wavelength-division-multiplexing optical transmission system, applying the signal to optical detector, and then monitoring optical signal-to-noise ratio from the quantity of noise occurring when the applied optical signals are detected by the optical detector.
To achieve the object according to the present invention, the present invention applicable to optical add-drop multiplexer, in which wavelength-division-multiplexed optical signals are split at each channel, provides an apparatus for monitoring optical signal-to-noise ratio in wavelength-division multiplexing optical transmission system, comprising: an optical splitting means for splitting optical signals applied from an external; an optical power measuring means for measuring intensities of optical signals out of a portion of said split optical signals; a noise measuring means for measuring intensities of noises occurring when detecting optical signals out of other portions of said split optical signals; and an optical signal-to-noise ratio (OSNR) calculating means for calculating optical signal-to-noise ratio from both said intensities of the optical signals and said intensities of the noises.
Preferably, said optical splitting means is either star coupler or grating device of an optical fiber for providing a portion of optical signals to both said power measuring means and said noise measuring means, after passing most of optical signals out of optical signals applied through an arbitrary optical fiber.
Preferably, said optical power measuring means is an optical power monitor for measuring intensities of optical signals out of optical signals applied through said optical splitting means.
Preferably, said optical power measuring means includes an optical signal detecting means for transforming optical signals, applied through said optical splitting means, into electric signals and an amplifier for measuring intensities of optical signals after amplifying only DC elements out of the electric signals detected from said optical signal detecting means.
Preferably, said noise measuring means includes an optical signal detecting means for transforming optical signals, applied through said optical splitting means, into electric signals, an AC amplifying means for amplifying only noise elements from said optical signal detecting means, and a noise intensity measuring means for measuring noises of the optical signal from said AC amplifying means.
More preferably, said AC amplifying means includes a capacitor cutting off low frequency for passing only AC elements and cutting off DC element of the detected optical signals from said optical signal detecting means, and an amplifier for amplifying AC elements having passed said capacitor.
Preferably, said noise intensity measuring means includes a analog-to-digital converting means for converting electric signals of the noise element being output from said AC amplifying means into digital signals, a fast fourier transforming means for performing fast fourier transformation on the converted digital signal from said analog-to-digital converting means, and a noise intensity calculating means for calculating noise intensity by using said fast fourier transformed value.
Preferably, said noise intensity measuring means includes an electric filtering means for extracting only noise elements of an optical signal detecting means after electrically filtering the electric signal of noise elements being output from said AC amplifying means and a power sensing means for detecting noises' intensities from the output of said electric filtering means.
Preferably, said optical signal-to-noise ratio (OSNR) calculating means calculates optical signal-to-noise ratio (OSNR) by applying such as intensities of optical signals (P total ) being monitored from said optical power measuring means, noises' intensities (N total ) being monitored from said noise measuring means, non-beat noise (N nonbeat ) already monitored, resolution (R), bandwidth of the optical signals (B o ), amplification constant (A) of optical signal detector and AC amplifying means, etc. to following Equation: N total = N beat + N shot + N thermal + N circuit + N signal = N beat + N nonbeat
P total = P sig + P ase = P sig ( 1 + 1 OSNR B o R )
N beat = A ( 2 P sig P ase 1 B o + P ase 2 1 B o ) = 2 A R P sig 2 ( 1 OSNR + B o 2 R · OSNR 2 ) [ Equation ]
Where, A is constant, and P sig , P ase , and B o are intensity of signal, intensity of amplified spontaneous emission (ASE) light, and bandwidth of optical signal respectively, and OSNR is optical signal-to-noise ratio being monitored with resolution of R.
Preferably, said optical signal-to-noise ratio (OSNR) calculating means calculates optical signal-to-noise ratio (OSNR) by applying such as noise intensities of noises (N total ) being monitored from said noise measuring means, non-beat noise (N nonbeat ) already monitored, resolution (R), bandwidth of the optical signals (B o ), amplification constants (C and D) of optical signal detector and AC amplifying means, etc. to following Equation: N total = N beat + N shot + N thermal + N circuit + N signal = N beat + N nonbeat
P total = P sig + P ase = P sig ( 1 + 1 OSNR B o R )
N beat [ dB ] = 10 log ( 2 A R ) + 2 P sig [ dB ] - C · OSNR [ dB ] = D + 2 P sig [ dB ] - C · OSNR [ dB ] [ Equation ]
Where, C and D are constants, and P sig , P ase , and B o are intensity of signal, intensity of amplified spontaneous emission (ASE) light, and bandwidth of optical signals respectively, and OSNR is optical signal-to-noise ratio being monitored with resolution of R.
BRIEF DESCRIPTION OF THE DRAWINGS
The embodiments of the present invention will be explained with reference to the accompanying drawings, in which:
FIG. 1 shows optical spectrums in wavelength-division-multiplexing (WDM) optical transmission network, after passing several optical add-drop multiplexer.
FIG. 2 A and FIG. 2B show optical spectrum measured by optical spectrum analyzer with resolution of 1.1 nm and 0.05 nm after passing an optical signal with 25 dB of optical signal-to-noise ratio through wavelength-division-multiplexing optical add-drop multiplexer.
FIG. 3 is a drawing illustrating an apparatus for monitoring optical signal-to-noise ratio according to a preferred embodiment of the present invention.
FIG. 4 through FIG. 6 are drawings illustrating apparatuses for monitoring optical signal-to-noise ratio in wavelength-division multiplexing optical transmission system according to other preferred embodiments of the present invention.
FIG. 7 shows an example applying an apparatus for monitoring optical signal-to-noise ratio according to the present invention to optical add-drop multiplexer of wavelength-division-multiplexing optical transmission system.
FIG. 8 shows a drawing illustrating an experimental device for monitoring optical signal-to-noise ratio of the optical signal by using optical signal-to-noise ratio according to the present invention.
FIG. 9 is a plot illustrating noise power density of an optical signal occurring in an optical detector, while varying optical signal-to-noise ratio from 10 dB to 35 dB.
FIG. 10 is a plot illustrating power density of beat noise according to optical signal-to-noise ratio.
FIG. 11 is a plot illustrating non-beat noise power density of optical power detector according to optical signal-to-noise ratio.
FIG. 12 is a plot illustrating errors between optical signal-to-noise ratio of the optical signal monitored by the apparatus for monitoring optical signal-to-noise ratio according to the present invention and optical signal-to-noise ratio of the optical signal monitored by the optical spectrum analyzer.
DETAILED DESCRIPTION OF THE INVENTION
Referring accompanied drawings, an apparatus for monitoring optical signal-to-noise ratio of wavelength-division-multiplexing (WDM) signals in optical transmission system according to the preferred embodiments of the present invention is described in detail.
FIG. 3 is a drawing illustrating an apparatus for monitoring optical signal-to-noise ratio according to a first preferred embodiment of the present invention.
As shown in FIG. 3, an apparatus for monitoring optical signal-to-noise ratio according to the first embodiment of the present invention is constructed by a first star coupler 101 , a second star coupler 102 , an optical detector 103 , a capacitor 104 , an amplifier 105 , an analog-to-digital (AD) converter 106 , a fast fourier transformer (FFT) 107 , an OSNR calculator 108 , and an optical power monitor 109 .
The first star coupler 101 passes most of wavelength-division-multiplexing optical signals applied through an arbitrary optical fiber and extracts a portion of optical signals and then provides them to the second star coupler 102 .
The second star coupler 102 provides optical signals, applied through the first star coupler 101 , to both the optical power monitor 109 and the optical detector 103 by dividing the optical signals at same magnitude.
The optical power monitor 109 monitors signal power of the optical signals and then provides them to the OSNR calculator 108 .
The optical detector 103 converts the applied optical signal into the electric signal. The DC components of the electric signal are cut off by the capacitor 104 and only AC components are provided to the amplifier 105 .
The amplifier 105 amplifies only the AC component and the analog-to-digital converter 106 converts the amplified AC component into the digital signal.
The digital signal is transformed into frequency region by the fast fourier transformer 107 and then is applied to the OSNR calculator 108 .
The OSNR calculator 108 calculates optical signal-to-noise ratio by using signal power of the optical signal, which is provided from the optical power monitor 109 , and noise power of the optical signal, which is provided from the fast fourier transformer 107 .
FIG. 4 through FIG. 6 are drawings illustrating apparatuses for monitoring optical signal-to-noise ratio in wavelength-division-multiplexing optical transmission system according to other preferred embodiments of the present invention.
Referring FIG. 4, an apparatus for monitoring optical signal-to-noise ratio according to a second preferred embodiment of the present invention is constructed by a star coupler 201 , an optical detector 202 , a DC amplifier 203 , a capacitor 204 , an AC amplifier 205 , an analog-to-digital (AD) converter 206 , a fast fourier transformer (FFT) 207 , and an OSNR calculator 208 .
The star coupler 201 passes most of wavelength-division-multiplexing optical signals applied through an arbitrary optical fiber and extracts a portion of the optical signals and then provides them to the optical detector 202 .
The optical detector 202 converts an optical signal into an electric signal and output it. As the DC component of the electric signal is cut off by the capacitor 204 , it is transferred to the DC amplifier 203 . And AC component is passed through the capacitor 204 and is provided to the AC amplifier 205 .
As the DC amplifier 203 amplifies DC component of the electric signal, it provides intensity of optical signal to the OSNR calculator 208 . And as the AC amplifier 205 amplifies AC component of the electric signal, it provides noise component of the optical signal to the analog-to-digital converter 206 .
The noise component of the optical signal is converted into the digital signal and transformed into frequency region by the fast fourier transformer 207 and noise intensity of the optical signal, which is calculated from the resultant value of the fast fourier transformer 207 , is applied to the OSNR calculator 208 .
The OSNR calculator 208 calculates optical signal-to-noise ratio by using signal power of the optical signal, which is provided from the DC amplifier 203 , and noise power of the optical signal, which is provided from the fast fourier transformer 207 .
Referring FIG. 5, an apparatus for monitoring optical signal-to-noise ratio according to a third preferred embodiment of the present invention is constructed by a first star coupler 301 , a second star coupler 302 , a first optical detector 303 , a first amplifier 304 , a second optical detector 305 , a capacitor 306 , a second amplifier 307 , an analog-to-digital (AD) converter 308 , a fast fourier transformer (FFT) 309 , and an OSNR calculator 310 .
The first star coupler 301 passes most of wavelength-division-multiplexing optical signals applied through an arbitrary optical fiber and extracts a portion of the optical signals and then provides them to the second star coupler 302 .
The second star coupler 302 provides the optical signals, applied through the first star coupler 301 , to both the first optical detector 303 and the second optical detector 305 by dividing the optical signals at same magnitude.
The first optical detector 303 converts the first optical signal, applied through the second star coupler 302 , into the first electric signal and the first amplifier 304 amplifies the first electric signal and then provides it to the OSNR calculator 310 . That is, the intensity of the optical signal, which was detected by the first optical signal, is provided to the OSNR calculator 310 .
The second optical detector 305 converts the second optical signal, applied through the second star coupler 302 , into the second electric signal and the capacitor 306 cuts off the DC component of the second electric signal and passes only the AC component of the second electric signal. The second amplifier 307 amplifies the AC component of the second electric signal and this is converted into the digital signal by the analog-to-digital converter 308 . The digital signal is transformed into frequency region by the fast fourier transformer 309 , and then noise intensity of the optical signal, which is extracted from the resultant value of the fast fourier transformer 309 , is provided to the OSNR calculator 310 .
The OSNR calculator 310 calculates optical signal-to-noise ratio by using signal intensity of the optical signal, which is provided from the first amplifier 304 , and noise intensity of the optical signal, which is provided from the fast fourier transformer 309 .
Referring FIG. 6, an apparatus for monitoring optical signal-to-noise ratio according to a fourth preferred embodiment of the present invention is constructed by a first star coupler 401 , a second star coupler 402 , an optical power monitor 403 , an optical detector 404 , a capacitor 405 , an amplifier 406 , an electric filter 407 , a power detector 408 and an OSNR calculator 409
As the first star coupler 401 , the second star coupler 402 , the optical power monitor 403 , the optical detector 404 , the capacitor 405 and the amplifier 406 are equal to those of the above-mentioned first embodiment in the composition and effect, detailed descriptions are omitted.
In the fourth embodiment, the noise measuring means, which is composed of the electric filter 407 and the power detector 408 , is different from that of the first embodiment, and detailed descriptions are as follows.
The electric filter 407 outputs only noise component of the optical detector 404 by electrically filtering the noise component of the optical signal, which is provided from the amplifier 406 .
The OSNR calculator 409 calculates optical signal-to-noise ratio by using signal intensity of the optical signal, which is provided from the amplifier 406 , and noise intensity, which is provided from the fast fourier transformer 408 .
FIG. 7 shows an example applying an apparatus for monitoring optical signal-to-noise ratio according to the present invention to an optical add-drop multiplexer of wavelength-division-multiplexing optical transmission system.
In FIG. 7, an optical signal, applied into the optical add-drop multiplexer, is amplified by an optical amplifier 501 and then dropped at each channel by a channel splitter 502 .
A measuring device 503 for measuring optical signal-to-noise ratio is connected to each port of the channel splitter 502 and then monitors optical signal-to-noise ratio of the optical signal at each channel.
An optical signal at each channel can be composed so as to be dropped, added, or passed and is transmitted through a channel coupler 504 and an optical amplifier 505 .
FIG. 8 shows a drawing illustrating an experimental device for monitoring optical signal-to-noise ratio of the optical signal by using optical signal-to-noise ratio according to the present invention.
First, an optical signal from a laser 601 is modulated by a modulator 603 , and added to the signal, which passed an amplified spontaneous emission (ASE) source and an optical attenuator 604 , in the first star coupler 605 .
As the added signal in the first star coupler 605 is divided by the second star coupler 606 , some portions of the optical signal is applied into an optical spectrum analyzer 608 and the rest of the optical signal is applied into a channel splitter 609 through an optical attenuator 607 . The optical signal, which is passed through a channel splitter 609 , is applied to an apparatus for monitoring optical signal-to-noise ratio (OSNR monitoring apparatus) 610 and the optical signal-to-noise ratio is monitored.
And, by comparing the optical signal-to-noise ratio analyzed by the optical spectrum analyzer 608 with the optical signal-to-noise ratio calculated by the OSNR monitoring apparatus 610 , optical signal-to-noise ratio error can be solved using the apparatus monitoring optical signal-to-noise ratio according to the present invention.
FIG. 9 is a plot illustrating noise power density of an optical signal produced in an optical detector, while varying optical signal-to-noise ratio from 10 dB to 35 dB. At this time, the intensity of the optical signal is varied from −40 dBm to −30 dBm. Also, noise power density was measured by averaging noise intensity obtained by doing fast fourier transformation on the noise component of the optical signal.
The noises in the optical detector can be divided into beat noise (N beat ), shot noise (N shot ), thermal noise (N thermal ), circuit noise (N circuit ) , etc. Here, though the beat noise is noise component varying according to optical signal-to-noise ratio, shot noise, thermal noise, and circuit noise are irrelevant to the optical signal-to-noise ratio.
Also, when measuring noise in the optical detector, not only these noises but also frequency component of the optical signal itself is considered as noise (N signal ). However, this frequency component of the optical signal itself is irrelevant to optical signal-to-noise ratio.
By defining these noises, irrelevant to the optical signal-to-noise ratio, as non-beat noises (N nonbeat ), total noise power density (N total ), measured in the optical detector, is expressed as following Equation 1.
N total =N beat +N shot +N thermal +N circuit +N signal =N beat +N nonbeat [Equation 1]
Referring FIG. 9, noise power density increases as the optical signal-to-noise ratio decreases and maintains nearly constant value if the optical signal-to-noise ratio is larger than 30 dB. The reason is that non-beat noise is dominant noise source in the region of above 30 dB.
Hence, the non-beat is measured by varying the intensity of the optical signal, while fixing optical signal-to-noise ratio at 35 dB.
FIG. 11 is a plot illustrating non-beat noise power density measured by doing this. The non-beat noise data of FIG. 11 can be easily expressed as an equation by polynomial approximation.
FIG. 10 is a plot illustrating power density of beat noise by subtracting the non-beat noise of FIG. 11 from the noise power density of FIG. 9 . The power density of beat noise increases as the intensity of the optical signal increases or optical signal-to-noise ratio increases. And the power density of beat noise can be expressed as Equation 2. N beat = A ( 2 P sig P ase 1 B o + P ase 2 1 B o ) = 2 A R P sig 2 ( 1 OSNR + B o 2 R · OSNR 2 ) [ Equation 2 ]
Where, A is constant, and P sig , P ase , and B o are intensity of signal, intensity of ASE light and a bandwidth of optical signal respectively, and OSNR is optical signal-to-noise ratio being monitored with resolution of R.
Although optical signal-to-noise ratio can be monitored more precisely by using Equation 2, the present invention calculates optical signal-to-noise ratio by approximating Equation 2 to Equation 3 so as to monitor optical signal-to-noise ratio more simply. N beat [ dB ] = 10 log ( 2 A R ) + 2 P sig [ dB ] - C · OSNR [ dB ] = D + 2 P sig [ dB ] - C · OSNR [ dB ] [ Equation 3 ]
Herein, C and D are varied according as the construction of optical detector, however C and D was calculated as 1.097 and 32.84 respectively in the present experiment.
The intensity of the optical signal, which is received in the optical detector, is sum of the intensity of the optical signal and the intensity of the ASE light. Therefore, the intensity of the optical signal, which is received in the optical detector, is expressed as Equation 4. P total = P sig + P ase = P sig ( 1 + 1 OSNR B o R ) [ Equation 4 ]
An optical signal-to-noise ratio can be calculated by using the intensity of the optical signal (P total ) and the noise power density (N total ) through above described Equations 1, 2, 4, and two constants such as B o and R.
The apparatus for monitoring optical signal-to-noise ratio (OSNR monitoring apparatus), constructed according to the present invention, was applied to four lasers, different from each other, and optical signal-to-noise ratio was monitored, and the monitored value was compared with the value monitored by optical spectrum analyzer.
FIG. 12 is a plot illustrating errors between optical signal-to-noise ratio of the optical signal monitored by the apparatus for monitoring optical signal-to-noise ratio according to the present invention and optical signal-to-noise ratio of the optical signal monitored by the optical spectrum analyzer.
Referring to FIG. 12, though the intensity of the optical signal is varied from −30 dBm to −38 dBm and the optical signal-to-noise ratio is varied from 16 dB to 28 dB, it is known that the maximum error is within 2 dB.
Although, the present invention was described on the basis of preferably desirable examples, these desirable examples do not limit the present invention but exemplify. Also, it will be appreciated by those skilled in the art that changes and variations in the embodiments herein can be made without departing from the spirit and scope of the present invention as defined by the following claims. | The optical signal-to-noise ratio (OSNR) of optical signals that are demultiplexed into a plurality of optical channels by a wavelength-division multiplexing (WDM) optical transmission system is monitored by an apparatus which outputs the optical signals of each optical channel on a first path and a second path, and measures the signal intensity of each of the optical signals on the first path. The apparatus selectively passes an AC component of each of the optical signals on the second path and processes the AC component by converting the AC component into a digital signal and performing a fast fourier transform on the digital signal. The apparatus measures the noise intensity of the processed AC component on the second path. The OSNR of each optical signal is calculated by comparing the measured signal intensity of each of the optical signals and the measured noise intensity of the processed AC component of each of the optical signals. | 7 |
OBJECT OF THE INVENTION
The invention refers to a disposable syringe that has been improved in determinate structural aspects with the object of achieving better performance and greater functional effectiveness than conventional syringes.
The object of the invention is to obtain a disposable syringe of the type comprising a main body in which the chamber for the liquid to be injected is determined, and a needle with a coupling cone on the end of said main body. The needle is complemented by a kind of sheath that protects and sterilises it. The syringe includes peculiarities with respect to the system for coupling the cone to the main body and coupling the protective sheath of the injection needle which, obviously, complements the assembly.
BACKGROUND OF THE INVENTION
There is a type of disposable syringe made up of a cylindrical, hollow body, which is open at its rear end to allow the movement of a rod corresponding to a piston that moves inside said cylindrical body for pushing and/or absorbing the liquid. The cylindrical body determines a chamber between its front end and the piston that can move axially in the same. Said axial rod ends in a kind of flattening or expansion to allow it to be manually actuated by the user.
This type of syringe is complemented by the corresponding needle which is housed in a covering in the form of a hood or sheath that constitutes a means for protecting the needle and also achieving hermetic sealing and the corresponding sterilisation, since the needle has a cone on its rear end for coupling to the corresponding end or neck established for this purpose on the front end of the main body of the syringe. The rear end of the sheath meets the perimeter of said coupling cone, thus achieving a hermetic seal and maintaining sterilisation of the needle, so that when the unit is going to be used, it is sufficient to couple the needle holder which slightly protrudes with respect to the rear end of the sheath over the neck of the body of the syringe, and then to extract or separate the sheath for the syringe to be ready to use.
As is clear, the coupling between the cone of the needle and the neck of the body of the syringe must be watertight to keep the liquid insulated inside the main body of the syringe, or what amounts to the same thing, in its corresponding chamber.
However, sometimes during handling, in the coupling and subsequent extraction of the protective sheath of the needle, a slight uncoupling and/or mobility of said cone occurs with respect to the neck of the body of the syringe, thus losing its hermetic seal and making it possible for air to enter the chamber, or even an unwanted exit of liquid.
When the protective sheath of the needle is being separated, it may also become badly aligned due to the tilting that may occur on the coupling cone, all of which means the risk of losing water-tightness of the liquid to be injected, or even problems of another kind with respect to the effectiveness and proper insertion of the needle in the muscular mass of the patient, as well as an irregular injection of liquid.
DESCRIPTION OF THE INVENTION
The syringe of the type referred to in the foregoing section, has a series of peculiarities on the basis of which the problems and drawbacks mentioned above are resolved.
More specifically, the first novel characteristic of the syringe of the invention is that the neck provided in the front end of the main body of the syringe, upon which the cone of the needle must be coupled, projects lengthwise with respect to the end in which the front end or part of the body extends, to define a large ring-shaped channel between said extension and the neck of the coupling. In said ring-shaped channel the rear end of the cone is housed, as well as the rear end of the sheath, although it is limited in its penetration in order to be able to separate it afterwards.
Another novel characteristic, is that the front extension of the main body of the syringe has an inner helicoidal fluting which determines a kind of thread for holding a ring-shaped rim provided in the rear part of the coupling cone. The latter thus remains completely held in place once it has been inserted into the concentric neck of the main body of the syringe, which makes it possible to extract and separate the sheath once the cone of the needle is coupled by pressure since, logically, to prevent the loss of water-tightness and therefore maintain sterilisation of the needle until it is to be used, the latter must be coupled to the body of the syringe with the sheath fitted and then finally extracted. Said sheath also includes a perimetric rear rim, which stops against the inner, slightly trunco-conical surface of the extension provided with the helicoidal fluting mentioned above, as the cone fits onto a complementary conical surface corresponding to the concentric neck of the main body. The liquid to be injected exits, pushed by the piston, through said neck and is injected by means of the needle that is coupled in the way described above.
In this way, an effective hermetic or watertight seal is achieved in the coupling of the cone to the body of the syringe, which will remain permanently intact since said cone is held in place by the inner fluting of the axial extension of the syringe's body, thus allowing the sheath to be extracted by pulling outwards without the coupling cone undergoing any movement or tilting during this operation of separation of the sheath.
DESCRIPTION OF THE DRAWINGS
To complement the description being given and in order to promote a fuller understanding of the features of the invention, in accordance with a preferred practical embodiment of the same, a set of drawings are attached as an integral part of said description, in which, illustratively and non-restrictively, the following is represented:
FIG. 1 shows an exploded view of the main body of the syringe that is the object of the invention, as well as of the assembly made up of the needle with its coupling cone and the protective sheath of the same.
FIG. 2 shows a view in longitudinal cross-section at ¼ of the syringe assembly, when the cone of the needle is coupled to the corresponding neck provided on the front end of the main body of the syringe, the sheath being in fitted position but ready for separation.
PREFERRED EMBODIMENT OF THE INVENTION
As may be observed in said drawings, the disposable syringe of the invention is made up of a main hollow cylindrical body, which is open at its rear end to allow the introduction of a piston for pushing the liquid to be injected. Between said piston and the front end of said main body the chamber for the liquid is established. Said front end of the main body ( 1 ) has an axial concentric neck ( 2 ) with a slightly trunco-conical shape while, externally to said neck ( 2 ), the body ( 1 ) has an extension ( 3 ) that is slightly shorter than the neck ( 2 ), a deep channel ( 4 ) being established between both of them. The wall ( 5 ) of said channel ( 4 ) converges downwards, that is, it defines an inverted conicality, with the peculiarity that in the surface of said inverted conical wall ( 5 ) a helicoidal fluting ( 6 ) is provided that determines a thread for effectively holding a cone ( 7 ) to carry the injection needle ( 8 ). Said cone ( 8 ) determines the means of coupling said needle to the main body of the syringe, with the peculiarity that said cone ( 7 ) has a perimetric rim or flattening ( 9 ) at its rear end which, when coupling or axial sliding on the neck occurs, causes a threading on the helicoidal fluting ( 6 ) of the inner conical surface ( 5 ) of the axial outer wall ( 3 ) of the body ( 1 ) of the syringe, thus fitting together the coupling cone ( 7 ) and the neck ( 2 ) of the body of the syringe by pressure, and therefore hermetically, and thus ensuring that the covering established by said body of the syringe ( 1 ) is watertight.
It is desirable that this type of needle ( 8 ) with its coupling cone ( 7 ) are complemented by a protective sheath ( 10 ) to maintain sterilisation and protection of the needle itself ( 8 ), which is coupled externally and by friction to the outer surface of the coupling cone ( 7 ). Therefore the separation of releasing of said sheath ( 10 ) is carried out once the cone ( 7 ) is coupled to the neck ( 2 ). In said coupling, logically and as may be observed in FIG. 2, the rear part, in which a flattening ( 11 ) of the sheath ( 10 ) is established, is housed in the channel ( 4 ) that determines the concentric neck ( 2 ) and the outer wall determined by the extension ( 3 ). The outer edge of said flattening ( 11 ) is stopped against the inner conical surface ( 5 ) of the wall ( 3 ), thus preventing, during said coupling, the sheath ( 10 ) from pressing excessively on the coupling cone ( 7 ), which allows the sheath ( 10 ) to be easily extracted once said cone ( 7 ) is coupled and held in place, without tilting, movement or loosening of the coupling cone ( 7 ) on the neck ( 2 ) of the syringe body ( 1 ) occurring during said operation. | An improved disposable syringe, made up of a cylindrical and hollow main body in which a piston can move that pushes the liquid to inject the same through a needle coupled to the front end of the main body, specifically to a neck established for this purpose in the same; the needle being complemented by a cone for coupling to said concetric neck provided at the front end of the main body; and the rear end to a protective sheath of the needle being, in turn, coupled by pressure to said cone in order to maintain sterilization of the needle. | 0 |
DESCRIPTION
This invention relates to spring-energised high-velocity air guns (e.g. air rifles or air pistols) of the kind operated by at least one piston which compresses air in a cylinder under the action of at least one main spring so as to eject a projectile from the barrel of the gun, the gun including cocking mechanism enabling the user to move the piston to a fully cocked position at which the main spring or springs are loaded ready for release, and trigger mechanism including retaining means for holding the piston at the fully cocked position until the trigger mechanism is actuated by the user. Guns of this kind are hereinafter referred to as "piston air guns".
The object of the invention is to provide mechanism for a piston air gun which is compact, reliable, and easily operated and which may, optionally be used to provide for operation of the gun at full power and at one or more stages of reduced power. The invention is particularly advantageous when embodied in an air pistol though it may be embodied in other types of piston air gun.
According to the invention there is provided a piston air gun including retaining means arranged to hold the piston at the fully cocked position and at least one intermediate position between the fully cocked position and its fully released position, and cocking mechanism engageable with the piston at the fully released position and at the or each intermediate position to move it towards the fully cocked position whereby the piston is fully cocked in two or more stages by successive repeat movements of the cocking mechanism.
Provision may be made for release of the piston from said intermediate position or positions enabling the gun to be selectively used at less than full power.
One way of carrying out the invention is now described in detail with reference to the accompanying drawing being a longitudinal sectional view of an air pistol embodying the invention .
As with many known types of piston air gun, the barrel 10 serves also as a cocking lever, thus cocking can be effected at the same time as the gun is "broken" and the provision of a separate cocking lever is unnecessary. In this design of pistol the air cylinder 11 is in end-to-end relationship with barrel 10 extending rearwards thereof and, in order to keep the overall length to manageable and pleasing proportions the length of barrel 10 is kept to a minimum, say about 170 mm so that the pistol "breaks" at approximately the halfway point.
In known pistols of this pattern the short barrel reduces the available leverage and makes cocking difficult, so much so that some patterns of pistol are provided with removable barrel extension tubes for cocking purposes.
In the present embodiment the spring loaded piston 13 is provided with a first bent or retaining recess 14 which cooperates with a sear or retaining detent 15 of the trigger mechanism to hold piston 13 at an intermediate position; and a second bent or retaining recess 16 which will cooperate with retaining detent 15 to hold piston 13 at its fully cocked most rearward position at which the main springs 17 are fully loaded in compression. The trigger 18 of the pistol can be operated in conventional manner to move retaining detent 15 out of engagement with either recess 16 or 14 to "fire" the gun from either piston position i.e. at full power, or at half power, with consequent reduction in recoil, a facility which is particularly useful for target shooting.
Cocking of the pistol is effected in two stages (assuming it is to be fully cocked) by means of a pivoted compression link 19 connected to barrel 10 forward of pivot 12 and having a rear end connected to a sliding push piece 20 guided for movement parallel to piston 13. The rear end of push piece 20 carries a pivoted pawl 21 which is sprung to urge it anti-clockwise as viewed in the drawings so that it will project through a groove in the lower wall of cylinder 11.
Piston 13 is provided with first and second pick-up recesses 22, 23 and at respective rearward and forward positions with one or the other of which pawl 21 co-acts immediately as push pieces 20 moves rearward from the position shown in the drawings. The first or rearward recess 12 is engageable by pawl 21 when piston 13 is at the fully released position shown in the drawing. The second or forward pick-up recess 23 is engageable by pawl 21 after returning barrel 10 with push piece 20 to the initial position while the piston is held at its intermediate position by engagement of retaining detent 15 with the first retaining recess 14.
A first full lever movement of barrel 10 will displace piston 13 rearwards from its fully released position to the intermediate position, and a second full movement will urge the piston back from the intermediate position to the fully cocked position for firing at full power.
When barrel 10 is returned to the normal in line "fire" position pawl 21 is retracted clear of piston 13.
This arrangement halves the maximum cocking force which has to be applied to barrel 10 as the mechanical advantage of the lever system is doubled by using the two successive repeat movements of the barrel.
Greater compactness of the lever mechanism is achieved as less travel is required per cocking stroke, thus a much neater appearance is possible in the vicinity of the barrel fulcrum (pivot 12) and the length of various components such as push piece 20 does not have to be so great, nor does the groove in the cylinder wall have to be so long thus giving increased strength.
The intermediate position may be selected to give the required low power mode of operation, for example if the low power is to be half the full power the piston travel in the low power mode may be more than half the total piston travel to compensate for the changing load of the spring (s) 17 during compression due to its rate characteristics.
The two stroke cocking movement may also reduce strain and wear on pivots and other components.
It is conceived that more than one intermediate position may be provided by having additional retaining recesses and pick-up recesses in the piston (it may be that a single recess suitably placed will serve both purposes for certain positions) and the arrangement described may be applied to other forms of piston air guns, for example rifles, guns having side or other cocking levers operated separately from their barrels, and/or dual or other multi-piston air guns. | A spring-energized air pistol or other air gun has cocking mechanism, typically lever actuated, e.g. utilizing break action of the gun barrel itself, for urging the air piston to the fully cocked position which operates in at least two stages, two or more strokes of the lever being required for full cocking. Initial strokes of the mechanism move the piston to one or more successive intermediate positions and, in some applications, the gun may be fired from the or an intermediate position enabling it to be selectively used at less than full power. | 5 |
This invention pertains to a method and apparatus for accurately positioning the parts in a predetermined location and orientation for pickup or other operations by a robot end effector.
BACKGROUND OF THE INVENTION
Modern production equipment and techniques have been developed in the last decade for performing manufacturing operations on production pads and assemblies that are significantly more accurate than the manual manufacturing techniques of the past. The primary goal is to reduce part variation and the secondary goal is to improve the performance and reduce the cost of the manufactured products. A substantial influence on the quality and cost of the manufactured products in the past has been pad variation, the reduction of which reduces the costs of rework and improves fit and function of the product.
One particular version of such a modern manufacturing system known as "virtual tooling", requires accurate information regarding the location and orientation of pads which are to be processed by the automated production machinery. The various types of airplane parts such as shear ties and brackets are picked up by a robot end effector and positioned by the robot at the precise position on a panel at which they are to be fastened. While held in this position, one or more coordination holes are drilled through the pad and the panel to establish the position on the panel where those pads will eventually be fastened. At a later stage in the manufacturing, the panel is hung from a simple fixture and the part is positioned on the panel and fastened thereto by appropriate means such as rivets, bolts and/or sealant.
The location of the pad on the panel is extremely accurate because of the accuracy of the robot, but that accuracy is dependent on an accurate position of the part when it is picked up by the end effector. The end effector must grip the pad at a known position on the pad otherwise there could be significant variation from pad to pad if the end effector were to pick up the pads at different positions on the part. A pad positioning system for presenting the pads to the robot end effector at an accurate and predetermined location and orientation and space was therefore necessary element of this manufacturing system in order to obtain its full potential accuracy.
A part positioning system for use in an airplane factory must be designed ruggedly to withstand continuous rough use over long periods of time without failure or loss of accuracy. It must also be easily and accurately checked for calibration and easily recalibrated if out of adjustment. It should preferably be a simple, uncomplicated construction and be inexpensive to manufacture and use. Finally, it should be fast acting to avoid creating time lags in the production sequence, and be simple and safe to operate.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide a method and apparatus for accurately positioning and orienting pads in space for operations by robotic equipment. Another object of this invention is to provide a method and apparatus for presenting parts of multiple different configurations in a particular predetermine position and orientation for gripping by a robotically controlled end effector.
These and other objects of the invention are attained in a part presentation system having a frame with a part receiving zone on which parts are placed for positioning by a pair of opposed positioners mounted on the base at opposite sides of the part receiving zone. The positioners are connected to a cable trained around a set of pulleys in a FIG. 8 configuration for opposed movement toward and away from the part when the cable is moved by a piston to which the cable is attached in a cable cylinder. The cable runs axially through the cylinder and is connected to the center of the piston for exerting a balanced axial force on the cable.
DESCRIPTION OF THE DRAWINGS
The invention and its many attendant objects and advantages will become more clear upon reading the following detailed description of the preferred embodiment in conjunction with the following drawings, wherein
FIG. 1 is a perspective view of a shear tie presentation module in accordance with this invention;
FIG. 1A is a side view of the structure shown in FIG. 1;
FIG. 2 is a front elevation of the parts presentation system shown in FIG. 1;
FIG. 3 is a top plan view of the parts presentation system shown in FIG. 1;
FIG. 4 is a bottom view of the structure shown in FIG. 3;
FIG. 5 is a schematic view of a the cable arrangement for the parts presentation system shown in FIG. 2, in the open position;
FIG. 6 is a schematic view of a the cable arrangement for the parts presentation system shown in FIG. 2, in the closed position;
FIG. 7 is a side elevation of a stringer clip presentation module disposed adjacent the shear tie presentation module shown in FIG. 1;
FIG. 8 is a front view, partly in section of the module shown in FIG. 7; and
FIG. 9 is an end view of the module shown in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, wherein like reference characters designate identical or corresponding parts, and more particularly to FIG. 1 thereof, a parts presentation system is shown having a shear tie presentation module mounted at an angle on a horizontal base 32. The base 32 is mounted on top of a supporting structure (not shown) adjacent a second module for presentation of stringer clips, shown in FIGS. 7-9.
The shear tie presentation module 30 accepts "T" and "L" cross section shear ties and similar fairing brackets, referred to collectively herein as "parts" 33. Shear ties and fairing brackets are parts which are fastened to the inside and outside, respectively, of a airplane fuselage for structural attachment of other airplane structures. The shear tie presentation module 30 receives a part 33 and positions the part at a known and repeatable position and orientation in space for pickup by a robot end effector, such as the end effector shown in U.S. Pat. application Ser. No. 5,482,409, the disclosure of which is incorporated herein by reference. The end effector carries the part to a fuselage panel and holds the part very accurately against the panel at a position specified in the original product definition data in the central computer depository for such information. While the part is held against the panel, coordination holes are drilled through the part and the panel which are later used during the fastening operations for the part to the panel. After drilling, the part is then carried back to the presentation module and is deposited into a bin for retrieval and bagging by the operator for subsequent fastening operation.
The shear tie presentation module 30 includes a frame 34 on which are mounted the other elements of the module. The frame includes a solid, sturdy body 35 to which all the parts are connected. The upper part of the body 35 extends upward to form a rear wall 38, and a series of plate extensions 36 fastened to the body 35 on a plane at right angles to the rear wall 38 form a top plate 36 The rear wall has a upright face 40 which extends a right angle to the plane of the top plate 36. As shown in FIG. 1A, the top surface of the top plate 36 is oriented at an angle to the horizontal, and the face of the upright face 40 of the rear wall 38 is also at an angle to the vertical so that the intersection of the upright face 40 and the top surface of the top plate 36 form and upwardly opening of V shaped channel to receive L shape shear ties or fairing brackets. The surface of the top plate 36 and the upright face 40 of the rear wall 38 forms a reference surface against which the parts can be placed and positioned so they are always in the same orientation for gripping by the parts presentation module 30.
A slot 42, shown in FIGS. 1A and 2, is machined in the body 35, the lower surface of which is coplanar with the top surface of the top plate 36 for receiving a projecting leg of a T shape shear tie or fairing bracket. A notch 44 in the rear wall 38 provides an access opening for the robot end effector to grip the shear tie after it has been centered by the shear tie presentation module 30.
A cable cylinder assembly 46 such as a model S100-3/4 from Tol-O-Matic Co. in Minneapolis, Minn., is connected to the body 35 on the left hand side of the frame as shown in FIGS. 2 and 4. The cable cylinder assembly 46 includes an air cylinder 48 closed at both ends by closures 50 and 52. A seal 54 and 56 is secured at each end of the cylinder 48, respectively, for admitting passage of a vinal-coated cable 60 through the cylinder 48 while sealing air pressure within the cylinder. A piston 62 shown in FIGS. 5 and 6, is disposed in the cylinder 48 for axially travel there along and has an axial opening therethrough for receiving the cable 60. The cable is connected to the piston 62 in the axially opening so that the movement of the piston in the cylinder drives the cable 60 along its length. Connection of the cable 60 to the piston 62 at the axially centerline of the piston provides for a pure axial force along the length of the cable without exerting a twist or a moment on the cable.
A pulley 64 is mounted at the left hand end of the cable cylinder assembly 46. The pulley has a peripheral grove for receiving the cable where is exits the seal 54 at the bottom run of the cable 60. The pulley 64 conveys the cable 180° around to the top run where it terminates at a threaded fitting 66 secured to a carriage 68 as by swaging or the like.
The cable 60 exits the seal 56 at the right hand side of the cable cylinder assembly and passes around one of two grooves aligned with the exit hole in the seal 56 on a right hand pulley 70 on the cable cylinder 46. The cable 60 is conveyed around the pulley 70 and passes over the top of a second double grove pulley 72 to the top run of a right hand side cable loop, where it terminates in a threaded fitting 74 swaged onto the end of the cable 60. The threaded fitting 74 is attached to a right hand carriage 76 to be described below.
A threaded fitting 78 swaged onto one end of a second cable 80 connects the second cable to a right hand carriage 76. The cable passes over a single groove pulley 84 fastened to the body 35 at the right hand end of the frame 34 which reverses the direction of the cable 80 180° to a lower run of the right hand cable loop. At the left hand end of the bottom run of the right hand loop of cable, the cable 80 passes under the front groove of the pulley 72 and over the front groove in the pulley 70 to the top run of the left hand loop of the cable where it attaches to the other side of the carriage 68 by a threaded fitting 88 swaged onto the other end of the cable 80. This arrangement of two adjacent lopes of cable crossing at adjacent pulleys 70 and 72 in a FIG. 8 arrangement enables the carriages 68 and 76 to move in opposite directions when the piston 62 in the cable cylinder assembly 46 is driven by air pressure in the cylinder 48.
The two carriages 68 and 76 are connected to the top runs of the two loops of cable and are guided for precise linear motion toward and away from each other by linear bearings 90 and 92 fastened to the back side of the carriages 68 and 76 and engaged with rails 94 and 96 respectively. The front side of each carriage 68 and 76 is milled out to provide a recess 98 and 100 respectively having four holes drilled to receive screws 102 which hold the linear bearings 90 and 92 to the back side of the carriages 68 and 76 respectively. Longitudinal holes are drilled through the sides of the carriage body in line with the rails 94 and 96 to receive the threaded fittings 66 and 88 on the left hand carriage and the fittings 74 and 78 on the right hand carriage 76. Nuts are screwed on to the threaded fittings to secure the end of the cable to the carriages 68 and 76. Tension in the cable may be adjusted by adjusting the torque on the nuts threaded on to the threaded fittings at the ends of the cables 60 and 80. Alignment of the upper runs of the two loops of cable with the rails 94 and 96 ensure that no unbalanced forces will be exerted through the bearings on the rails 94 and 96 which could shorten their life.
Operation of the opposed motion FIG. 8 device describes thus far is as follows: Air pressure is delivered to the air cylinder 48 through and air fitting 110 having a flow control valve 112 for adjustment of the speed of operation of the piston in the cylinder 48. The air pressurizes the right hand side of the cylinder 48 and moves the piston 62 in to the left in FIGS. 2 and 6. The cable 60, attached to the piston 62, is driven by the piston axially along the air cylinder 48. Air in the left hand side of the cylinder 48 to the left of the piston 62 is expelled through a left hand air fitting 113 and exhausted through a muffler to the atmosphere. The clockwise motion of the cable around the left hand loop is reversed in the right hand loop because of the crossing of the cables around the pulleys 70 and 72. Thus the top run of the left loop of cable moves to the right when the piston 62 moves to the left and the cylinder 48, while the top run of the cable right hand loop moves to the left as the piston 62 moves to the left in the air cylinder 48.
When it is desired to move the carriages 68 and 76 apart, the air cylinder 48 is pressurized through the left hand fitting 113 to pressurize the air cylinder 48 on the left side of the piston 62, moving the piston 62 to the right in the air cylinder 48 and driving the bottom run of the cable 60 to the right with the piston 62. The left hand end of the cable 60, attached to the left side of the left carriage 68 is pulled to the left by the cable 62 and the right hand carriage 76 is pulled to the right by the right hand end of the second cable 80 at its attachment to the carriage 76 at the threaded fitting 78.
Cable cylinder assembly 46 has a longitudinal axis 114 that is set at a slight angle to the longitudinal access of the frame 34, as most clearly shown in FIG. 4, so that the line of action of the top run of the left hand loop of cable is parallel to the track 94 and exactly aligned with the offset rear groove in the pulley 70, The top run of the right hand loop of cable is arranged parallel with the track 96 and the bottom run of that right hand lope of cable, as shown in FIG. 4, extends at a slight angle to the longitudinal axis of the frame 34 to engage the front groove of the pulley 72 so that it is aligned with the front groove of the pulley 70 for its portion of the top run of the left hand loop of cable.
Two part grippers 120 and 122 are fastened to the top of the carriages 68 and 76 respectively. The two part gripper 120 and 122 are identical, apart from being mirror images of each other, so only one part gripper 120 will be described with the understanding that the same description applies to the other part gripper 122. The part gripper 120 includes a body 124 having a base portion 126 and an upstanding ear 128 on the top of the base 126. The inner surface of the upstanding ear 128 forms an upstanding abutment 129 which engages the end of the part when the part grippers close on the part. The right hand end of the base 126 facing the center of the frame 34 is beveled to provide a ramp surface 130 for purpose to be described.
A roller arm 132 in the form of an inverted U channel is pivotally connected to the ear 128 by a pivot pin 134. A roller 136 is mounted on the right hand end of the roller arm 132 and is positioned right above the ramp 130. The other end of the roller arm has a vertical hole to receive a vertical pin 138 which is threaded into a internally threaded hole in the base 126 and receives a compression spring which is compressed between the left hand end of the roller arm and a flat on the base 126. A nut and a jam nut pair 140 and 142 are threaded onto the upper end of the pin 138 to provide an adjustment of the low or ready position of the roller 136.
In operation, a part such as a shear tie or a fairing bracket is placed on the frame top plate 36 and is presence is detected by a proximity sensor 144 which signals to the robot control system that a part is present on the part presenter. The operator presses the start button to pressurize the gas cylinder 48 and move the piston 62 to the left in FIG. 5 driving the cable 60 in a clockwise direction. This pulls the carriage 76 to the left, pulling the cable 80 with it which pulls the carriage 68 to the right thus bringing the two carriages and their attached grippers together on the part. When the grippers 120 and 122 reach the part, the ramp surface 130 slides under the part and lifts it up the ramp 130. The rollers 136 on the gripper 120 and 122 hold the part down against the surface of the ramp 130 until the edge of the part reaches the facing abutment surface 129 of the ear 128 which halts the movement of the carriages toward the center of the frame. At this point the air pressure in the cylinder 48 exerts a biasing force on the carriages 68 and 76 to hold the abutment surfaces of the ears 128 against the edge of the part, and the roller 136 hold the part down against the inner section of the abutment and the ramp 130. The part is now held in a precisely center position on the parts presenter and a precisely elevated position for gripping by a robot end effector.
Turning now to FIG. 7, a stringer clip presentation module 32 is shown in FIG. 7. The module 32 repeatably presents stringer clips to a know position and orientation in space for pickup by an end effector such as the end effector in U.S. Pat. No. 5,127,139 for placement and drilling in a stringer.
The module 82 includes a body 150 having a recess 152 in which an air cylinder 154 is connected by screws 156. A piston 158 in the air cylinder 154 has a holder 160 mounted on the end of the piston and two spaced pins 162 are mounted in parallel spaced relationship in the holder 160. A spring 164 mounted on the end of the holder prevents the holder 160 from impacting against the end of the recess 152 at the end of the travel of the piston 158.
The pins 162 extend through aligned holes in the body 150 and communicate between the recess 152 and a forward recess in the body 150. Two pairs of rollers 166 and 168 are mounted in the forward recess on H-frames 170, each frame 170 supporting two rollers. A spring 172 compressed between a depression in the center of each H-frame and a tension adjusting screw 174 in the body 150 biases the rollers 166 and 168 to the right in FIG. 8 pushing the right hand leg 176 of a stringer clip 180 to the right against a reference surface of a longitudinal slot milled in the body 150 to receive the leg 176 of the stringer clip 180.
A large diameter narrow roller 182 is mounted on the outside edge of the body 150, as shown in FIGS. 7 and 9, on a roller arm 184. The roller arm 184 has a projection 186 on which the roller 182 is mounted and a second projection of equal size 188 by which the roller arm is pivotally mounted on the body 150 by a pivot pin 189. A lower extension 190 projects beyond the projection 188 to provide a lever arm for a spring 192 compressed between the body 150 and the extension 190 to bias the arm 184 counter clockwise about its mounting pivot in the projection 188 to bias the roller 182 to the left in FIG. 7 to bear against the web 194 of the stringer clip 180 to push the web against a reference surface in a slot milled in the body 150 to receive the stringer clip. Thus is can be seen, specially from FIG. 9, that the stringer clip 180 is pressed by the rollers 166 and 168 against one reference surface while the roller 182 presses the web 194 of the stringer clip against an orthogonal reference surface thereby precisely locating the stringer clip 180 precisely on a predetermined axis.
The position of the stringer clip 180 along its axis is determined by the position to which it is pushed by the air cylinder 154 acting through the holder 160 on the pins 162. The ends of the pins 162 bear against the end of the leg 176 of the stringer clip 180 and allow the pins 162 to push the stringer clip to the precisely desired longitudinal position when the stringer clip is to be picked up by the end effector. The bottom roller of each pair of rollers 166 and 168 has a groove, shown in FIG. 7, to permit the pin 162 to engage the end of the leg 176 of the stringer clip 180 without interfering of the roller.
A pair of sensors 196 and 198 are positioned in the body 150 to sense when a stringer has been inserted into its slot in the end of the body 150 and when it has been removed. A third sensor 200 is provided in the lower recess 152 to sense when the holder 160 has been extended fully to push the stringer clip 180 out into the jaws of the end effector. | A method and apparatus for accurately positioning parts precisely in a predetermined location, including a frame having a part receiving zone on which said parts are placed for movement to the predetermined location. Two positioners are mounted on linear bearings connected to the frame and are connected to a cable for opposed motion toward and away from the part on the receiving zone under control of the cable. The cable is trained around a four pulleys mounted on said frame and connected to a cable cylinder. The cable passes axially through cylinder and connects to a piston on the centerline of the piston. Movement of the piston in one direction in the cylinder is operative to move the cable and the attached positioners toward each other to center the part. Movement of the piston in the opposite direction moves the positioners away from each other to release the part. | 8 |
TECHNICAL FIELD
The present invention relates to image sensors, and more particularly, towards a structure for improving the formation of micro-lenses in an image sensor.
BACKGROUND
Image sensors are electronic integrated circuits that can be used to produce still or video images. Solid state image sensors can be either of the charge coupled device (CCD) type or the complimentary metal oxide semiconductor (CMOS) type. In either type of image sensor, a light gathering pixel is formed in a substrate and arranged in a two-dimensional array. Modern image sensors typically contain millions of pixels to provide a high resolution image. Important parts of the image sensor are the color filters and micro-lens structures formed atop of the pixels. The color filters, as the name implies, are operative, in conjunction with signal processing, to provide a color image. The micro-lenses serve to focus the incident light onto the pixels, and thus to improve the fill factor of each pixel.
Conventionally, micro-lenses are formed by spin coating a layer of micro-lens material onto a planarized layer. The micro-lens material is then developed to form cylindrical or other shaped regions that are centered above each pixel. Then, the micro-lens material is heated and reflowed to form a hemispherical micro-lens. FIG. 1 shows a prior art cross-sectional simplified diagram of an image sensor 101 having micro-lenses formed thereon. As seen in FIG. 1, the image sensor includes a plurality of pixels that have light detecting elements 103 formed in the substrate. The light detecting elements 103 may be one of several types, such as a photodiode, a photogate, or other solid state light sensitive element. Formed atop of each pixel is a micro-lens 105 . The micro-lens 105 focuses incident light onto the light detecting elements 103 . Moreover, in the region between the light detecting elements 103 and the micro-lens 105 , denoted by reference numeral 107 , there are various intervening layers that would typically include the color filter layers and various metal conducting lines.
In the prior art, the color filters are formed by the repetitive deposition and etching of the various color filter layers. Typically, there are three color filter layers that are deposited and etched: red, blue and green layers. Alternatively, cyan, yellow, and magenta layers are used. The process of depositing and etching the color filters will sometimes result in an uneven surface. In other words, the color filter layer is not very planar.
This may cause difficulties in forming consistent high quality micro-lenses across all of the multiple image sensor dies on a single wafer. This is because the micro-lens material is spin coated onto the color filter layers. Due to the non-planar nature of the color filter layers, and other irregularities, it has been found that the spin coated micro-lens material is often not evenly distributed across the entire semiconductor wafer.
For example, if a 300 millimeter wafer is used as the substrate to carry the image sensor die, there may be thousands or even tens of thousands of image sensor dies on the single wafer. It is important to be able to evenly distribute the micro-lens material over each of the image sensor dies in a uniform manner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a prior art cross sectional view of a portion of an image sensor.
FIG. 2 is a top view of a wafer showing a plurality of image sensors formed thereon.
FIG. 3 is a top view of an image sensor having dummy patterns formed thereon in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
The present invention relates to a method and apparatus for evenly distributing a spin coating of material, specifically a micro-lens material that will be used to form micro-lenses for image sensors of either the CMOS or CCD type. In the following description, numerous specific details are provided to provide a thorough understanding of the embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, etc. In other instances, well-known structures or operations are not shown or described in detail to avoid obscuring aspects of various embodiments of the invention.
Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
As noted above, the formation of the micro-lenses almost always involves the formation of a thin layer of micro-lens material using spin coating techniques. The spin coating technique involves the dispensing of a liquid material onto a wafer and then rotating the wafer until the liquid material is dispersed into a uniform and generally thin (1-10 microns) layer over the entire wafer surface. The prior art spin coating state of the art is discussed in U.S. Pat. No. 6,436,851 to Young et al.
Nevertheless, because of the irregularities generated in the color filter layers, and because of other irregularities, it has been found that it is difficult to spin coat a micro-lens material evenly and consistently over an entire wafer of image sensor dies.
FIG. 2 shows a top view of a wafer 201 that contains a plurality of image sensor dies 203 . There are typically thousands, if not tens of thousands, image sensor dies on a single wafer. Also shown in FIG. 2 are the scribe lines 205 that are between the image sensor dies 203 . Only two scribe lines 205 are shown, but it can be appreciated that scribe lines are generally present between each image sensor die. The scribe lines are used in the dicing of the image sensor dies into individual pieces.
A section of the wafer 201 is shown in greater detail in FIG. 3 . As seen in Figure three, the image sensor dies 203 have a dummy pattern 301 formed thereon, and specifically, at each of the four corners of the image sensor die 203 . The purpose of the dummy pattern 301 is to aid in the even distribution of micro-lens material over the entire wafer 201 .
The dummy pattern 301 is simply raised portions of material (also referred to as ridges) that are higher than the surrounding topography. One type of pattern is shown in FIG. 3, though it can be appreciated that the dummy pattern 301 may be comprised of a variety of equivalent shapes and sizes. In one embodiment, the dummy pattern 301 is placed at each corner of the image sensor die 203 for ease of fabrication and consistency. Further, the dummy pattern 301 in one embodiment is shaped to be convex relative to the periphery of the image sensor die 203 . For example, the dummy pattern 301 is formed from several distinct arcuate segments 303 that are convex to the corner of the image sensor die 203 . It has been found that this arcuate shape serves to more evenly distribute flow of the micro-lens material.
The dummy pattern 301 may be formed from nearly any type of material, including the underlying color filter material. Alternatively, it can be made from an interlayer dielectric or a planarizing dielectric. Typically, the interlayer dielectric or the planarizing dielectric is formed from an oxide. It should be noted that the dummy pattern 301 is formed prior to the formation of the micro-lenses. Because of this, depending upon the location of the color filter layers in the stack of layers above the pixels, the dummy pattern 301 may be formed either before or after the color filter layers. In the typical case, the color filter layers are formed atop of the pixels and prior to formation of the micro-lenses. Therefore, it may be advantageous to form the dummy pattern 301 as a part of the color filter layers since there is masking and etching of the various color filter layers. Then, it would be easy to modify the masking and etching steps to include the dummy pattern 301 , in which case, the dummy pattern 301 would be formed from the same material as the color filter layers. The dummy pattern in one embodiment would have a height of between 1-20 microns, though other lower or higher dummy patterns would also be suitable.
The formation of color filter layers is known in art and will not be described herein to avoid any unnecessary obscuration with the description of the present invention. For example, U.S. Pat. Nos. 6,297,071, 6,362,513, and 6,271,900 show the current state of the color filter art.
From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the spirit and scope of the invention. For example, there are numerous techniques for forming the dummy patterns. The material and shape of the dummy pattern is variable dependent upon various parameters, such as shape and size of the image sensor die. Accordingly, the invention is not limited except as by the appended claims. | An image sensor die formed on a wafer is disclosed. The image sensor die comprises a plurality of pixels formed in a semiconductor substrate, each pixel including a light sensitive element. Further, a dummy pattern is formed on the image sensor die, wherein the dummy pattern comprises ridges of a dummy pattern material that is operative to evenly distribute a micro-lens material over said wafer. | 7 |
This is a divisional application Ser. No. 09/166,507, filed Oct. 5, 1998, now U.S. Pat. No. 6,218,534, which claims the benefit U.S. Provisional Application Ser. No. 60/061,195, filed Oct. 6, 1997.
FIELD OF THE INVENTION
The present invention describes a method for the preparation of asymmetric N,N′-disubstituted cyclic ureas, which are useful as HIV protease inhibitors, through the selective acylation of substituted 1,4 diamino butanes.
BACKGROUND OF THE INVENTION
U.S. Pat. No. 5,610,294 discloses cyclic urea compounds of formula (X) which are useful as HIV protease inhibitor compounds.
U.S. Pat. No. 5,532,357 discloses methods for the preparation of compounds of formula (X), for example compound (X-a) via the isourea intermediate (XX).
The isourea, (XX), can be used to prepare compounds of formula (X) which are unsymmetrical cyclic ureas.
A key intermediate in the synthesis of cyclic urea HIV protease inhibitors, such as (X-a), is the symmetrical diamine (I) (L. Rossano et al Tetrahedron. Lett., 1995, 36, 4967-4970).
Methodology has been developed that allows for mono acylation of (I) enabling manipulation to unsymmetrical compounds such as (X-a). This mono acylation allows for the synthesis of unsymmetrical cyclic ureas by differentiating the symmetrical amines in (I). Additionally, mono acyl (I) can be prepared by first bis acylation of (I) followed by a selective hydrolysis to the same mono acyl derivative of (I).
T. Blacklock et al ( J. Org. Chem, 1988, 53, 836-844) disclose the regioselective trifluoroacylation of L-lysine with ethyl trifluoroacetate in an aqueous sodium hydroxide medium using pH control to cause selective acylation. T. Shawe et al ( Synthetic Communications, 1996, 26, 3633-3636) disclose the regiospecific trifluoroacyclation of N-methylethylenediamine by reaction with ethyl trifluoroacetate; although this chemistry uses ethyl trifluoroacetate as the acylating agent, it is distinguishing a primary amine over a secondary amine where one would expect there to be a difference in reactivity between the amines based on steric arguments. These references teach acylation of diamino compounds wherein the diamines are non equivalent sterically and chemically.
D Xu et al ( Tetrahedron Letters, 1995, 36, 7357-7360) disclose the mono-trifluoro acylation of diamines, wherein acylation occurs rapidly with one equivalent of acylating agent in a polar solvent such as tetrahydrofuran at or below 0° C. The authors describe mono acylation of a primary amine in a 1,2 diamine system wherein one amine acts as an internal base to activate the other amine. However, in the case of trans 1,2 diaminocyclohexane, a statistical mixture of diamine, mono-acylated and di-acylated material is obtained, indicating that no selectivity has occured. The authors postulate that this result is because one amine is not in close proximity to the other and so cannot promote acylation. Furthermore, the authors teach as the chain length between the amines increases, the degree of selectivity observed decreases.
The process of the present invention should not be amenable to selective acylation following the teachings of the literature, In the stereochemical configuration of diamine (I), the two primary amines have a trans configuration. Additionally, the diamines have a 1,4 relationship and thus there is an increase in the chain length between the amines. In addition, titration of (I) against hydrochloric acid reveals one inflection after two equivalents of acid have been added; because there is only one equivalence point, the two primary amines in (I) are not ‘communicating’ with each other thus one amine cannot be acting as an internal base. Lastly, the two primary amines in (I) are not differentiated sterically.
Experimentally, following the teachings of the literature, in the process of the invention the acylation of diamine (I) results in very little selectivity. The selective trifluoroacylation of (I) occurs with an excess of ethyl trifluoroacetate in a non-polar solvent such as toluene at elevated temperatures; the use of polar solvents, such as tetrahydrofuran, tend to degrade the selectivity.
Despite the various methods for their preparation, there still exists a need for more efficient and cost effective methods for the preparation of unsymmetrical N,N′-disubstututed cyclic urea HIV protease inhibitor compounds in high yield. The present invention provides improved processes for the synthesis of such compounds and processes for the synthesis of intermediates for their synthesis.
The diamine (I) is a key intermediate in the synthesis of unsymmetrical cyclic ureas that can be used as HIV protease inhibitors. This process allows the differentiation of the symmetrical primary amines in diamines of formula (I) in high yield. This process is suitable for large scale and is very volume efficient, providing excellent reactor through put in high yield and with low cost. The intermediates of the invention can be alkylated to give a wide range of unsymmetrical products which are useful as HIV protease inhibitors for the treatment of HIV infection. The dialkylated diamine intermediates of the invention provide starting materials, generally crystalline, suitable for large scale cyclization to cyclic ureas, which are, generally, crystalline.
The present invention provides an improved process for the cyclization of linear dialkylated diamines to cyclic ureas. Deleterious conditions of known processes are presented by an acid rearrangement mechanism, production to a high degree of byproduct, and the unsymmetrical amines of the substrate molecule. The present invention, through use of acid-base salt precipitates, unexpectedly improves upon the process by avoiding the acid rearrangement and minimizing the byproduct; therefore, resulting in a higher yield of cyclized urea in a process more suitable for large scale cyclization.
SUMMARY OF THE INVENTION
The present invention concerns an improved process for the preparation of asymmetric cyclic ureas as well as intermediates in the preparation of asymmetric cyclic ureas. In the process, a diamine of formula (I) is selectively monoacylated to give an asymmetric monoacylated diamine which can be converted into asymmetric intermediates, which can be further alkylated to give compounds which are useful as HIV protease inhibitors for the treatment of HIV infection. The invention allows for scalable preparation of a wide variety of asymmetrical cyclic ureas. The processes of the invention can be conducted on a kilogram scale, provide for high yields, and yield stable intermediates.
DETAILED DESCRIPTION OF THE INVENTION
In a first embodiment, the present invention provides a process for the preparation of compounds of formula (VI):
wherein:
R 7 is selected from the following:
C 1 -C 8 alkyl substituted with 0-3 R 11 ;
C 2 -C 8 alkenyl substituted with 0-3 R 11 ;
C 2 -C 8 alkynyl substituted with 0-3 R 11 ; and
a C 3 -C 14 carbocyclic ring system substituted with 0-3 R 11 ;
R 10 is C 1 -C 10 alkyl, benzyl, naphthylmethyl, 3,4-methylenedioxybenzyl, or C 1 -C 4 alkyl substituted with phenyl wherein said phenyl is substituted with 0-3R 10a ;
R 10a is C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo or cyano;
R 11 is selected from one or more of the following:
C 1 -C 4 alkoxy, C 1 -C 4 alkyl, C 2 -C 6 alkoxyalkyl, benzyl, phenethyl, phenoxy, benzyloxy, methylenedioxy, ethylenedioxy, C 2 -C 4 alkenyl, C 3 -C 10 cycloalkyl, C 3 -C 6 cycloalkylmethyl, C 3 -C 6 cycloalkoxy, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkylcarbonyloxy, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkylcarbonylamino, 2-(1-morpholino)ethoxy;
—C(═O)R 13 , keto, cyano, nitro, —CH 2 NR 13 R 14 , —NR 13 R 14 , —CO 2 R 13 , —OC(═O)R 13 , —OR 13 , —OCH 2 CO 2 R 13 , —S(O) 2 R 13 , —C(═O)NR 13 R 14 , —NR 14 C(═O)R 13 , ═NOR 14 , —NR 14 C(═O)OR 14 , —OC(═O)NR 13 R 14 , —NR 13 C(═O)NR 13 R 14 , —NR 14 SO 2 NR 13 R 14 , —NR 14 SO 2 R 13 , —SO 2 NR 13 R 14 ;
C 1 -C 4 alkyl substituted with —NR 13 R 14 ; and
C 3 -C 14 carbocyclic residue substituted with 0-3 R 16 ;
R 13 is independently selected from:
C 1 -C 6 alkyl substituted with 0-3 R 15 ;
C 2 -C 6 alkenyl substituted with 0-3 R 15 ; and
phenyl substituted with 0-3 R 16 ;
R 14 is independently selected from:
C 1 -C 6 alkoxy, C 2 -C 6 alkenyl, phenyl, benzyl, and
C 1 -C 6 alkyl substituted with 0-3 C 1 -C 4 alkoxy; or
R 13 and R 14 can alternatively join to form —(CH 2 ) 4 —, —(CH 2 ) 5 —, —CH 2 CH 2 N(CH 3 )CH 2 CH 2 —, or —CH 2 CH 2 OCH 2 CH 2 —;
R 15 is selected from one or more of the following:
C 1 -C 4 alkoxy, C 1 -C 4 alkyl, C 2 -C 6 alkoxyalkyl, benzyl, phenethyl, phenoxy, benzyloxy, methylenedioxy, ethylenedioxy, C 2 -C 4 alkenyl, C 3 -C 10 cycloalkyl, C 3 -C 6 cycloalkylmethyl, C 3 -C 6 cycloalkoxy, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkylcarbonyloxy, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkylcarbonylamino, 2-(1-morpholino)ethoxy;
—C(═O)R 23 , cyano, nitro, —CH 2 NR 23 R 24 , —NR 23 R 24 , —CO 2 R 23 , —OC(═O)R 23 , —OR 23 , —OCH 2 CO 2 R 23 , —S(O) 2 R 23 , —C(═O)NR 23 R 24 , —NR 24 C(═O)R 23 , ═NOR 24 , —NR 24 C(═O)OR 24 , —OC(═O)NR 23 R 24 , —NR 23 C(═O)NR 23 R 24 , —NR 24 SO 2 NR 23 R 24 , —NR 24 SO 2 R 23 , —SO 2 NR 23 R 24 ;
C 1 -C 4 alkyl substituted with —NR 23 R 24 ; and phenyl substituted with 0-3 R 16 ;
R 16 is selected from one or more of the following:
H, halogen, cyano, nitro, —CH 2 NR 23 R 24 , —NR 23 R 24 , —CO 2 R 23 , —OC(═O)R 23 , —OR 23 , —S(O) 2 R 23 , —C(═O)NR 23 R 24 , —NR 24 C(═O)R 23 , ═NOR 24 , —NR 24 C(═O)OR 24 , —OC(═O)NR 23 R 24 , —NR 23 C(═O)NR 23 R 24 , —NR 24 SO 2 NR 23 R 24 , —NR 24 SO 2 R 23 , —SO 2 NR 23 R 24 ;
C 1 -C 4 alkyl, C 2 -C 4 alkenyl, C 3 -C 6 cycloalkylmethyl, phenyl, benzyl, phenethyl, phenoxy, benzyloxy, C 3 -C 6 cycloalkoxy, methylenedioxy, ethylenedioxy, C 1 -C 4 alkoxycarbonyl, pyridylcarbonyloxy, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkylcarbonylamino, 2-(1-morpholino)ethoxy; and
C 1 -C 4 alkyl substituted with —NR 23 R 24 ;
R 23 is C 1 -C 4 alkyl substituted with 0-3 C 1 -C 4 alkoxy;
R 24 is C 1 -C 4 alkyl substituted with 0-3 C 1 -C 4 alkoxy; or
R 23 and R 24 can alternatively join to form —(CH 2 ) 4 —, —(CH 2 ) 5 —, —CH 2 CH 2 N(CH 3 )CH 2 CH 2 —, or —CH 2 CH 2 OCH 2 CH 2 —; and
G taken together along with the oxygen atoms to which G is attached forms a group selected from:
—O—C(—CH 2 CH 2 CH 2 CH 2 CH 2 —)—O—, —O—C(CH 2 CH 3 ) 2 —O—,
—O—C(CH 3 )(CH 2 CH 3 )—O—, —O—C(CH 2 CH 2 CH 2 CH 3 ) 2 —O—,
—O—C(CH 3 )(CH 2 CH(CH 3 )CH 3 )—O—, —O—CH(phenyl)—O—, —OCH 2 O—,
—OC(CH 3 ) 2 O—, and —OC(OCH 3 )(CH 2 CH 2 CH 3 )O—;
said process comprising:
(1) contacting a compound of formula (I):
with an acylating agent of formula R 1 C(═O)R 2 ;
wherein:
R 1 is C 1 -C 4 haloalkyl;
R 2 is —OR 3 , —SR 3 , O-succinimide, or imidazolyl;
R 3 is selected from the group:
C 1 -C 6 alkyl, C 2 -C 6 alkene, C 2 -C 6 alkyne,
C 1 -C 4 haloalkyl, C 3 -C 10 cycloalkyl, pentafluorophenyl,
pyridin-2-yl, and phenyl substituted with 0-3 R 3a ;
R 3a is selected from the group:
C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, —CN, and —NO 2 ;
to form a compound of formula (II).
(2) contacting a compound of formula (II) with a compound of formula R 7 C(═O)H and subsequently contacting the imine product with a reducing agent to form a compound of formula (III):
(3) contacting a compound of formula (III) with a suitable strong base at a temperature sufficient to form a compound of formula (IV):
(4) contacting a compound of formula (IV) with 3-nitrile-4-fluoro-benzaldehyde and subsequently contacting the imine product with a reducing agent to form a compound of formula (V):
(5) contacting a compound of formula (V) with phosgene in the presence of a second suitable base to form a compound of formula (VI).
In a preferred embodiment, the present invention provides a process for the preparation of a compound of formula (VI) wherein:
R 7 is C 1 -C 8 alkyl or phenyl;
the reducing agent of step (2) is selected from sodium triacetoxy borohydride, sodium borohydride, pyridine/borane, lithium aluminium hydride, lithium borohydride, sodium cyanoborohydride, sodium amalgam, H 2 /Pd/C, H 2 /Pt/C, H 2 /Rh/C, and H 2 /Raney-Nickel;
the suitable strong base in step (3) is NaOH or KOH;
the reducing agent of step (4) is selected from sodium triacetoxy borohydride, sodium borohydride, pyridine/borane, lithium aluminium hydride, lithium borohydride, sodium cyanoborohydride, sodium amalgam, H 2 /Pd/C, H 2 /Pt/C, H 2 /Rh/C, and H 2 /Raney-Nickel; and
the suitable base in step (5) is selected from triethylamine, N,N-diisopropylethylamine, N,N-dimethyloctylamine, N,N,N′,N′-tetramethylethylenediamine, tris(hydroxymethyl)aminomethane, and 1,8-bis(dimethylamino)napthalene.
In a more preferred embodiment, the present invention provides a process for the preparation of a compound of formula (VI) wherein:
the reducing agent of step (2) is sodium triacetoxy borohydride or H 2 /Pt/C;
the suitable strong base in step (3) is NaOH or KOH;
the reducing agent of step (4) is sodium triacetoxy borohydride; and
the suitable base in step (5) is tris(hydroxymethyl)-aminomethane or N,N,N′,N′-tetramethylethylenediamine
In a second embodiment, the present invention provides a process for the preparation of a compound of formula (II):
wherein:
R 1 is C 1 -C 4 haloalkyl;
R 10 is C 1 -C 10 alkyl, benzyl, naphthylmethyl, 3,4-methylenedioxybenzyl, or C 1 -C 4 alkyl substituted with phenyl wherein said phenyl is substituted with 0-3 R 10a ;
R 10a is C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo or cyano; and
G taken together along with the oxygen atoms to which G is attached forms a group selected from:
—O—C(—CH 2 CH 2 CH 2 CH 2 CH 2 —)—O—, —O—C(CH 2 CH 3 ) 2 —O—,
—O—C(CH 3 )(CH 2 CH 3 )—O—, —O—C(CH 2 CH 2 CH 2 CH 3 ) 2 —O—,
—O—C(CH 3 )(CH 2 CH(CH 3 )CH 3 )—O—, —O—CH(phenyl)—O—, —OCH 2 O—,
—OC(CH 3 ) 2 O—, and —OC(OCH 3 )(CH 2 CH 2 CH 3 )O—;
the process, comprising:
(1) contacting a compound of formula (I):
with an acylating agent of formula R 1 C(═O)R 2 ;
wherein:
R 2 is —OR 3 , —SR 3 , O-succinimide, or imidazolyl;
R 3 is selected from the group:
C 1 -C 6 alkyl, C 2 -C 6 alkene, C 2 -C 6 alkyne,
C 1 -C 4 haloalkyl, C 3 -C 10 cycloalkyl, pentafluorophenyl,
pyridin-2-yl, and phenyl substituted with 0-3 R 3a ;
R 3a is selected from the group:
C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, —CN, and —NO 2 ;
to form a compound of formula (II).
In a preferred second embodiment, the present invention provides a process for the preparation of a compound of formula (II), wherein:
R 1 is —CF 3 , —CF 2 CF 3 , —CF 2 CF 2 CF 3 , —CF 2 Cl, —CF 2 Br, —CCl 3 , —CBr 3 , or CH 2 F; and
R 2 is —OCH 3 or —OCH 2 CH 3 .
or wherein:
R 1 is —CF 3 ; and
R 2 is —OCH 3 , —OCH 2 CH 3 , —OCH 2 CH 2 CH 3 , —OCH(CH 3 ) 2 , —OCH 2 CH═CH 2 , —OCH 2 CF 3 , —SCH 2 CH 3 , —O-phenyl, —O-(4-nitrophenyl), or —O—(2-pyridine).
In a more preferred second embodiment, the present invention provides a process for the preparation of a compound of formula (II) by contacting a compound of formula (II) with a suitable acid to form an acid addition salt.
In an even more preferred second embodiment, the present invention provides a process for the preparation of a compound of formula (II) wherein R 1 is C 1 -C 4 haloalkyl;
the process, comprising:
(1) contacting a compound of formula (I):
with an acylating agent of formula R 1 C(═O)R 2 ;
wherein:
R 2 is —OR 3 , —SR 3 , O-succinimide, or imidazolyl;
R 3 is selected from the group:
C 1 -C 6 alkyl, C 2 -C 6 alkene, C 2 -C 6 alkyne,
C 1 -C 4 haloalkyl, C 3 -C 10 cycloalkyl, pentafluorophenyl,
pyridin-2-yl, and phenyl substituted with 0-3 R 3a ;
R 3a is selected from the group:
C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo, —CN, and —NO 2 ;
to form a compound of formula (II).
In a third embodiment, the present invention provides a process for the preparation of a compound of formula (II):
wherein:
R 1 is C 1 -C 4 haloalkyl;
R 10 is C 1 -C 10 alkyl, benzyl, naphthylmethyl, 3,4-methylenedioxybenzyl, or C 1 -C 4 alkyl substituted with phenyl wherein said phenyl is substituted with 0-3 R 10a is C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo or cyano; and
G taken together along with the oxygen atoms to which G is attached forms a group selected from:
—C(—CH 2 CH 2 CH 2 CH 2 CH 2 —)—O—, —O—C(CH 2 CH 3 ) 2 —O—,
—O—C(CH 3 )(CH 2 CH 3 )—O—, —O—C(CH 2 CH 2 CH 2 CH 3 ) 2 —O—,
—O—C(CH 3 )(CH 2 CH(CH 3 )CH 3 )—O—, —O—CH(phenyl)—O—, —OCH 2 O—,
—OC(CH 3 ) 2 O—, and —OC(OCH 3 )(CH 2 CH 2 CH 3 )O—;
the process, comprising:
(1B) contacting a compound of formula (XI):
with a suitable base to form a compound of formula (II).
In a preferred third embodiment, the present invention provides a process for the preparation of a compound of formula (II), wherein R 1 is —CF 3 , —CF 2 CF 3 , —CF 2 CF 2 CF 3 , —CF 2 Cl, —CF 2 Br, —CCl 3 , —CBr 3 , or CH 2 F.
In a more preferred third embodiment, the present invention provides a process for the preparation of a compound of formula (II) wherein the suitable base in step (1B) is a hydroxide salt of sodium, potassium, lithium, calcium or magnesium; or a C 1 -C 10 alkoxide salt of sodium, potassium, or lithium; or potassium t-butoxide in a mixture of tetrahydrofuran/methanol/water.
In an even more preferred third embodiment, the present invention provides a process for the preparation of a compound of formula (II) by further contacting a compound of formula (II) with a suitable acid to form an acid addition salt.
In an even more preferred embodiment, the present invention provides a process for the preparation of a compound of formula (II):
wherein R 1 is C 1 -C 4 haloalkyl;
the process, comprising:
(1B) contacting a compound of formula (XI):
with a suitable base to form a compound of formula (II).
In a fourth embodiment, the present invention provides a process for the preparation of a compound of formula (VI):
wherein:
R 7 is selected from the following:
C 1 -C 8 alkyl substituted with 0-3 R 11 ;
C 2 -C 8 alkenyl substituted with 0-3 R 11 ;
C 2 -C 8 alkynyl substituted with 0-3 R 11 ; and
a C 3 -C 14 carbocyclic ring system substituted with 0-3 R 11 ;
R 10 is C 1 -C 10 alkyl, benzyl, naphthylmethyl, 3,4-methylenedioxybenzyl, or C 1 -C 4 alkyl substituted with phenyl wherein said phenyl is substituted with 0-3 R 10a ;
R 10a is C 1 -C 4 alkyl, C 1 -C 4 alkoxy, halo or cyano;
R 11 is selected from one or more of the following:
C 1 -C 4 alkoxy, C 1 -C 4 alkyl, C 2 -C 6 alkoxyalkyl, benzyl, phenethyl, phenoxy, benzyloxy, methylenedioxy, ethylenedioxy, C 2 -C 4 alkenyl, C 3 -C 10 cycloalkyl, C 3 -C 6 cycloalkylmethyl, C 3 -C 6 cycloalkoxy, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkylcarbonyloxy, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkylcarbonylamino, 2-(1-morpholino)ethoxy;
—C(═O)R 13 , keto, cyano, nitro, —CH 2 NR 13 R 14 , —NR 13 R 14 , —CO 2 R 13, —OC(═O)R 13 , —OR 13 , —OCH 2 CO 2 R 13 , —S(O) 2 R 13 , —C(═O)NR 13 R 14 , —NR 14 C(═O)R 13 , ═NOR 14 , —NR 14 C(═O)OR 14 , —OC(═O)NR 13 R 14 , —NR 13 C(═O)NR 13 R 14 , —NR 14 SO 2 NR 13 R 14 , —NR 14 SO 2 R 13 , —SO 2 NR 13 R 14 ;
C 1 -C 4 alkyl substituted with —NR 13 R 14 ; and
C 3 -C 14 carbocyclic residue substituted with 0-3 R 16 ;
R 13 is independently selected from:
C 1 -C 6 alkyl substituted with 0-3 R 15 ;
C 2 -C 6 alkenyl substituted with 0-3 R 15 ; and
phenyl substituted with 0-3 R 16 ;
R 14 is independently selected from:
C 1 -C 6 alkoxy, C 2 -C 6 alkenyl, phenyl, benzyl, and
C 1 -C 6 alkyl substituted with 0-3 C 1 -C 4 alkoxy; or
R 13 and R 14 can alternatively join to form —(CH 2 ) 4 —, —(CH 2 ) 5 —, —CH 2 CH 2 N(CH 3 )CH 2 CH 2 —, or —CH 2 CH 2 OCH 2 CH 2 —;
R 15 is selected from one or more of the following:
C 1 -C 4 alkoxy, C 1 -C 4 alkyl, C 2 -C 6 alkoxyalkyl, benzyl, phenethyl, phenoxy, benzyloxy, methylenedioxy, ethylenedioxy, C 2 -C 4 alkenyl, C 3 -C 10 cycloalkyl, C 3 -C 6 cycloalkylmethyl, C 3 -C 6 cycloalkoxy, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkylcarbonyloxy, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkylcarbonylamino, 2-(1-morpholino)ethoxy;
—C(═O)R 23 , cyano, nitro, —CH 2 NR 23 R 24 , —NR 23 R 24 , —CO 2 R 23 , —OC(═O)R 23 , —OR 23 , —OCH 2 CO 2 R 23 , —S(O) 2 R 23 , —C(═O)NR 23 R 24 , —NR 24 C(═O)R 23 , ═NOR 24 , —NR 24 C(═O)OR 24 , —OC(═O)NR 23 R 24 , —NR 23 C(═O)NR 23 R 24 , —NR 24 SO 2 NR 23 R 24 , —NR 24 SO 2 R 23 , —SO 2 NR 23 R 24 ;
C 1 -C 4 alkyl substituted with —NR 23 R 24 ; and
phenyl substituted with 0-3 R 16 ;
R 16 is selected from one or more of the following:
H, halogen, cyano, nitro, —CH 2 NR 23 R 24 , —NR 23 R 24 , —CO 2 R 23 , —OC(═O)R 23 , —OR 23 , —S(O) 2 R 23 , —C(═O)NR 23 R 24 , —NR 24 C(═O)R 23 , ═NOR 24 , —NR 24 C(═O)OR 24 , —OC(═O)NR 23 R 24 , —NR 23 C(—═O)NR 23 R 24 , —NR 24 SO 2 NR 23 R 24 , —NR 24 SO 2 R 23 , —SO 2 NR 23 R 24 ;
C 1 -C 4 alkyl, C 2 -C 4 alkenyl, C 3 -C 6 cycloalkylmethyl, phenyl, benzyl, phenethyl, phenoxy, benzyloxy, C 3 -C 6 cycloalkoxy, methylenedioxy, ethylenedioxy, C 1 -C 4 alkoxycarbonyl, pyridylcarbonyloxy, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkylcarbonylamino, 2-(1-morpholino)ethoxy; and
C 1 -C 4 alkyl substituted with —NR 23 R 24 ;
R 23 is C 1 -C 4 alkyl substituted with 0-3 C 1 -C 4 alkoxy;
R 24 is C 1 -C 4 alkyl substituted with 0-3 C 1 -C 4 alkoxy; or
R 23 and R 24 can alternatively join to form —(CH 2 ) 4 —, —(CH 2 ) 5 —, —CH 2 CH 2 N(CH 3 )CH 2 CH 2 —, or —CH 2 CH 2 OCH 2 CH 2 —; and
G taken together along with the oxygen atoms to which G is attached forms a group selected from: —O—C(—CH 2 CH 2 CH 2 CH 2 CH 2 —)—O—, —O—C(CH 2 CH 3 ) 2 —O—, —O—C(CH 3 )(CH 2 CH 3 )—O—, —O—C(CH 2 CH 2 CH 2 CH 3 ) 2 —O—,
—O—C(CH 3 )(CH 2 CH(CH 3 )CH 3 )—O—, —O—CH(phenyl)—O—, —OCH 2 O—,
—OC(CH 3 ) 2 O—, and —OC(OCH 3 )(CH 2 CH 2 CH 3 )O—;
said process comprising:
(5) contacting a compound of formula (V):
with a cyclizing agent selected from phosgene, diphosgene, and triphosgene, in the presence of a suitable base to form a compound of formula (VI).
In a preferred fourth embodiment, the present invention provides a process for the preparation of a compound of formula (VI) wherein R 7 is C 1 -C 8 alkyl or phenyl; said process comprising:
(5) contacting a compound of formula (V) with a cyclizing agent selected from phosgene, diphosgene, and triphosgene, in the presence of a suitable base to form a compound of formula (VI).
In a more preferred fourth embodiment, the present invention provides a process for the preparation of a compound of formula (VI) wherein the suitable base in step (5) is selected from triethylamine, N,N-diisopropylethylamine, N,N-dimethyloctylamine, N,N,N′,N′-tetramethylethylenediamine, tris(hydroxymethyl)aminomethane, and 1,8-bis(dimethylamino)napthalene.
In a fifth embodiment, the present invention provides compounds of formula
and acid addition salts thereof, wherein:
R 1 is —CF 3 , —CF 2 CF 3 , —CF 2 CF 2 CF 3 , —CF 2 Cl, —CF 2 Br, —CCl 3 , —CBr 3 or CH 2 F; and
R 7 is propyl or phenyl.
In a sixth embodiment, the present invention provides compounds of formula
and acid addition salts thereof, wherein:
R 1 is —CF 3 , —CF 2 CF 3 , —CF 2 CF 2 CF 3 , —CF 2 Cl, —CF 2 Br, —CCl 3 , —CBr 3 or CH 2 F; and
R 7 is propyl or phenyl.
In a seventh embodiment, the present invention provides compounds of formula
and acid addition salts thereof, wherein R 7 is propyl or phenyl.
In a eighth embodiment, the present invention provides compounds of formula
and acid addition salts thereof wherein R 7 is propyl or phenyl.
In a ninth embodiment, the present invention provides a process for the preparation of a compound of formula (X):
comprising contacting a compound of formula (VI) with hydrazine, or a hydrazine equivalent, under conditions sufficient to form a compound of formula (X), or a pharmaceutically acceptable salt form thereof; wherein a condition sufficient to form a compound of formula (X) comprises:
(a) removing the diol protecting group G of formula (VI) before contacting a compound of formula (VI) with hydrazine, or a hydrazine equivalent; or
(b) removing the diol protecting group G of formula (VI) after contacting a compound of formula (VI) with hydrazine, or a hydrazine equivalent.
The reactions of the synthetic methods claimed herein are carried out in suitable solvents which may be readily selected by one of skill in the art of organic synthesis, said suitable solvents generally being any solvent which is substantially nonreactive with the starting materials (reactants), the intermediates, or products at the temperatures at which the reactions are carried out, i.e., temperatures which may range from the solvent's freezing temperature to the solvent's boiling temperature. A given reaction may be carried out in one solvent or a mixture of more than one solvent. Depending on the particular reaction step, suitable solvents for a particular reaction step may be selected.
As used herein, suitable aprotic solvents include, by way of example and without limitation, ether solvents and hydrocarbon solvents. Suitable ether solvents include tetrahydrofuran, diethyl ether, diethoxymethane, ethylene glycol dimethyl ether, ethylene glycol diethyl ether, diethylene glycol dimethyl ether, diethylene glycol diethyl ether, triethylene glycol dimethyl ether, or t-butyl methyl ether. Suitable hydrocarbon solvents include: butane, pentane, hexane, heptane, octane, nonane, decane, cyclohexane, cycloheptane, methylcyclohexane; as well as aryl hydrocarbon solvents.
As used herein, suitable acetate solvents include methyl, ethyl, propyl and iso-propyl acetate.
As used herein, suitable halogenated sol anded to chlorobutane, methylene chloride, chloroform, dichloroethane, and carbon tetrachloride.
As used herein, suitable aryl solvents include toluene, benzene, o-xylene, m-xylene and p-xylene.
As used herein the term “acylating agent” or “strongly electrophilic acylating agent” refers to any agent which can acylate a primary amine. “Acylating agent” generally refers to agents of formula R 1 C(═O)R 2 which can selectively acylate one primary amine in the presence of a second primary amine. Examples of acylating agents include R 2 as an alkoxy or phenoxy group and R 1 as a C 1 -C 4 haloalkyl group, such as CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 Cl, CF 2 Br, CCl 3 , CBr 3 , or CH 2 F. “Strongly electrophilic acylating agent” generally refers to agents which can nonselectively acylate two primary amines in one molecule, for example anhydrides of formula, R 1 (CO)O(CO)R 1 , or R 1 substituted acid halides, eg. R 1 C(═O)Cl, but may also include acylating agents of formula R 1 C(═O)R 2 depending on the reaction conditions as determined by one of skill in the art to synthesize a compound of formula (II). Examples of strongly electrophilic acylating agents are where R 1 is a C 1 -C 3 haloalkyl, such as CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 Cl, CF 2 Br, CCl 3 , CBr 3 , or CH 2 F.
As used herein, the term “reducing agent” refers to any agent which can effect the reduction of an imine to an amine without effecting a chemical change on any other substitutents on the diamine substrate. Examples of reducing agents include hydrogen metal catalysts, chemical reducing agents, and catalytic transfer hydrogenation. Examples of hydrogen metal catalysts include, but are not limited to, Pd/C, Pt/C, Rh/C, and Raney-Nickel. Examples of chemical reducing agents include, but are not limited to, sodium triacetoxy borohydride, sodium borohydride, pyridine/borane, lithium aluminium hydride, lithium borohydride, sodium cyanoborohydride, and sodium amalgam.
As used herein, the term “hydrolyzing agent” means a reagent capable of generating sufficient hydroxide ion in solution to remove the acyl group from a compound of formula (III). Examples of suitable hydrolyzing agents include but are not limited to sodium hydroxide in methanol, potassium hydroxide in isopropanol and potassium hydroxide in n-butanol.
As used herein, the term “cyclizing agent” means a reagent that can effect the formation of a cyclic urea from the diamine of formula (V). Examples of suitable cyclizing agents include but are not limited to phosgene, diphosgene, triphosgene, 1,1′-carbonyl diimidazole, phenyl chloroformate, 4-nitro-phenyl chloroformate, phenyl tetrazoylformate, oxalyl chloride, N,N′-disuccinimidyl carbonate, trichloromethyl chloroformate, C 1 -C 4 dialkyl carbonate, ethylene carbonate, vinylene carbonate, and 2(S),3 pyridinediyl carbonate.
As used herein, “alkyl” is intended to include both branched and straight chain saturated aliphatic hydrocarbon groups having one to twelve carbon atoms; for example, C 1 -C 4 alkyl includes methyl, ethyl, n-propyl, 1-propyl, n-butyl, 1-butyl, s-butyl, and t-butyl. “Alkenyl” is intended to include hydrocarbon chains of either a straight or branched configuration and one or more unsaturated carbon-carbon bonds which may occur in any stable point along the chain, such as ethenyl, 1-propenyl, 2-propenyl, 1-butenyl, 2-butenyl, 3-butenyl, 1,3-butadienyl and the like; and “alkynyl” is intended to include hydrocarbon chains of either a straight or branched configuration and one or more triple carbon-carbon bonds which may occur in any stable point along the chain, such as ethynyl, propynyl, butynyl and the like.
As used herein, “cycloalkyl” is intended to include saturated ring groups, including mono-, bi- or poly-cyclic ring systems, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, adamantyl and cyclooctyl.
As used herein, “carbocycle” or “carbocyclic” is intended to mean any stable 3- to 7-membered monocyclic or bicyclic or 7- to 14-membered bicyclic or tricyclic or an up to 26-membered polycyclic carbon ring, any of which may be saturated, partially unsaturated, or aromatic. Examples of such carbocyles include, but are not limited to, cyclopropyl, cyclopentyl, cyclohexyl, phenyl, biphenyl, naphthyl, indanyl, adamantyl, or tetrahydronaphthyl (tetralin).
As used herein “halo” or “halogen” refers to fluoro, chloro, bromo and iodo.
As used herein “haloalkyl” is intended to include both branched and straight-chain saturated aliphatic hydrocarbon groups having the specified number of carbon atoms, substituted with 1 or more halogen. For example, C 1 -C 4 haloalkyl includes, but is not limited to, CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 CF 2 CF 2 CF 3 , CF 2 Cl, CF 2 Br, CCl 3 , CBr 3 , CH 2 F, CH 2 CF 3 , and the like.
As used herein “alkoxy” represents an alkyl group of indicated number of carbon atoms attached through an oxygen bridge. For example C 1 -C 4 alkoxy includes methoxy, ethoxy, propoxy and butoxy. As used herein “cycloalkoxy” represents a cycloalkyl group of indicated number of carbon atoms attached through an oxygen bridge. For example C 3 -C 6 cycloalkoxy includes cyclopropyloxy, cyclobutyloxy, cyclopentyloxy, and cyclohexyloxy.
As used herein “alkylcarbonyl” is intended to include an alkyl group of an indicated number of carbon atoms attached through a carbonyl group to the residue of the compound at the designated location. For example C 1 -C 4 alkylcarbonyl includes methylcarbonyl, ethylcarbonyl, propylcarbonyl and butylcarbonyl.
As used herein “alkylcarbonyloxy” is intended to include an alkyl group of an indicated number of carbon atoms attached to a carbonyl group, where the carbonyl group is attached through an oxygen atom to the residue of the compound at the designated location.
As used herein “alkylcarbonylamino” is intended to include an alkyl group of an indicated number of carbon atoms attached to a carbonyl group, where the carbonyl group is attached through an amino group to the residue of the compound at the designated location.
As used herein, “pharmaceutically acceptable salts” refer to derivatives of the disclosed compounds wherein the parent compound is modified by making acid or base salts thereof. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of basic residues such as amines; alkali or organic salts of acidic residues such as carboxylic acids; and the like. The pharmaceutically acceptable salts include the conventional non-toxic salts or the quaternary ammonium salts of the parent compound formed, for example, from non-toxic inorganic or organic acids. For example, such conventional non-toxic salts include those derived from inorganic acids such as hydrochloric, hydrobromic, sulfuric, sulfamic, phosphoric, nitric and the like; and the salts prepared from organic acids such as acetic, propionic, succinic, glycolic, stearic, lactic, malic, tartaric, citric, ascorbic, pamoic, maleic, hydroxymaleic, phenylacetic, glutamic, benzoic, salicylic, sulfanilic, 2-acetoxybenzoic, fumaric, toluenesulfonic, methanesulfonic, ethane disulfonic, oxalic, isethionic, and the like.
The pharmaceutically acceptable salts of the present invention can be synthesized from the parent compound which contain a basic or acidic moiety by conventional chemical methods. Generally, pharmaceutically acceptable salts of the compounds of the invention can be prepared by reacting the free acid or base forms of these compounds with a stoichiometric amount of the appropriate base or acid, respectively, in water or in an organic solvent, or in a mixture of the two; generally, nonaqueous media like ether, ethyl acetate, ethanol, isopropanol, or acetonitrile are preferred. Lists of suitable salts are found in Remington's Pharmaceutical Sciences, 17th ed., Mack Publishing Company, Easton, Pa., 1985, p. 1418, the disclosure of which is hereby incorporated by reference.
It is understood that where the processes of the invention describe the use of a suitable acid to form an acid addition salt, one of skill in the art of synthesis can use an inorganic or an organic acid which could also render a pharmaceutically acceptable salt. In addition to the acids listed above for pharmaceutically acceptable salts the following acids are examples of suitable acids for the formation of an acid addition salt: phthalic acid, salicylic acid, isophthalic acid, and malonic acid.
As used herein, suitable recrystallization solvents include those in which the product will dissolve when heated and crystallize when cooled. Examples include, but are not limited to alkanes, ethers, esters (acetates), alcohols, aryls, halogenated alkanes, organic acids and water.
When any variable (for example, R 10a , R 3a , etc.) occurs more than one time in any constituent or formula for a compound, its definition on each occurrence is independent of its definition at every other occurrence. Thus, for example, if a group is shown to be substituted with 0-3 R 10a , then said group may optionally be substituted with up to three R 10a and R 10a at each occurrence is selected independently from the defined list of possible R 10a . Also, combinations of substituents and/or variables are permissible only if such combinations result in stable compounds. By stable compound or stable structure it is meant herein a compound that is sufficiently robust to survive isolation to a useful degree of purity from a reaction mixture. Similarly, by way of example, for the group —C(R 10a ) 2 —, each of the two R 10a substituents on C is independently selected from the defined list of possible R 10a .
The compounds herein described may have asymmetric centers. All chiral, diastereomeric, and racemic forms are included in the present invention. It will be appreciated that certain compounds of the present invention contain an asymmetrically substituted carbon atom, and may be isolated in optically active or racemic forms. It is well known in the art how to prepare optically active forms, such as by resolution of racemic forms or by synthesis, from optically active starting materials. All chiral, diastereomeric, racemic forms and all geometric isomeric forms of a structure are intended, unless the specific stereochemistry or isomer form is specifically indicated.
Combinations of substituents and/or variables are permissible only if such combinations result in stable compounds. By stable compound or stable structure it is meant herein a compound that is sufficiently robust to survive isolation to a useful degree of purity from a reaction mixture.
The term “substituted”, as used herein, means that one or more hydrogen on the designated atom is replaced with a selection from the indicated group, provided that the designated atom's normal valency is not exceeded, and that the substitution results in a stable compound.
The present invention is contemplated to be practiced on at least a multigram scale, kilogram scale, multikilogram scale, or industrial scale. Multigram scale, as used herein, is preferably the scale wherein at least one starting material is present in 10 grams or more, more preferably at least 50 grams or more, even more preferably at least 100 grams or more. Multikilogram scale, as used herein, is intended to mean the scale wherein more than one kilogram of at least one starting material is used. Industrial scale as used herein is intended to mean a scale which is other than a laboratory scale and which is sufficient to supply product sufficient for either clinical tests or distribution to consumers.
The following terms and abbreviations are used herein and defined as follows. The abbreviation: “THF” as used herein means tetrahydrofuran, “HPLC” as used herein means high performance liquid chromatograpy, “TLC” as used herein means thin layer chromatography, “liq” as used herein means liquid, “n-BuOH” as used herein means n-butanol and “TMEDA” as used herein means N,N,N′,N′-tetramethylethylenediamine.
The methods of the present invention, by way of example and without limitation, may be further understood by reference to Scheme 1. Scheme 1 details the general synthetic method for the preparation of asymmetric cyclic ureas starting from monoacylation of a 1,4-diaminobutane. In Scheme 1, R 10 is a substituted or unsubstituted benzyl group and G is a diol protecting group.
Step 1: Monoacylation: Preparation of a Compound of Formula (II).
This step is conducted by reacting a diamine of formula (I) with an acylating agent, R 1 C(═O)R 2 , to form a monoacylated compound, (II), which can be used as is or can be reacted with a suitable acid to form an isolable acid addition salt. By way of general guidance, at least one equivalent, preferably one to two, more preferably 1.4 to 1.6 equivalents, of an acylating agent is added to a solution of compound (I) in a suitable solvent; while stirring at a suitable temperture the reaction is monitered for completion by HPLC analysis of reaction samples. Upon completion of the reaction, monoacylated compound, (II), can be isolated as a free base or as an acid addition salt by separation methods known to one skilled in the art. Separation methods and examples of standard work up are shown in Examples 1-8. Preferably, the free base is obtained by distilling off the acylating agent or the acid addition salt is obtained by addition of a suitable acid which results in precipitation of the acid addition salt. More preferably, the monoacylated compound, (II), is isolated as the phthalate salt from a mixture of toluene and isopropanol. The phthalic acid salt can be recrystallised from acetonitrile if further purification is required.
In Step 1 the reaction is considered complete by HPLC analysis when the ratio of the area percent product to area percent starting material is at least 10:1; preferably greater than 12:1; more preferably greater than 15:1.
Suitable solvents for the reaction of (I) with the acylating agent in step (1) are non-polar solvents such as toluene, methyl-t-butyl ether, cyclohexane, hexane, and heptane; most preferably toluene. The suitable acid in step (1) can be added neat, for example as a solid, as a suspension in a second solvent, or as a solution in a second solvent, selected by one of skill in the art; preferably an organic solvent miscible with the reaction solvent; more preferably isopropanol.
It is understood that a large scope of acylating agents, R 1 C(═O)R 2 , are suitable for this reaction. It is prefered that R 2 is an alkoxy or phenoxy group, such as methoxy, ethoxy, propoxy, isopropoxy, butoxy, phenoxy, and equivalents thereof; and that R 1 is a C 1 -C 4 haloalkyl, preferably C 1 -C 3 haloalkyl, such as CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 Cl, CF 2 Br, CCl 3 , CBr 3 , or CH 2 F. More preferably the acylating agent is F 3 CC(═O)OCH 2 CH 3 .
A suitable temperature for the monoacylation reaction is from about 0° C. to reflux of the solvent. The preferred temperature depends on the acylating agent, for example with F 3 CC(═O)OCH 2 CH 3 the preferred range is 40-50° C.; and is readily determined by one skilled in the art.
It is understood that one skilled in the art can determine the preferred reaction time of Step (1) as dependent on acylating agent and temperature of the reaction. For example with F 3 CC(═O)O(p-C 6 H 4 NO 2 ) the reaction can be complete within 5 minutes at 0° C. However, with Cl 3 CC(═O)OCH 2 CH 3 the reaction was heated at 110° C. for three days. Preferably the reaction is complete in less than twenty four hours; more preferably reaction is complete within 4-5 hours at 40-50° C., for example when F 3 CC(═O)OCH 2 CH 3 is the acylating agent.
Suitable acids for the preparation of the acid addition salt are phthalic acid, salicylic acid, isophthalic acid, malonic acid; preferably phthalic acid.
The reaction carried out in Step 1 has been run on various scales in kilo laboratory glassware and pilot plant scale.
Step 2: Reductive Amination: Preparation of a Compound of Formula (III).
This step is conducted by reacting an aldehyde of formula R 7 CH 2 CHO with a compound of formula (II) to form an imine which is subsequently reduced to a compound of formula (III) by a suitable reducing agent. By way of general guidance, compound (II) is dissolved in an organic solvent and neutralized by the addition of aqueous hydroxide solution (sodium or potassium) if the acid addition salt of (II) is used. The reaction is dried, for example by extraction and azeotropic distillation, afterwhich about one equivalent of R 7 CH 2 CHO is added to form the imine intermediate. Formation of the imine intermediate can be driven by additional drying of the reaction solvent by methods known to one skilled in the art, such as molecular sieves (for example 4 A sieves) or distillation, preferably via azeotropic removal of water. Subsequently, the imine is reduced by addition of a suitable reducing agent to form compound (III) which can be isolated by standard methods of work up. Examples of work up are given in Example 19, 19a, and 19b. It is optional that compound (III) can be isolated as an acid addition salt.
Suitable organic solvents for step 2 are toluene, cyclohexane, hexane, heptane, isopropyl acetate, and ethyl acetate; more preferably toluene.
The imine intermediate can be reduced to (III) with a variety of suitable reducing agents, such as, hydrogen metal catalysts, chemical reducing agents, and catalytic transfer hydrogenation.
For reductions using hydrogen preferred metal catalysts are Pd/C, Pt/C, Rh/C, and Raney-Nickel. Additionally, preferred solvents for reductions using hydrogen metal catalysts are methanol, ethanol, isopropanol, cyclohexane, toluene, tetrahydrofuran, ethyl acetate, isopropyl acetate or acetonitrile.
For reductions using chemical reducing agents preferred agents are sodium triacetoxy borohydride, sodium borohydride, pyridine/borane, lithium aluminium hydride, lithium borohydride, sodium cyanoborohydride, and sodium amalgam. Preferred solvents for reductions using chemical reducing agents are toluene, cyclohexane, methanol, ethanol, tetrahydrofuran and ether.
It is understood that one skilled in the art of organic synthesis will judiciously choose a suitable reducing agent based on the stability of R 7 substituents on the aldehyde. For example, when R 7 is propyl, it is more preferred that the reducing agent is 10% Pd/C in toluene. However, when R 7 is phenyl, it is more preferred that the reducing agent is 5% Pt/C in methanol or ethanol between 25-45° C. or sodium triacetoxy borohydride in toluene or cyclohexane between 25-45° C.
It is understood that the acid addition salt of (III), if prepared, can be prepared from a number of suitable acids known to and judiciously chosen by one skilled in the art. Preferred acids are para-toluene sulphonic acid or methanesulfonic acid. For example, when R 7 is phenyl, para-toluene sulphonic acid is preferred; and when R 7 is propyl, methane sulphonic acid is preferred. Additionally, the acid addition salt of (III) can be prepared in a number of solvents; preferred solvents include ethyl acetate, isopropyl acetate or a mixture of cyclohexane and isopropanol.
The reaction carried out in Step 2 has been run on a kilogram scale.
Step 3: De-acylation: Preparation of a Compound of Formula (IV).
This step is conducted by reacting a compound of formula (III) as prepared in Step 2 with a suitable hydrolyzing agent under forcing conditions to form the primary amine compound of formula (IV). By way of general guidance, the protecting group is removed by hydrolysis wherein hydroxide ion in an alcohol solvent is preferred under refluxing conditions. Compound (IV) can be isolated or carried forward into Step 4.
Preferred hydrolyzing agents are sources of hydroxide ion in an alcohol solvent and include sodium hydroxide in methanol, potassium hydroxide in isopropanol and potassium hydroxide in n-butanol. A more preferable condition is isopropanol with 4 equivalents of potassium hydroxide at reflux.
Step 4: Reductive Amination: Preparation of a Compound of Formula (V).
This step is conducted by reacting 3-nitrile, 4-fluoro benzaldehyde with a compound of formula (IV) to form an imine which is subsequently reduced by a suitable reducing agent to form a compound of formula (V); as similarly described in Step 2. By way of general guidance, about one equivalent of 3-nitrile, 4-fluoro benzaldehyde is contacted with a compound of formula (IV) to form an imine intermediate, wherein azeotropic distillation of the water formed is preferred. The imine formed is contacted with a about 1 to about 3 equivalents of a suitable reducing agent, preferably a chemical reducing agent, more preferably sodium triacetoxy borohydride in toluene or cyclohexane between 25-45° C. to form a compound of formula (V). The product can be isolated by standard methods of work up as shown in Example 20 and 20a. It is preferred that the compound of formula (V) is isolated and purified by recrystalising from n-heptane, hexane(s) or cyclohexane; more preferably n-heptane.
The reaction carried out in Step 4 has been run on a kilogram scale.
Step 5: Cyclization: Preparation of a Compound of Formula (VI).
This step is conducted by reacting a diamine compound of formula (V) with a cyclizing agent in the presence of a suitable base to form a compound of formula (VI). By way of general guidance a diamine compound of formula (V) and about 1.2 to about 3.0 equivalents, preferably 1.2 to 2.0 equivalents, of a suitable base are dissolved under reflux into a suitable solvent. About 0.4 to about 3.0 equivalents of cyclizing agent, depending on the equivalents of base, dissolved into the same suitable solvent are added subsurface, over a controlled period of time, to the refluxing mixture of compound (V) and base. During the addition of cyclizing agent the total volume of refluxing solution may be controlled by distilling off the solvent such that the maximum volume of refluxing solution is about 0.10 molar to about 0.13 molar, preferably 0.11 to 0.12 molar, in relation to compound (V). Upon complete addition of the cyclizing agent the reaction is cooled, the base-HCl salt formed removed, preferably by filtration or extraction, and the product compound (VI) isolated. Examples of workup are shown in Examples 22 and 22a.
Optionally, the cyclic urea (VI) can either be isolated and then deprotected, or subjected in situ to acidic conditions to remove the protecting group G to form compounds of Formula (VII). Methanolic hydrochloric acid or sulphuric acid is preferred to remove the diol protecting group G to form the free diol; whereupon the free diol generally crystallizes from the reaction mixture or can be isolated by methods known to one skilled in the art. Preferably, the protecting group G is acetonide.
The base is used to scavenge hydrochloric acid that is generated during the reaction and generally a non nucleophilic or weakly nucleophilic base can be used. Preferred suitable bases include N,N-diisopropylethylamine, triethylamine, N,N,N′,N′-tetramethylethylenediamine, N,N-dimethyloctylamine, tris(hydroxymethyl)aminomethane, and 1,8-bis(dimethylamino)napthalene. More preferable is N,N,N′,N′-tetramethylethylenediamine or tris(hydroxymethyl)aminomethane as the base. Most preferrable is tris(hydroxymethyl)aminomethane.
A suitable aprotic solvent for this step includes: benzene, cyclohexane, pentane, hexane, toluene, methylcyclohexane, heptane, ethylbenzene, m-, o-, or p-xylene, octane, indane, nonane, naphthalene, tetramethylurea, nitromethane, nitrobenzene, dimethoxymethane, tetrahydrofuran, 1,3-dioxane, 1,4-dioxane, furan, diethyl ether, ethylene glycol dimethyl ether, ethylene glycol diethyl ether, diethylene glycol dimethyl ether, diethylene glycol diethyl ether, triethylene glycol dimethyl ether, t-butyl methyl ether, carbon tetrachloride, bromodichloromethane, dibromochloromethane, bromoform, chloroform, bromochloromethane, dibromomethane, butyl chloride, dichloromethane, tetrachloroethylene, trichloroethylene, 1,1,1-trichloroethane, 1,1,2-trichloroethane, 1,1-dichloroethane, 2-chloropropane, hexafluorobenzene, 1,2,4-trichlorobenzene, o-dichlorobenzene, chlorobenzene, or fluorobenzene.
Preferred solvents for step 5 include toluene, cyclohexane, chlorobenzene, 1,2-dichlorobenzene, and anisole. The more preferred solvent is toluene.
Preferred cyclizing agents for Step 5 are phosgene, diphosgene, and triphosgene; more preferred is 1.0-3.0 equivalents phosgene and about 0.4-0.6 equivalents of triphosgene; most preferred is 1.2-2.0 equivalents of phosgene.
The reaction carried out in Step 5 has been run on a kilogram scale.
Step 6: Preparation of Compounds of Formula (X); Amino Indazolyl Formation and Alcohol Deprotection.
This step is conducted by reacting a compound of formula (VI) or (VII) with hydrazine or a hydrazine equivalent in the presence of a base, such base being suitable for scavenging HF produced in the reaction, to form an amino indazolyl derivative of a compound of formula (VI) or (VII). Amino indazolyl derivatives of a compound of formula (VI) have an alcohol protecting group G which can be removed by conditions described in Step 5 above, ie acidic conditions, to form a compound of formula (X). Amino indazolyl derivatives of a compound of formula (VII) have already been alcohol deprotected as described by conditions in Step 5 above, ie acidic conditions, and therefore form a compound of formula (X) upon reaction with hydrazine or a hydrazine equivalent. By way of general guidance one equivalent of a compound of formula (VI) or (VII) is reacted with at least one equivalent to an excess, preferably at least two equivalents, more preferably at least five equivalents of hydrazine or a hydrazine equivalent in the presence of an HF scavenging base. Examples are shown in Examples 23 and 23a.
Bases suitable for scavenging HF are inorganic as well as organic bases. Preferred bases are carbonate salts such as potassium carbonate, cesium carbonate, and calcium carbonate. A more preferred base used to scavenge hydrofluoric acid is calcium carbonate. Optionally, hydrazine itself may function as the base to scavenge HF produced.
A suitable solvent for this step includes: low molecular weight alcohols, such as ethanol, propanol, butanol, pentanol, and hexanol; and ethers, such as tetrahydrofuran. Preferred is 2-propanol or n-butanol. Optionally, hydrazine itself may function as the solvent.
Hydrazine equivalents for this step include anhydrous hydrazine, hydrazine hydrate, and salts of hydrazine, such as hydrazine acetate, hydrazine bromide, hydrazine hydrochloride, and hydrazine sulfate. It is understood by one skilled in the art that when hydrazine salts are used an additional quantity of base must be used to neutralize the acid of the hydrazine salt. Preferred is hydrazine hydrate.
The reaction carried out in Step 6 has been run on a kilogram scale.
The present invention, by way of example and without limitation, may be further exemplified by reference to Scheme 2.
Step 1A: Bis-acylation: Preparation of a Compound of Formula (XI).
This step is conducted by reacting a diamine compound of formula (I) with an excess of a strongly electrophilic acylating agent (VIII) in the presence of a base to give a bis-acylated compound of formula (XI). By way of general guidance, to a solution of a diamine of formula (I) and about 3 equivalents base is slowly added an excess, preferably about 2 to about 5, more preferably about 2.5 equivalents of a strongly electrohphilic acylating agent while controlling the temperature. It is understood that one skilled in the art can determine the rate of addition as dependent on acylating agent and maintaining a preferred temperature of the reaction between about 0 to about 35° C. After addition of the acylating agent the reaction is aged for a sufficient amount of time, preferably about 30 minutes to about 24 hours, more preferably about 1 hour to about 3 hours, at a temperature of about 0° C. to reflux to form the bis-acylated compound (XI). The preferred temperature depends on which acylating agent is used, preferably the acylating agent is CF 3 (CO)O(CO)CF 3 wherein the preferred temperature range is about 0 to about 35° C. The product (XI) may be separated from the reaction as a stable solid by standard methods of workup, an example of which is shown in Example 17.
It is understood that a large scope of strongly electrophilic acylating agents are suitable for this reaction, such as anhydrides, R 1 (CO)O(CO)R 1 , or R 1 substituted acid halides, eg. R 1 C(═O)Cl. It is preferred that R 1 is a C 1 -C 3 haloalkyl, such as CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 Cl, CF 2 Br, CCl 3 , CBr 3 , or CH 2 F. More preferably the acylating agent is CF 3 (CO)O(CO)CF 3 .
Preferred solvents for Step 1A include toluene, cyclohexane, hexane, heptane, methyl t-butyl ether, tetrahydrofuran, acetonitrile, water or mixtures of any of these solvents and water. Most preferably toluene.
In Step 1A, it is understood that a wide range of bases are suitable. Preferred bases include trialkylamines, pyridine, and inorganic bases; more preferably triethylamine, pyridine, sodium hydroxide, or potassium carbonate; most preferably triethylamine.
Step 1B: Mono-deacylation: Preparation of a Compound of Formula (II).
This step is conducted by reacting a diacyl diamine of formula (XI) with a suitable base to form a compound of formula (II). By way of general guidance, a diacyl diamine of formula (XI) is reacted with about 1 to 3, preferably about 1 to 2, more preferably about 1.0 to about 1.2 equivalents of a suitable base in a suitable solvent at a suitable temperature for a sufficient amount of time and subsequently quenched with about 1.0 to about 1.2 equivalents of a quenching acid, preferably acetic acid, to form the monoacylated derivative (II). Compound (II) can be used as is or can be reacted with an acid to form a suitable isolable acid addition salt. An example of workup is shown in Example 18.
Preferred acids in Step 1B for the preparation of an isolable acid addition salt include phthalic acid, salicylic acid, isophthalic acid, and malonic acid; more preferrable the acid is phthalic acid. When R 1 is CF 3 the product is preferably isolated as the phthalate salt from a mixture of toluene and isopropanol.
A preferrable advantage to preparation of isolable acid addition salts is the further utilization of this step as a purification procedure. For example, the phthalic acid salt of (II) can be recrystallised from acetonitrile if further purification is required.
In Step 1B many suitable bases can be utilized as a suitable source of hydroxide ion such as sodium hydroxide, potassium hydroxide, lithium hydroxide, calcium hydroxide, magnesium hydroxide, potassium carbonate and water. Additional bases include a C 1 -C 10 alkoxide salt of sodium, potassium, or lithium, in the presence of water; for example sodium methoxide and water, sodium ethoxide and water, potassium tert-butoxide and water; as well as n-butyl lithium and water. Preferably a mixture of potassium tert-butoxide and water.
A number of solvents can be used such as 2-propanol, ethanol, methanol, tetrahydrofuran, toluene, methyl t-butyl ether, cyclohexane, hexane, heptane, acetonitrile, mixtures thereof or mixtures thereof with water. More preferable is a mixture of tetrahydrofuran/methanol/water or tetrahydrofuran/methanol; most preferable is a mixture of tetrahydrofuran/methanol/water.
A suitable temperature for the mono-deacylation reaction is from about 0° C. to reflux of the solvent. The preferred temperature depends on R 1 and is readily determined by one skilled in the art. For example, when R 1 is CF 3 the preferred range in THF/methanol/water is about 58 to about 64° C.
It is understood that a compound of formula (II) can be synthesized from a large scope of acylating agents. It is prefered that R 1 in Step 1B is a C 1 -C 4 haloalkyl, preferably C 1 -C 3 haloalkyl, such as CF 3 , CF 2 CF 3 , CF 2 CF 2 CF 3 , CF 2 Cl, CF 2 Br, CCl 3 , CBr 3 , or CH 2 F. More preferably R 1 is CF 3 .
The following examples are meant to be illustrative of the present invention. These examples are presented to exemplify the invention and are not to be construed as limiting the inventor's scope.
Starting materials, alkylating agents and reagents of the invention can be obtained commercially or prepared in a number of ways well known to one skilled in the art of organic synthesis. The starting materials and alkylating agents of the invention can be synthesized using the methods described in U.S. Pat. No. 5,532,356, U.S. Pat. No. 5,610,294, U.S. Pat. No. 5,530,124, U.S. Pat. No. 5,532,357, U.S. Pat. No. 5,559,252, and U.S. Pat. No. 5,637,780, the disclosures of which are hereby incorporated by reference. Where the above references describe alkylating agents that are benzyl halides or alkyl halides or the like, it is understood that one skilled in the art of organic synthesis can readily oxidize the halide to an aldehyde by methods known in the art.
As described herein, HPLC conditions for the determination of starting materials, products and intermediates in Step (1) are: Column: Waters Symmetry-C18, 150×3.9 mm, 5 μm; flow rate: 1.5 ml/minute; injection volume: 5 microliters; wavelength: 220 nm; Oven temperature: 40° C.; Solvent A: 5 mM sodium dihydrogen phosphate and 5 mM diammonium hydrogen phosphate in water; Solvent B: acetonitrile; gradient timetable for solvents: T=0 minutes 65:35 A:B; T=12 minutes 30:70 A:B; T=15 minutes 15:85 A:B.
EXAMPLE 1
Monoacylation of Substituted 1,4 diaminobutane wherein the acylating agent is Methyl trifluoroacetate; R 1 =OMe.
To a stirred solution of (I) (14.63 g, 43.03 mmole) in toluene (100 ml) under nitrogen at 25° C. was added methyl trifluoroacetate (6.06 ml, 7.71 g, 60.24 mmole, 1.4 eq) and stirred at 25° C. for 1.5 hr. Upon completion of the reaction, as determined by HPLC, the excess methyl trifluoroacetate was removed via vacuum distillation. To the reaction mixture was added 2-propanol (43 ml) followed by phthalic acid (6.79 g, 40.88 mmole, 0.95 eq) in five equal portions over 1 hr. The resulting slurry was stirred at 50° C. for 1 hr, cooled to 20° C., stirred for 2 hrs and filtered. The product was dried to a constant weight in vacuo to give 21.74 g (84%) of (II-a).
EXAMPLE 2
Monoacylation of Substituted 1,4 diaminobutane, as in Example 1, wherein the acylating agent is Ethyl trifluoroacetate, R 1 =OEt.
To a stirred solution of (I) (1.03 Kg, 3.03 moles) in toluene (7.00 liters) under nitrogen at 25° C. was added ethyl trifluoroacetate (0.506 liters, 0.604 Kg, 4.24 moles, 1.4 eq). The reaction was warmed to 45° C. and stirred for 4 hrs. Upon completion of the reaction, as determined by HPLC, the excess ethyl trifluoroacetate was removed via vacuum distillation. The reaction mixture was cooled to 25° C. and 2-propanol (3.10 liters) was added followed by phthalic acid (0.48 Kg, 2.88 moles, 0.95 eq) in five equal portions over 1 hr. The resulting slurry was stirred at 50° C. for 1 hr, cooled to 20° C., stirred for 2 hrs and filtered. The product was dried to a constant weight in vacuo to give 1.65 Kg (90%) of (II-a).
EXAMPLE 3
Monoacylation of Substituted 1,4 diaminobutane, as in Example 1, wherein the acylating agent is Isopropyl trifluoroacetate, R 1 =O-isopropyl.
To a stirred solution of (I) (5.21 g, 15.33 mmole) in toluene (35 ml) under nitrogen at 25° C. was added isopropyl trifluoroacetate (4.10 ml, 4.55 g, 29.13 mmole, 1.9 eq) and stirred at 55° C. for 24 hr. Upon completion of the reaction, as determined by HPLC, 2-propanol (15 ml) was added followed by phthalic acid (2.32 g, 14.56 mmole, 0.95 eq) in five equal portions over 1 hr. The resulting slurry was stirred at 50° C. for 1 hr, cooled to 20° C., stirred for 2 hrs and filtered. The product was dried to a constant weight in vacuo to give 8.04 g (87%) of (II-a).
EXAMPLE 4
Monoacylation of Substituted 1,4 diaminobutane, as in Example 1, wherein the acylating agent is Ally trifluoroacetate, R 1 =O-allyl.
To a stirred solution of (I) (5.21 g, 15.33 mmole) in toluene (35 ml) under nitrogen at 25° C. was added ally trifluoroacetate (2.68 ml, 3.17 g, 20.57 mmole, 1.34 eq) and stirred at 25° C. for 2 hr. Upon completion of the reaction, as determined by HPLC, 2-propanol (15 ml) was added followed by phthalic acid (2.32 g, 14.56 mmole, 0.95 eq) in five equal portions over 1 hr. The resulting slurry was stirred at 50° C. for 1 hr, cooled to 20° C., stirred for 2 hrs and filtered. The product was dried to a constant weight in vacuo to give 8.30 g (90%) of (II-a).
EXAMPLE 5
Monoacylation of Substituted 1,4 diaminobutane, as in Example 1, wherein the acylating agent is S-ethyltrifluoro thioacetate, R 1 =thio ethyl.
To a stirred solution of (I) (5.21 g, 15.33 mmole) in toluene (35 ml) under nitrogen at 0° C. was added S-ethyltrifluoro thioacetate (2.63 ml, 3.25 g, 20.57 mmole, 1.34 eq) and warmed to 25° C. over 1 hr. Upon completion of the reaction, as determined by HPLC, 2-propanol (15 ml) was added followed by phthalic acid (2.32 g, 14.56 mmole, 0.95 eq) in five equal portions over 1 hr. The resulting slurry was stirred at 50° C. for 1 hr, cooled to 20° C., stirred for 2 hrs and filtered. The product was dried to a constant weight in vacuo to give 8.26 g (89%) of (II-a).
EXAMPLE 6
Monoacylation of Substituted 1,4 diaminobutane, as in Example 1, wherein the acylating agent is 2,2,2-Trifluoroethyl trifluoroacetate, R 1 =2,2,2-Trifluoro ethoxy.
To a stirred solution of (I) (5.21 g, 15.33 mmole) in toluene (35 ml) under nitrogen at 0° C. was added 2,2,2-Trifluroethyl trifluoroacetate (2.36 ml, 3.46 g, 17.64 mmole, 1.15 eq). Upon completion of the reaction, as determined by HPLC, 2-propanol (15 ml) was added, the reaction was warmed to 25° C. and phthalic acid (2.32 g, 14.56 mmole, 0.95 eq) was added in five equal portions over 1 hr. The resulting slurry was stirred at 50° C. for 1 hr, cooled to 20° C., stirred for 2 hrs and filtered. The product was dried to a constant weight in vacuo to give 8.26 g (89%) of (II-a).
EXAMPLE 7
Monoacylation of Substituted 1,4 diaminobutane, as in Example 1, wherein the acylating agent is Phenyl trifluoroacetate, R 1 =OPh.
To a stirred solution of (I) (5.21 g, 15.33 mmole) in toluene (35 ml) under nitrogen at 0° C. was added phenyl trifluoroacetate (2.63 ml, 3.35 g, 17.64 mmole, 1.15 eq) and warmed to 25° C. over 1 hr. Upon completion of the reaction, as determined by HPLC, 2-propanol (15 ml) was added followed by phthalic acid (2.32 g, 14.56 mmole, 0.95 eq) in five equal portions over 1 hr. The resulting slurry was stirred at 50° C. for 1 hr, cooled to 20° C., stirred for 2 hrs and filtered. The product was dried to a constant weight in vacuo to give 8.33 g (90%) of (II-a).
EXAMPLE 8
Monoacylation of Substituted 1,4 diaminobutane, as in Example 1, wherein the acylating agent is 4-nitro phenyl trifluoroacetate, R 1 =Op—NO 2 Ph.
To a stirred solution of (I) (5.21 g, 15.33 mmole) in toluene (35 ml) under nitrogen at 0° C. was added phenyl trifluoroacetate (4.15 g, 17.64 mmole, 1.15 eq) and warmed to 25° C. over 1 hr. Upon completion of the reaction, as determined by HPLC, 2-propanol (15 ml) was added followed by phthalic acid (2.32 g, 14.56 mmole, 0.95 eq) in five equal portions over 1 hr. The resulting slurry was stirred at 50° C. for 1 hr, cooled to 20° C., stirred for 2 hrs and filtered. The product was dried to a constant weight in vacuo to give 8.46 g (92%) of (II-a).
EXAMPLE 9
Monoacylation of Substituted 1,4 diaminobutane, as in Example 1, wherein the acylating agent is 2-(Trifluroacetoxy) pyridine, R 1 =2-hydroxy pyridine.
To a stirred solution of (I) (5.00 g, 14.70 mmole) in toluene (35 ml) under nitrogen at 0° C. was added 2-(trifluroacetoxy) pyridine (2.80 g, 2.07 ml, 14.70 mmole, 1.0 eq. Upon completion of the reaction, as determined by HPLC, the solvent was removed under reduced pressure and the yield of the mono trifluoro acetyl derivative determined by nmr to be 10%.
EXAMPLE 10
Monoacylation of Substituted 1,4 diaminobutane wherein the acylating agent is Ethyl pentafluoropropionate, R 2 CF 2 CF 3 .
To a stirred solution of (I) (10.40 g, 30.66 mmole) in toluene (70 ml) under nitrogen at 25° C. was added ethyl pentafluoropropionate (11.18 g, 8.61 ml, 58.25 mmole, 1.9 eq) and the reaction warmed to 60° C. Upon completion of the reaction, as determined by HPLC, the solvent was removed under reduced pressure to give the mono pentafluoro amide product in 79% yield.
EXAMPLE 11
Monoacylation of Substituted 1,4 diaminobutane, as in Example 10, wherein the acylating agent is Ethyl heptafluorobutyrate, R 2 =CF 2 CF 2 CF 3 .
To a stirred solution of (I) (5.00 g, 14.70 mmole) in toluene (35 ml) under nitrogen at 25° C. was added ethyl heptafluorobutyrate (6.76 g, 4.84 ml, 27.93 mmole, 1.9 eq) and stirred at 60° C. for 2.5 days. Upon completion of the reaction, as determined by HPLC, the solvent was removed under reduced pressure to give the mono heptafluoro amide product in 79% yield.
EXAMPLE 12
Monoacylation of Substituted 1,4 diaminobutane, as in Example 10, wherein the acylating agent is Ethyl bromofluoroacetate, R 2 =CF 2 Br.
To a stirred solution of (I) (5.00 g, 14.70 mmole) in toluene (35 ml) under nitrogen at 25° C. was added ethyl bromofluoroacetate (4.17 g, 2.64 ml, 20.58 mmole, 1.4 eq) and stirred at 25° C. overnight. Upon completion of the reaction, as determined by HPLC, the solvent was removed under reduced pressure to give the bromo difluoro amide product in 82% yield.
EXAMPLE 13
Monoacylation of Substituted 1,4 diaminobutane, as in Example 10, wherein the acylating agent is Methyl-2-chloro-2,2-difluoroacetate, R 2 =CF 2 Cl.
To a stirred solution of (I) (5.21 g, 15.33 mmole) in toluene (35 ml) under nitrogen at 250C was added methyl-2-chloro-2,2-difluoroacetate (2.49 g, 1.86 ml, 17.63 mmole, 1.15 eq) and stirred at 25° C. for 5 hrs. Upon completion of the reaction, as determined by HPLC, the solvent was removed under reduced pressure to give the chloro difluoro amide product in 86% yield.
EXAMPLE 14
Monoacylation of Substituted 1,4 diaminobutane, as in Example 10, wherein the acylating agent is Ethyl trichloroacetate, R 2 =CCl 3 .
To a stirred solution of (I) (5.00 g, 14.70 mmole) in toluene (35 ml) under nitrogen at 25° C. was added ethyl trichloroacetate (5.33 g, 3.88 ml, 27.93 mmole, 1.9 eq) and stirred at reflux for 3 days. Upon completion of the reaction, as determined by HPLC, the solvent was removed under reduced pressure to give the trichloro amide product in 63% yield.
EXAMPLE 15
Monoacylation of Substituted 1,4 diaminobutane, as in Example 10, wherein the acylating agent is Ethyl tribromoacetate, R 2 =CBr 3 .
To a stirred solution of (I) (5.00 g, 14.70 mmole) in toluene (35 ml) under nitrogen at 25° C. was added ethyl tribromoacetate (6.39 g, 2.74 ml, 20.58 mmole, 1.4 eq) and stirred at 45° C. for 3 days. Upon completion of the reaction, as determined by HPLC, the solvent was removed under reduced pressure to give the tribromo amide product in 80% yield.
EXAMPLE 16
Monoacylation of Substituted 1,4 diaminobutane, as in Example 10, wherein the acylating agent is Ethyl fluoroacetate, R 2 =CH 2 F.
To a stirred solution of (I) (5.00 g, 14.70 mmole) in toluene (35 ml) under nitrogen at 25° C. was added ethyl fluoroacetate (2.18 g, 1.99 ml, 20.58 mmole, 1.4 eq) and stirred at reflux for 7 days. Upon completion of the reaction, as determined by HPLC, the solvent was removed under reduced pressure to give the monofluoro amide product in 33% yield.
EXAMPLE 17
Bis-acylation: Preparation of a Compound of Formula (XI) wherein R 1 =CF 3 .
To a stirred solution of (I) (53.3 g, 157 mmole), toluene (113 ml) and triethylamine (65 ml, 470 mmole, 3 eq) under nitrogen was slowly added trifluoroacetic anhydride (55 ml, 391 mmole, 2.5 eq) over 0.75 h at 0 to 35C. The reaction mass was aged for 1 h at about 25° C. To the reaction mixture was added water (250 ml) and ethyl acetate (250 ml) and the layers were separated, discarded aqueous phase. The organic phase was washed with 5% aqueous sodium bicarbonate (250 ml). The reaction mass was concentrated in vacuo to 102 g of an oily solid. Toluene (170 ml) was added and the resulting slurry heated to 70° C. to dissolve. Cyclohexane (350 ml) was slowly added at about 70° C. The resulting slurry was allowed to cool slowly to about 20° C., stirred for 3.5 days, filtered and washed with cyclohexane (3×50 ml). The product was dried to a constant weight in vacuo to give 42.0 g (50%) of (XI-a).
EXAMPLE 18
Mono-deacylation, Step 1B: Preparation of a Compound of Formula (II) wherein R 1 =CF 3 .
To a stirred solution of (XI-a) (106.5 g, 0.20 mole) in tetrahydrofuran (500 ml) under nitrogen at about 25° C. was added a solution of potassium tert-butoxide in tetrahydrofuran (1.0 M, 220 ml, 0.22 mole, 1.1 eq), water (4 ml, 0.22 mole, 1.1 eq) and methanol (250 ml). The reaction mass was heated to about 60° C. and aged for 18 hr. The reaction mass was cooled to about 20° C. and acetic acid (13.7 ml, 0.24 moles, 1.2 eq) was added. The reaction mass was distilled under vacuum to about 300 ml total volume. Toluene (700 ml) was added and the distillation continued to about 400 ml final volume. Toluene (100 ml), water (400 ml) and potassium carbonate (25 g) were added to about pH 10. The layers were separated, and the aqueous phase discarded. The organic phase was washed with 10% aqueous sodium chloride (500 ml), then vacuum distilled to about 400 ml final volume. Toluene (100 ml) and 2-propanol (220 ml) were added and the reaction mass was heated to 45° C. Phthalic acid (31.6 g, 0.19 mole, 0.95 eq) was added in five equal portions over 30 mins. The resulting slurry was stirred at about 500C for 1 hr, cooled to 20° C., stirred for 2 hrs, filtered and washed with toluene (3×100 ml). The product was dried to a constant weight in vacuo to give 109.1 g (91%) of (II-a).
EXAMPLE 19
Reductive Amination: Preparation of a Compound of Formula (III-a) using a Chemical Reducing agent.
To a 22 L round bottom flask was added toluene (4.30 liters), (II-a) (1.20 Kg, 1.99 moles), water (4.30 liters) and 50% sodium hydroxide solution (335 g, 4.18 moles, 2.1 eq.). The mixture was stirred vigorously for 30 mins., agitation stopped, and the aqueous phase discarded. To the organic phase was added toluene (4.30 liters) and the solution was heated to reflux, distilling to a Dean and Stark trap until no more water was evolved, then cooled to 80° C. The Dean and Stark trap was drained, benzaldehyde (211 g, 203 ml, 1.99 moles) added to the reaction, and the reaction mixture heated to reflux, distilling to the Dean and Stark trap until no more water was evolved. The reaction mixture was cooled to 25° C., acetic acid (145 g, 135 ml, 2.34 moles, 1.2 eq.) and sodium triacetoxy borohydride (633 g, 2.99 moles, 1.5 eq.) were added. The reaction mixture was stirred overnight at 25° C. Water (2.15 liters) was slowly added, the pH of the aqueous phase was adjusted to 7-8 by the addition of 50% sodium hydroxide and the aqueous phase then discarded. The solvent was removed via vacuum distillation to give an oil which was dissolved in cyclohexane (9.75 liters). A solution of para-toluene sulphonic acid (378 g, 1.99 moles) in 2-propanol (4.20 liters) was added in five equal portions over 1 hour. The resulting slurry was heated at reflux for 20 mins., cooled to 10° C. and filtered. The product was dried to a constant weight in vacuo to give 1.25 Kg (90%) of (III-a).
EXAMPLE 19a
Reductive Amination: Preparation of a Compound of Formula (III-a) using a Hydrogenation metal catalyst.
To a 5 L round bottom flask was added toluene (3.00 liters), (II-a) (0.468 Kg, 0.77 moles), water (1.30 liters) and 50% sodium hydroxide solution (0.13 g, 1.62 moles, 2.1 eq.). The mixture was stirred vigorously for 30 mins., agitation stopped, and the aqueous phase discarded. The solution was heated to reflux, distilling to a Dean and Stark trap until no more water was evolved, then cooled to 80° C. The Dean—Stark trap was drained, benzaldehyde (82 g, 79 ml, 0.77 moles) added to the reaction, and the reaction mixture heated to reflux, distilling to the Dean and Stark trap until no more water was evolved. The Dean—Stark trap was replaced with a distillation apparatus and 2.5 liters of toluene was distilled. The solution was cooled to 55° C., methanol (1.7 liters) was added and 1.7 liters of solvent was distilled. The solution was cooled to 30° C. and methanol (2.5 liters) was added. The imine was hydrogenated over 5% Pt/C at 25° C. at 40 psi. Once the reaction was complete, as determined by hydrogen uptake, the reaction mixture was filtered through celite and the methanol removed via vacuum distillation. The crude product was dissolved in cyclohexane (1.5 liters) and 2-propanol (1.5 liters) and para-toluene sulphonic acid (80 g, 0.77 moles) was added portion wise. The resulting slurry was heated to reflux, cooled to 5° C. and filtered. The product was dried to a constant weight in vacuo to give 458 g (85%) of (III-a).
EXAMPLE 19b
Reductive Amination: Preparation of a Compound of Formula (III-b) using a Hydrogenation metal catalyst.
To a slurry of (II-a) (100 g, 0.166 moles) in toluene (400 ml) was added water (200 ml) and 10N sodium hydroxide solution (36.4 ml, 0.364 mol, 1.2 eq). The mixture was stirred for 30 mins, the agitation stopped and the phases separated. The aqueous layer was washed with toluene (200 ml) and the combined organic layers were washed with water (200 ml), clarified through a Celite bed, and concentrated to a residual volume of 600 mL by vacuum distillation, then diluted with toluene (200 ml) to a final volume of 800 ml. To the solution was added 10% palladium on carbon (15 g, 50% water content), triethylamine (1.0 g, 0.01 moles, 0.06 eq.), and butyraldehyde (14.6 g 0.202 moles, 1.2 eq.). After evacuating and purging with hydrogen (3×), the mixture was hydrogenated for a period of 24 hrs under 1 psi of hydrogen pressure. After completion of the reaction, as determined by HPLC, the catalyst was removed by filtration, washed with toluene (100 ml), and the filtrate concentrated to 200 ml by vacuum distillation. Isopropyl acetate (500 ml) was added and the solution warmed to 25-28° C. A solution of methanesulfonic acid (16.2 g, 0.168 moles) in isopropyl acetate (140 ml) was added slowly over a period of 20 minutes as the temperature increased to 34-36° C. The resulting slurry was cooled to 25° C. and stirred for 1 hour. The product was filtered, washed with isopropyl acetate (100 ml) and dried to a constant weight in vacuo to give 83 g (85%) of (III-b).
EXAMPLE 20
Combined Deacylation, Step 3, and Reductive Amination, Step 4: Preparation of a Compound of Formula (V-a).
A mixture of (III-a) (1.20 Kg, 1.72 moles), 2-propanol (3.25 liters) and a solution of potassium hydroxide (385 g, 6.86 moles, 4.0 eq.) in water (2.60 liters) was heated at reflux for 60 mins. The reaction was cooled to 25-30° C., and the 2-propanol removed via vacuum distillation until the volume was reduced by approximately half. Toluene (2.50 liters) was added, the phases separated and the aqueous phase discarded. Toluene (5.00 liters) was added and the solution was distilled at atmospheric pressure until the temperature of the distillate was ≧110° C. The solution was cooled to 80° C., 3-nitrile, 4-fluoro benzaldehyde (256 g, 1.72 moles, 1 eq.) was added and the reaction mixture was heated to reflux, distilling to a Dean and Stark trap until no more water was evolved. The reaction mixture was cooled to 25° C., acetic acid (124 g, 118 ml, 2.06 moles, 1.2 eq.) and sodium triacetoxy borohydride (546 g, 2.57 moles, 1.5 eq.) were added. The reaction mixture was stirred overnight at 25° C. Water (1.85 liters) was slowly added, the pH of the aqueous phase was adjusted to 7-8 by the addition of 50% sodium hydroxide and the aqueous phase then discarded. The solvent was removed via vacuum distillation to a final volume of 1.5-2.0 liters. Heptane (7.75 liters) was added, the resulting slurry was heated to reflux, cooled to 10° C. and filtered. The product was dried to a constant weight in vacuo to give 866 g (90%) of (V-a).
EXAMPLE 20a
Combined Deacylation; Step 3, and Reductive Amination, Step 4: Preparation of a Compound of Formula (V-b).
A mixture of (III-b) (0.70 Kg, 1.2 moles), 2-propanol (1.4 liters), potassium hydroxide (0.30 kg, 4.5 moles, 3.8 eq.) and water (0.44 liters) was distilled to 83° C. pot temperature. The reaction mass was cooled to about 70° C., and toluene (1.4 liters) and water (1.4 liters) were added. The pH of the mixture was adjusted by adding acetic acid to pH≦9 and then adding sodium carbonate to pH≧10. The reaction mass was distilled at atmospheric pressure until the pot temperature was ≧103° C. The solution was cooled to about 25° C., toluene (1.4 liters) was added and the layers were separated, discarding the aqueous phase. The organic phase was washed with water (1.4 liters). The solution was distilled at atmospheric pressure until the temperature of the distillate was >110° C. The solution was cooled to 35° C., 3-cyano-4-fluorobenzaldehyde (0.19 kg, 1.2 moles, 1 eq.) and toluene (0.7 liters) were added. The solution was distilled at atmospheric pressure until the temperature of the distillate was >110° C. The reaction mixture was cooled to about 25° C., acetic acid (0.08 liter, 1.43 moles, 1.2 eq.) and sodium triacetoxy borohydride (0.45 kg, 2.14 moles, 1.8 eq.) were added. The reaction mixture was stirred overnight at about 25° C. A solution of sodium carbonate (0.13 kg, 1.2 moles, 1 eq) in water (1.4 liters) was slowly added, the layers separated and the aqueous phase discarded. The organic phase was washed with water (1.4 liters). The reaction mass was concentratedvia distillation to provide (V-b) as a solution in toluene. This solution was used as is in the next step assuming a quantitative yield of (V-b) from (III-b).
EXAMPLE 22
Cyclization; Step 5: Preparation of a Compound of Formula (VII-a) via the intermediate (VI-a)
To a solution of (V-a) (210 g, 0.3725 moles) and N,N,N′,N′-tetramethylethylenediamine (78 g, 104 ml, 0.67 moles, 1.8 eq) in toluene (1260 ml) at reflux was added a solution of phosgene in toluene (0.15 M, 4470 ml, 0.67 moles, 1.8 eq) subsurface over 5-6 hours. During the addition of the phosgene solution, toluene was distilled off such that the maximum the volume of the reaction mixture was not allowed to exceed 3150 ml's. The reaction was cooled to 10° C. and then filtered to remove TMEDA.HCl salt. Toluene was removed via vacuum distillation until the final volume was 1000 ml. The reaction mixture was cooled to 40° C., methanol (210 ml) and concentrated hydrochloric acid (420 mL) were added, stirred at 55-65° C. for 1 hour, then cooled to 50° C. The phases were separated and the aqueous phase was discarded. The organic phase was washed with water that was preheated to 50° C. (210 ml), the phases were separated and the aqueous phase discarded. To the organic phase was added water (840 ml) and the resulting slurry stirred for 30 minutes at 5-10° C. The entire contents were filtered and the cake washed with toluene (210 ml) and water (840 ml). The product was dried to a constant weight in vacuo to give 154 g (75%) of (VII-a).
EXAMPLE 22a
Cyclization; Step 5: Preparation of a Compound of Formula (VI-b).
To a solution of (V-b)(296 g, 0.559 moles) and N,N,N′,N′-tetramethylethylenediamine (117 g, 152 ml, 1.00 moles, 1.8 eq) in toluene (1940 ml) at reflux was added a solution of phosgene in toluene (0.15 M, 6670 ml, 1.8 eq) subsurface over 5-6 hours. During the addition of the phosgene solution, toluene was distilled off such that the maximum the volume of the reaction mixture was not allowed to exceed 4900 ml's. The reaction was cooled to 20° C., silica gel (78 g) was added and the reaction mixture stirred for 30 mins at 20° C., then filtered. The reaction mixture was washed with water (3×1500 ml) and the aqueous phases discarded. The solvent was removed in vacuo to give an oil which was dissolved in a mixture of amylacetate (89 ml) and heptane (4760 ml). (VI-b) slowly crystalised and the resulting slurry was stirred at 10-20° C. for 4-8 hrs, then filtered. The product was dried to a constant weight in vacuo to give 233 g (75%) of (VI-b).
EXAMPLE 23
Synthesis of Compound of Formula (X-b).
A mixture of (VI-b) (0.28 Kg, 0.50 moles), 2-propanol (0.56 liters), hydrazine monohydrate (0.24 liters) and calcium carbonate (32 g) was heated at reflux under nitrogen for 6 hours. The reaction was checked for completion by HPLC (criteria for completion <0.3 area % (VI-b) remaining). The reaction was cooled to room temperature, ethyl acetate (1.8 liters) was added and the reaction mixture stirred for 10 minutes. The inorganic salts were filtered off and washed with ethyl acetate (0.2 liters). The combined organic filtrates were washed with 2M hydrochloric acid (2.1 liters). Methanol was added to the organic phase followed by the slow addition of 2M hydrochloric acid (1.2 liters). The reaction mixture was stirred at room temperature until the reaction was complete as determined by HPLC (<0.1 A% acetonide remaining). A 30% solution of sodium chloride (1.4 liters) was added and the mixture stirred for 10 minutes, the phases separated and the organic phase was washed with 2M hydrochloric acid (2.1 liters) and 10% aqueous potassium bicarbonate solution (1.4 liters). The organic phase was distilled to a head temperature of 75° C., additional ethyl acetate was added as required such that the volume did not fall below 2.0 liters. The solution was cooled to 50° C. and methanesulphonic acid (33 ml, 0.50 moles, 1.0 eq), ethanol (0.20 liters) and benzoyltrifluoroacetone (11.5 g, 0.1 eq) were added and the reaction mixture was heated at 65° C. for 2 hours. The solution was cooled to 20° C. and washed with a 10% aqueous solution of potassium bicarbonate (1.4 liters). The organic phase was distilled to a head temperature of 75° C., additional ethyl acetate was added as required such that the volume did not fall below 2.0 liters. The solution was cooled to 20° C. and seeded. The resulting slurry was cooled to 5° C. and stirred for one hour, filtered and washed with ethyl acetate until the yellow colour was removed. The product was dried in vacuo to give 224 g (85%) of (X-b).
EXAMPLE 23a
Synthesis of Compound of Formula (X-a).
A mixture of (VII-a) (0.56 Kg, 1.00 moles), 2-propanol (1.1 liters), hydrazine monohydrate (0.50 liters) and calcium carbonate (62 g) was heated at reflux under nitrogen for 6 hours. The reaction was checked for completion by HPLC (criteria for completion <0.3 area % (VII-a) remaining). The reaction was cooled to room temperature, ethyl acetate (4.0 liters) was added and the reaction mixture stirred for 10 minutes. The inorganic salts were filtered off and washed with ethyl acetate (1.6 liters). The combined organic filtrates were washed twice with 2M hydrochloric acid (4.2 liters) and once with a 10% aqueous solution of potassium bicarbonate (2.8 liters). The organic phase was distilled to a head temperature of 75° C., additional ethyl acetate was added as required such that the volume did not fall below 5.6 liters. The solution was cooled to 50° C. and ethanesulphonic acid (112 g, 1.02 moles, 1.02 eq), ethanol (0.65 liters) and benzoyltrifluoroacetone (22.4 g, 0.1 eq) were added. The solution was heated at 60° C. for 2 hours then cooled to 35° C. and seeded, cooled to 20° C., stirred for one hour then filtered. The wet cake was washed with ethyl acetate until the yellow colour was removed. The product was dried in vacuo to give 571 g (85%) of (X-a). | The present invention concerns an improved process for the preparation of asymmetric cyclic ureas as well as intermediates in the preparation of asymmetric cyclic ureas. In the process, a diamine of formula (I-a)
is selectively monoacylated to give an asymmetric monoacylated diamine which can be converted into asymmetric intermediates. The asymmetric intermediates can be further alkylated, cyclized, and/or modified to give compounds which are useful as HIV protease inhibitors for the treatment of HIV infection. The invention allows for scalable preparation of a wide variety of asymmetrical cyclic ureas. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to a modular window well egress and a method of installing the same. More specifically, though not exclusively, the invention relates to a modular egress window well with modular walls that are structurally identical and providing a simple means of installing a window well egress below ground level that is also easy to manufacture.
As land prices have increased, homeowners have looked for means of better utilizing a building's footprint. To do so, building owners have turned to using basement or below grade level space as living space. This raises several issues, such as being able to quickly exit the building in case of an emergency. To allow egress from the basement, building designers have incorporated means of exiting through a basement window into window well designs. These designs have included window well walls with built in steps, hand grips, and other devices that facilitate exiting through the basement window.
Many different designs have been used to create basement window wells. Early designs incorporated window wells into foundations of the building or home. The well was lined with bricks and then capped with additional bricks, wood or iron plating. This was done in an attempt to retain soil and increase the amount of light that entered into the below ground living space. The window was also used to allow the passage of materials, typically coal, into the basement without having to carry the material through the house. These early designs had to be incorporated at the beginning of construction and were nearly impossible to install after the building was formed.
The next step in the design evolution was to create a structure that could be manufactured separately from the foundation of the building. Still in use today, this design typically involves using corrugated and galvanized sheets of metal bent into a generally U-shaped structure that was then attached to the exterior of a building's foundation. The galvanized metal resisted the elements better than previous materials and was easily manufactured. Unfortunately, the galvanized material is unsightly and unattractive to an individual looking out the window. Further, the unitary design increases the difficulty of handling and installing the galvanized metal well structure.
For relatively shallow window wells, there was no need for the window well to incorporate devices or structures that would assist an individual in exiting through a basement window. But with increased building code regulations, the size of a basement window has increased to facilitate egress from within the basement. With this increase in window size, came the requirement for window wells to become deeper. With a deeper window well, there is a need for a structure within the well itself to facilitate exiting the window well. The first solution was the incorporation of a ladder structure outside of the confines of the window well that had to be lowered in. Later designs incorporated recesses and protrusions in the surface of the window well itself. Because the wells were typically constructed of galvanized corrugated sheet metal, the steps and handles were difficult to form and slippery when wet.
U.S. Pat. No. 3,999,334 to Webb discloses a basement escape window structure with a one-piece unit that has a hinged top that serves as an escape hatch from the basement. It also discloses a device with a plurality of steps that allow for easily ascending from the basement in order to escape from an opening in a basement wall. Because of the unitary design, the system is difficult to install. Further because of the lid, the device does not allow sunlight into the basement and completely obstructs the view that might have been afforded with the use of a more traditional window well.
The most recent development in egress window well design is a modular approach as demonstrated in U.S. Pat. Nos. 5,107,640 to 5,657,587 to Gefroh. Instead of the structure being constructed as a single unit, it is instead comprised of multiple parts and modules. The modular design allows for ease of construction, either during the original construction of the building or as a later addition. The modular concept also allows for the replacement of damaged and weathered parts without complete removal and disposal of the entire egress structure. The current designs are deficient in that they are comprised of multiple components of various sizes and shapes.
The variance in the modular pieces increases the cost of manufacturing a complete modular egress window well structure. Multiple tool sets are required to be used in the production of the individual walls. A greater number of individualized components cause a manufacturer's boxing and shipping system to be more complex to ensure that the correct components are shipped. The variance in shapes and size of the components also increase the number of shipping containers necessary to transport the entire system to the final destination. Further, because of the variety of necessary components, a retailer must stock many more components than is necessary to meet on demand needs.
Therefore, there is a need for an improved egress window well structure that consists of a limited number of components that can be easily manufactured. This structure should consist of components that are sightly yet constructed of material that are durable to environmental elements.
FEATURES OF THE INVENTION
A general feature of the present invention is the simplification of the construction of a below ground modular window well egress.
A further feature of the present invention is the provision of a modular window well egress with walls that are structurally identical.
An additional feature of the present invention is the provision of window well egress walls that interlock with one another.
Yet another feature of the present invention is the provision of a wall termination strip that interlocks with a window well egress wall.
Another general feature of the present invention is the provision of a rigid step that is placed between two non-parallel window well egress walls.
Still another feature of the present invention is the ability to stack the window well egress walls one on top of another to vary the depth below ground of the window well.
Still yet another feature of the present invention is the provision of a rigid wall for a modular egress window well structure that is easy to mass produce.
BRIEF SUMMARY OF THE INVENTION
The present invention generally comprises a method and apparatus for installing an egress window well. This structure consists of structurally identical walls that interlock via a system of protruding tenon and recessed notch. The pattern of protruding tenon and recessed notch could consist of any multiple number of tenon and notches such that one end pattern is the reciprocal of the other. Further, the walls are constructed of any material rigid enough to retain soil away from a below ground window. The space created allows the admittance of light and further allow the window to be used as an egress from the interior of a building. The walls are secured to the foundation of the building via interlocking termination strips.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of the invention.
FIG. 2 is an exploded view of the embodiment shown in FIG. 1 .
FIG. 3 is a perspective view of another embodiment of the invention.
FIG. 4 is an exploded view of the embodiment shown in FIG. 3 .
FIG. 5 is a perspective view of an embodiment of a modular wall section.
FIGS. 5A and 5B is a perspective view of another embodiment of a modular wall section.
FIG. 6 is a perspective view of an embodiment of the invention including a rigid step.
FIG. 7 is a perspective view of another embodiment of the invention comprising multiple layers of wall components.
FIG. 8 is a cross-sectional view of a building foundation and the surrounding soil.
FIG. 9 is a cross-sectional view of a building foundation in a hole excavated adjacent to the foundation.
FIG. 10 is a perspective view of a section of the building foundation with a first and second interlocking strip mounted thereon.
FIG. 11 is a perspective view of FIG. 10 with a first interlocking wall section joining with the first termination strip.
FIG. 12 is a perspective view of FIG. 11 with a second interlocking wall section joining with the second termination strip.
FIG. 13 is a perspective view of FIG. 12 with a third interlocking wall section interlocking with the first and second wall sections.
FIG. 14 is a perspective view of FIG. 13 with multiple layers of wall components.
FIG. 15 is a perspective view of FIG. 14 with soil back filled around the egress window well.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will be described as it applies to its preferred embodiment. It is not intended that the present invention be limited to the described embodiment. It is intended that the invention cover all modifications and alternatives, which may be included within the spirit and scope of the invention. In a preferred embodiment, the modular egress window well is constructed as three identical planar structures that interlock and connect to a building foundation via termination strips.
Now, referring to the drawings, FIG. 1 illustrates the preferred embodiment as a modular egress window well 10 having a first side wall 14 , a second side wall 18 , and a front wall 22 . FIG. 1 illustrates the first side wall 14 and second side wall 18 attaching to termination strips 24 . As shown in FIG. 2 , the front wall 22 interlocks with the first side wall 14 and second side wall 18 .
FIG. 3 illustrates another embodiment of a modular egress window well 10 having a first arcuate side wall 16 and a second arcuate side wall 20 . FIG. 3 illustrates that two arcuate walls 16 , 20 attaching to termination strips 24 that attach to the foundation of a building. Further, the arcuate side walls 16 , 20 interlock to form a solid barrier to form a space about a below ground window. The two embodiments described disclose a planar and arcuate rectangular wall to form the necessary side walls to create an egress window well. Other shapes and sizes are contemplated, including shapes with an upper surface 26 and a lower surface 28 that is sinusoidal, scalloped, triangular, and/or of any other fanciful design that can have the reciprocal image formed along the opposite surface (see FIGS. 5 , 5 A, 5 B).
As shown in FIG. 5 , the generic modular egress window well wall 12 has an interior surface 30 , exterior surface 32 , upper surface 26 , and a lower surface 28 . The wall 12 further has a first end 34 and second end 36 that consist of a pattern of tenon 38 and notch 40 . The first ends 34 pattern of tenon 38 and notch 40 is the reciprocal of the second ends 36 pattern of tenon 38 and notch 40 . The pattern created by the tenon 38 and notch 40 can vary both by the number of each and the spacing between and still be effective so long as the two ends 34 , 36 have a reciprocal pattern that facilitates the wall 12 interlocking with each other.
A further feature is depicted in FIG. 6 . A rigid step 42 is shown to be spanning two non-parallel walls 18 , 22 . The rigid step 42 rests upon the upper surface 26 and engages the interior 30 and exterior 32 surfaces of the two walls 18 , 22 . The rigid step 42 provides further rigidity to the egress window well 10 as well as provide a stepping surface for providing escape from deeper window wells.
To provide for deeper window wells, the modular walls 12 can be stacked on top of one another. FIG. 7 depicts multiple walls 12 stacked one on top of another to create a deeper well. Depending upon the design of the upper surface 26 and lower 28 surface, the stacked walls 12 may interlock vertically as well as horizontally.
FIGS. 8-15 relate to a method of installing a modular egress window well. FIG. 8 depicts a cross-section of a building foundation 44 and the soil 46 that is adjacent to the foundation 44 . FIG. 9 shows a hole 48 dug in the soil 46 adjacent to the foundation 44 . FIG. 9 shows the preferred method of installation. Another method would be the installation of the modular egress window well 10 before soil 46 is placed against the foundation 44 and hence there would be no need of a hole 48 . The size and dimension of the hole 48 is dependent upon the size of the window within the foundation 44 and the desired size of the window well.
FIG. 10 is a perspective view of a foundation 44 . Two termination strips 24 are secured to the foundation 44 separated by a space. The first termination strip 24 is secured by glue, nails, screws or other suitable methods to foundation 44 . The second termination strip 24 is also secured to the foundation 44 with the opposite orientation of the tenon 38 and notch 40 pattern. The two termination strips 24 are parallel to each other and are horizontally level with the bottom edge of each aligning with the other.
The termination strips 24 can be constructed of any material that provide sufficient rigidity to be formed into a tenon 38 and notch 40 pattern and secure the modular wall 12 to the foundation 44 . Examples of material that could be used to form the termination strip 24 include aluminum and high density plastic.
FIG. 10 further depicts a foundation 44 without a window. The egress window well 10 can be installed before or after installation of a window into the foundation 44 .
FIG. 11 shows the installation of the first side wall 14 onto the termination strip 24 . The modular wall 12 is constructed of a material sufficiently rigid to retain soil 46 and to be formed with tenon 38 and notch 40 . The walls 12 are constructed of high density plastic in the preferred embodiment but also may be made of high density polyethylene skin in a linear low density polyethylene core.
FIG. 12 further illustrates the installation of an egress window well 10 with an insertion of a second side wall 18 into a termination strip 24 . FIG. 13 shows a front wall 22 interlocking with the first side wall 14 and a second side wall 18 . FIG. 14 shows a second layer of wall sections 12 having been stacked on top of the first layer of wall sections 12 and terminated unto additional termination strips 24 . FIG. 15 depicts the egress window well 10 having been backfilled around, thus creating a space within the structure that can be used as an egress in conjunction with a window.
A general description of the present invention as well as a preferred embodiment to the present invention has been set forth. Those skilled in the art which the present invention pertains will recognize and be able to practice additional variations in the method and systems described which fall within the teachings of this invention. Accordingly, all such modifications and additions are deemed to be within the scope of the invention which is to be limited only by the claims appended hereto. | A modular egress window well structure which is constructed of structurally identical walls that interlock and attach to the foundation of a building via a termination strip. The identical wall members allow for ease of manufacturing and installation of the egress window well. The method of installation comprises removing soil away from the foundation of a building, securing the termination of strips to the foundation, assembling the egress window well and then backfilling the soil around the structure. | 4 |
FIELD OF THE INVENTION
This invention relates to medical apparatus and methods in general, and more particularly to apparatus and methods for reconstructing ligaments.
BACKGROUND OF THE INVENTION
Ligaments are tough bands of tissue which serve to connect the articular extremities of bones, or to support or retain organs in place within the body. Ligaments are typically composed of coarse bundles of dense white fibrous tissue which are disposed in a parallel or closely interlaced manner, with the fibrous tissue being pliant and flexible, but not extensible.
In many cases, ligaments are torn or ruptured as a result of accidents. As a result, various procedures have been developed to repair or replace such damaged ligaments.
For example, in the human knee, the anterior and posterior cruciate ligaments (i.e., the ACL and PCL) extend between the top end of the tibia and the bottom end of the femur. The ACL and PCL cooperate, together with other ligaments and soft tissue, to provide both static and dynamic stability to the knee. Often, the anterior cruciate ligament (i.e., the ACL) is ruptured or torn as a result of, for example, a sports-related injury. Consequently, various surgical procedures have been developed for reconstructing the ACL so as to restore normal function to the knee.
In many instances, the ACL may be reconstructed by replacing the ruptured ACL with a synthetic or harvested graft ligament. More particularly, with such procedures, bone tunnels are typically formed in the top end of the tibia and the bottom end of the femur, with one end of the graft ligament being positioned in the femoral tunnel and the other end of the graft ligament being positioned in the tibial tunnel. The two ends of the graft ligament are anchored in place in various ways well known in the art so that the graft ligament extends between the femur and the tibia in substantially the same way, and with substantially the same function, as the original ACL. This graft ligament then cooperates with the surrounding anatomical structures so as to restore normal function to the knee.
It will, of course, be appreciated that a complex interdependency exists between the ACL and the other elements of the knee, e.g., the bones, the other knee ligaments, and other soft tissue. Consequently, it is critical that the graft ACL be disposed in exactly the right position relative to the other anatomical structures of the knee if normal knee function is to be restored. Correspondingly, it has been found that the aforementioned bone tunnels must be precisely positioned in the tibia and femur if successful reconstruction of the ACL is to be achieved. Unfortunately, proper positioning of these bone tunnels to satisfy isometric considerations can sometimes lead to anatomical conflicts within the knee when the graft ACL is installed within the knee.
More particularly, the ACL normally extends between the bottom end of the femur and the top end of the tibia, with the body of the ACL passing through the femur's intercondylar notch and across the interior of the knee joint. See, for example, FIGS. 1 and 2, which show a natural ACL 5 extending between the bottom end of a femur 10 and the top end of a tibia 15, with the body of ACL 5 passing through the femur's intercondylar notch 20. Also shown is a natural PCL 25 extending between the bottom end of femur 10 and the top end of tibia 15.
It is to be appreciated that the position of the various knee elements move relative to one another as the knee is flexed through a range of natural motions. See, for example, FIG. 3, which shows ACL 5 moving across a 40° arc as the knee joint is flexed through a 140° motion.
Due to the complex geometries of the knee, where a damaged ACL is to be replaced by a graft ACL, it is critical that the graft ACL be connected at precisely the right locations on the bottom end of the femur and top end of the tibia. Thus, and looking now at FIGS. 4 and 5, where a damaged ACL is to be replaced by a graft ACL, the damaged ACL is first cleared away and then bone tunnels 30 and 35 are formed in the tibia and femur, respectively. The precise locations of these bone tunnels 30 and 35 are dictated by the isometric relationships of the knee. In practice, bone tunnels 30 and 35 are formed using a surgical drill guide which is keyed to certain parts of the patient's anatomy, e.g., to the patient's tibial plateau. Once bone tunnels 30 and 35 have been formed, the graft ACL may be installed in ways well known in the art. See, for example, FIGS. 6 and 7, which show a graft ACL 5A having one end mounted to femur 10 and the other end mounted to tibia 15.
Unfortunately, in some situations, proper isometric placement of bone tunnels 30 and 35 may cause anatomical conflicts within the knee when the graft ACL is installed in the patient. By way of example, and of particular interest in connection with the present invention, proper isometric placement of bone tunnels 30 and 35 may result in portions of the femur impinging upon the graft ACL as the knee is moved through its full range of natural motions. See, for example, FIG. 8, which shows one of the femur's condyles 40 impinging upon a graft ACL 5A extending through the femur's intercondylar notch 20; and FIG. 9, which shows the roof 08 the femur's intercondylar notch impinging on the graft ACL 5A in the vicinity of arrow 42.
Impingement can occur for a variety of reasons. For one thing, the intercondylar notch of many patients (particularly those who are susceptible to rupture of the ACL) is frequently small to begin with. For another thing, the graft ACL (i.e., the synthetic or harvested graft ligament which is being installed in place of the damaged natural ACL) is generally fairly large.
Additionally, slight mispositioning of bone tunnels 30 and 35 can also lead to impingement problems.
Unfortunately, impingement of the femur on the graft ligament can reduce the effectiveness of the ACL reconstruction procedure or even cause it to fail altogether.
Thus, when performing an ACL reconstruction procedure, the surgeon generally tries to ensure that there is sufficient room within the patient's intercondylar notch to receive the graft ligament. This is generally done by performing notchplasty, i.e., by surgically removing any impinging bone from the sides and/or roof of the intercondylar notch. At the same time, of course, it is also important that the surgeon remove no more bone than is absolutely necessary, so as to minimize trauma to the patient.
Unfortunately, it is difficult for the surgeon to accurately gauge the precise amount of bone that must be removed from the notch in order to avoid impingement. For one thing, the ACL reconstruction procedure is typically performed arthroscopically, so that the surgeon's view of the surgical site is frequently fairly restricted. For another thing, the surgeon typically will not know the precise space that the graft ACL will occupy until the graft is actually in place; but at that point in the procedure, it is frequently difficult to insert additional bone-cutting instruments into the joint so as to remove more bone, particularly without cutting the graft ACL. Furthermore, experience has shown that the most serious problems with impingement occur superiorly; but even with the graft ligament in place, the surgeon is generally unable to see impingement at this location due to limitations in arthroscopic visualization. Also, the surgeon typically performs the ACL reconstruction procedure in a relatively static context, i.e., with the knee being relatively stationary at any given moment during the reconstruction procedure. However, the knee must perform (and impingement must be avoided) in a relatively dynamic context, i.e., as the knee is moved throughout a full range of natural motions. This complicates the surgeon's task of eliminating impingement.
OBJECTS OF THE INVENTION
Accordingly, one object of the present invention is to provide improved apparatus for reconstructing a ligament.
Another object of the present invention is to provide improved apparatus for reconstructing an anterior cruciate ligament (ACL).
And another object of the present invention is to provide improved apparatus for quickly, easily and reliably eliminating impingement problems when reconstructing an anterior cruciate ligament.
Still another object of the present invention is to provide improved apparatus for quickly, easily and reliably removing any anatomical structures (e.g., bone) which will conflict with the location of a graft ACL at the completion of an ACL reconstruction procedure.
Yet another object of the present invention is to provide improved apparatus for quickly, easily and reliably removing any anatomical structures (e.g., bone) which will conflict with the location of a graft ACL as the knee is moved through a full range of natural motions.
And an object of the present invention is to provide an improved method for reconstructing a ligament.
Another object of the present invention is to provide an improved method for reconstructing an anterior cruciate ligament (ACL).
And another object of the present invention is to provide an improved method for quickly, easily and reliably eliminating impingement problems when reconstructing an anterior cruciate ligament.
Still another object of the present invention is to provide an improved method for quickly, easily and reliably removing any anatomical structures (e.g., bone) which will conflict with the location of a graft ACL at the completion of an ACL reconstruction procedure.
Yet another object of the present invention is to provide an improved method for quickly, easily and reliably removing any anatomical structures (e.g., bone) which will conflict with the location of a graft ACL as the knee is moved through a full range of natural motions.
SUMMARY OF THE INVENTION
These and other objects are addressed by the present invention, which comprises the provision and use of novel apparatus for removing impinging bone during a ligament reconstruction procedure.
In one preferred form of the invention, the novel apparatus comprises a guidewire and a router assembly.
The guidewire is similar to other guidewires of the sort well known in the art, except that it is preferably formed out of a pseudoelastic material, i.e., a "shape memory alloy (SMA)/stress induced martensite (SIM)" material such as Nitinol.
The router assembly comprises a cannulated router device and a shield assembly. The cannulated router device comprises a cannulated cutting head which is attached to a cannulated shaft. The shield assembly comprises a body and a hood. The body includes a hole therein. The hood extends about one end of the body. The router assembly is assembled so that the router device has its cutting head disposed at one end of the shield assembly's body and the router device has its shaft extending through the hole in the shield assembly's body. The shield assembly's hood covers a first portion of the router device's cutting head while leaving a second portion of the cutting head exposed.
The guidewire is deployed in the body so that it extends along the length where the graft ACL will reside. The router assembly is mounted on the guidewire by passing the guidewire through the router device's shaft and cutting head, such that the router assembly is movable along the guidewire. The router device's shaft is rotatable in the shield assembly such that the cutting head can be turned so as to remove bone while the router assembly is riding on the guidewire. Portions of the router assembly engaging the guidewire are formed so as to be flexible. On account of the fact that both the guidewire and portions of the router assembly are formed so as to be flexible, the router assembly can be used to remove impinging bone as the knee is flexed through a full range of natural motions.
In accordance with another form of the invention, there is provided alternative apparatus for removing impinging bone, the alternative apparatus comprising a guidewire and a cannulated router device. Again, the guidewire is preferably formed out of a pseudoelastic material. The cannulated router device comprises a cannulated cutting head which is attached to a cannulated shaft. In this embodiment of the invention, the cutting head is devoid of cutting means on a first portion of the periphery thereof and is provided with cutting means on a second portion of the periphery thereof. The second portion of the cutting head is engageable with the impinging bone portions which are to be removed.
Again, the guidewire is deployed in the body so that it extends along the length where the graft ACL will reside. The router device is mounted on the guidewire by passing the guidewire through the router device's shaft and cutting head, such that the router device is movable on the guidewire. The router device is rotatably movable in an oscillating fashion such that the cutting head's second portion moves in alternating opposite directions across the impinging bone to remove portions thereof. The first portion of the cutting head is smooth and non-destructive with respect to any anatomical structures which the first portion may come into contact with. Portions of the router device engaging the guidewire are formed so as to be flexible. On account of the fact that both the guidewire and portions of the router device are formed so as to be flexible, the router device can be used to remove impinging bone as the knee is flexed through a full range of natural motions.
In accordance with another form of the invention, there is provided alternative apparatus for removing impinging bone, the alternative apparatus comprising a guidewire and a cannulated router device. Again, the guidewire is preferably formed out of a pseudoelastic material. The cannulated router device comprises a cannulated cutting head which is attached to a cannulated shaft. In this embodiment of the invention, the cutting head is adapted to cut bone which comes into contact with the cutting head, but to leave unharmed soft tissue which comes into contact with the cutting head.
Again, the guidewire is deployed in the body so that it extends along the length where the ACL graft will reside. The router device is mounted on the guidewire by passing the guidewire through the router device's shaft and cutting head, such that the router device is movable on the guidewire. The router device is rotatably movable on the guidewire so as to cut away impinging bone. Again, portions of the router device engaging the guidewire are formed so as to be flexible. On account of the fact that both the guidewire and portions of the router device are formed so as to be flexible, the router device can be used to remove impinging bone as the knee is flexed through a full range of natural motions.
In accordance with another form of the invention, there is provided apparatus for marking portions of impinging bone which are to be thereafter removed, the apparatus comprising a guidewire and a cannulated marking device. Again, the guidewire is preferably formed out of a pseudoelastic material. The cannulated marking device comprises a cannulated marker head attached to a cannulated shaft.
Again, the guidewire is deployed in the body so that it extends along the length where the graft ACL will reside. The marking device is mounted on the guidewire by passing the guidewire through the marking device's shaft and marking head, such that the marking head is movable on the guidewire. The marking head is adapted to hold a dye and to release that dye upon contact with bone, whereby to mark the impinging portions of the bone proximate to the guidewire as the marking head moves on the guidewire. Portions of the marking device engaging the guidewire are formed so as to be flexible. On account of the fact that both the guidewire and portions of the marking device are formed so as to be flexible, the marking device can be used to mark impinging bone as the knee is flexed through a full range of natural motions.
In accordance with a further feature of the invention, there is provided a method for removing impinging portions of bone, the method comprising the steps of providing a flexible guidewire and a flexible cannulated router device. The guidewire is anchored in the bone so that it extends along the length where the graft ACL will reside, and the cannulated router device is rotatably mounted on the guidewire so that it is movable on the guidewire. Then the cannulated router device is rotated on the guidewire as the knee is flexed through a range of natural motions so as to dynamically remove impinging bone.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the present invention will be more fully disclosed or rendered obvious by the following detailed description of the preferred embodiments of the invention, which are to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein:
FIG. 1 is a schematic front view of a normal knee, where the leg is substantially straight;
FIG. 2 is a schematic side view, partially in section, of the knee shown in FIG. 1;
FIG. 3 is a schematic side view, showing how the ACL moves about within the knee joint as the knee is flexed through a range of natural motions;
FIG. 4 is a schematic front view of a knee, where the knee is bent at approximately a 90° angle, and where a damaged ACL has been removed and bone tunnels have been formed in the tibia and the femur;
FIG. 5 is a schematic side view of the knee shown in FIG. 4;
FIG. 6 is a schematic front view of a knee, where the knee is bent at approximately a 90° angle, showing a graft ACL installed in the knee;
FIG. 7 is a schematic side view of the knee shown is FIG. 6;
FIG. 8 is a schematic front view showing how portions of the femur can impinge upon a graft ACL;
FIG. 9 is a schematic side view showing how portions of the femur can impinge upon a graft ACL;
FIG. 10 is a schematic side view of the guidewire used in connection with the present invention;
FIG. 11 is a schematic perspective view showing one form of router assembly formed in accordance with the present invention;
FIG. 12 is a schematic perspective view of the router assembly's cannulated router device;
FIG. 13 is a schematic side view, in section, of the cannulated router device shown in FIG. 12;
FIG. 14 is a schematic side view, in section, of a portion of the router assembly's shield assembly;
FIG. 15 is a schematic perspective view of the shield assembly's collar;
FIG. 16 is a schematic side view, in section, of the router assembly shown in FIG. 11;
FIG. 17 is a schematic side view of a knee, where the knee is bent at approximately a 90° angle, and where a damaged ACL has been removed and a bone tunnel has been formed in the tibia, and showing a guidewire extending through the tibial bone tunnel and into the femur;
FIG. 18 is a schematic side view of the knee shown in FIG. 17;
FIG. 19 is a schematic front view like that of FIG. 17, except showing a router assembly removing lateral bone structures from the femoral notch so as to prevent those lateral bone structures from impinging on a graft ACL;
FIG. 20 is a schematic side view showing a router assembly removing lateral bone structures from the femoral notch so as to prevent those lateral bone structures from impinging on a graft ACL;
FIG. 21 is a schematic front view, showing the leg substantially straight and the router assembly removing roof bone structures from the femoral notch so as to prevent those roof bone structures from impinging on a graft ACL;
FIG. 22 is a schematic side view of the knee and router assembly shown in FIG. 21;
FIG. 23 is a schematic side view, showing the knee flexed at approximately a 140° angle and the router assembly removing bone structures from the femoral notch so as to prevent those bone structures from impinging on a graft ACL;
FIG. 24 is a schematic perspective view showing an alternative form of router assembly formed in accordance with the present invention;
FIG. 25 is a schematic perspective view showing the collar used in connection with the router assembly shown in FIG. 24;
FIG. 26 is a schematic side view, in section, of the router assembly shown in FIG. 24;
FIG. 27 is a schematic perspective view of another form of router device which can be used in connection with the present invention;
FIG. 28 is a schematic perspective view of yet another form of router device which can be used in connection with the present invention;
FIG. 29 is a schematic side view of a cannulated marking device formed in accordance with the present invention; and
FIG. 30 is a schematic side view of a novel type of guidewire assembly formed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Looking first at FIGS. 10-16, the present invention provides apparatus and a method for removing bone structures from the femoral notch so as to prevent those bone structures from impinging upon a graft ACL installed as part of an ACL reconstruction procedure. The apparatus and method of the present invention are intended to be utilized in an ACL reconstruction procedure after the damaged ACL has been removed from the knee and after bone tunnel 30 has been formed in tibia 15, but before bone tunnel 35 has been formed in femur 10 and the graft ACL has been positioned in the joint.
Still looking now at FIGS. 10-16, in one preferred embodiment of the present invention, the apparatus of the present invention comprises a guidewire 50 (FIGS. 10 and 11) and a router assembly 55 (FIGS. 11-16).
Guidewire 50 is generally of the sort well known in the art for guiding cannulated elements to a target structure. As such, guidewire 50 includes a sharp point 60 (FIG. 10) on its distal end, whereby the guidewire can be drilled or tapped into a target structure (e.g., femur 10, as will hereinafter be described in further detail). However, unlike other guidewires of the sort known in the art, and in accordance with one preferred embodiment of the present invention, guidewire 50 is preferably formed out of a highly elastic yet firm material. Preferably, guidewire 50 is formed out of a so-called pseudoelastic material, i.e., a "shape memory alloy (SMA)/stress induced martensite (SIM)" material such as Nitinol. By forming guidewire 50 out of such a highly elastic yet firm material, the guidewire has the rigidity needed to penetrate into bone, yet has the high elasticity needed to undergo substantial elastic deformation during joint flexure, as will hereinafter be described in further detail.
Still looking now at FIGS. 11-16, router assembly 55 comprises a cannulated router device 65 (FIGS. 11-13 and 16) which comprises a cannulated cutting head 67 attached to a cannulated shaft 70. At least the distal portion 70' (FIGS. 12, 13 and 16) of cannulated shaft 70 is flexible; the proximal portion 70" of cannulated shaft 70 may or may not be flexible, as desired. On account of this construction, cannulated router device 65 can ride on guidewire 50 as rotary cutting motion is imparted to cutting head 67 by means of shaft 70. In particular, by forming at least the distal portion 70' of cannulated shaft 70 so as to be flexible, router device 65 can ride on guidewire 50 and rotate even as guidewire 50 is subjected to substantial bending during knee joint flexure, as will hereinafter be discussed in further detail.
Router assembly 55 also comprises a shield assembly 75 (FIGS. 11 and 14-16). Shield assembly 75 comprises a body assembly 80 and a hood 85.
Body assembly 80 comprises a hollow outer tube 82 (FIGS. 14 and 16) and an inner collar 83 (FIGS. 15 and 16). At least the distal portion 82' (FIGS. 14 and 16) of hollow outer tube 82 is flexible; the proximal portion 82" of hollow outer tube 82 may or may not be flexible, as desired. Collar 83 is sized and positioned so as to terminate at the juncture of the hollow tube's distal portion 82' and its proximal portion 82" (FIG. 16). Collar 83 includes a hole 90 (FIGS. 15 and 16) for receiving shaft 70 of router device 65. Hole 90 is preferably centered within body 80, whereby the router device's cutting head 67 will be centered within shield assembly 75.
Hood 85 is attached to body 80 and includes a hole 95 (FIGS. 14 and 16) for receiving guidewire 50. Hood 85 surrounds a portion of the router device's cutting head 67 but leaves another portion of the cutting head (i.e., the portion extending outboard of hood 85) exposed for routing operations. By way of example but not limitation, hood 85 might cover approximately 2/3 of the circumferential region surrounding cutting head 67 and leave approximately 1/3 of the circumferential region surrounding cutting head 67 exposed for cutting purposes. Shield 85 may be formed flexible or rigid, as desired.
As a result of this construction, router assembly 55 can ride on guidewire 50 as a unit, with shaft 70 rotating cutting head 67 so as to cut away any material (e.g., impinging bone) exposed to the cutting head, even as hood 85 shields a substantial portion of the cutting head from inadvertently cutting other material (e.g., the patient's PCL). Significantly, due to the flexible nature of shaft portion 70' and tube portion 82', router assembly 55 is able to ride on guidewire 50 even as guidewire 50 is subjected to substantial deformation during knee joint flexure.
Looking next at FIGS. 17-23, guidewire 50 and router assembly 55 are intended to be used as follows.
First, femur 10 and tibia 15 are set at approximately a 90° angle and tibial bone tunnel 30 is formed in tibia 15. Then guidewire 50 is passed through tibial bone tunnel 30 and into femur 10 until the sharp distal end 60 of the guidewire is embedded in the femur, e.g., by drilling or tapping in ways well known in the art (see FIGS. 17 and 18). If desired, a cannulated guide of the sort well known in the art (not shown) may be disposed about guidewire 50 to help stabilize it as it is embedded into femur 10. Guidewire 50 is positioned in the patient so that it will extend along the length where the graft ACL will reside.
Next, router assembly 55 is loaded onto the proximal end of guidewire 50 and moved down into the interior of the knee joint so that the router assembly's cutting head 67 is in the vicinity of femoral notch 20 (see FIGS. 19 and 20). Then body 80 of router assembly 55 is turned so that the router assembly's cutting head 67 is directed toward the impinging portions of the femur which are to be removed, and so that the router assembly's protective hood 85 is placed between the cutting head and the PCL so as to protect the PCL from the cutting head. Then shaft 70 is rotated, e.g., with a power driver (not shown) of the sort well known in the art, so as to rotate cutting head 67 and thereby cut away any anatomical structures it comes into contact with.
By turning body 80 circumferentially as required, cutting head 67 can be used to enlarge femoral notch 20 while keeping the cutting head from engaging (and thereby cutting) the PCL and/or other sensitive anatomical structures. In particular, by turning router assembly 55 so that it faces in the manner shown in FIGS. 19 and 20, lateral notch structures can be removed. Similarly, by turning router assembly 55 so that it faces in the manner shown in FIGS. 21 and 22, roof notch structures can be removed.
Significantly, the impinging bone can be removed quickly, easily and safely, without direct visualization of the anatomical structures being trimmed away, due to the use of guidewire 50 and the guidewire-following router assembly 55.
In particular, it is to be appreciated that, by positioning guidewire 50 so that it will extend along the length where the graft ACL will reside, and by properly sizing the radial dimensions of router assembly 55 relative to the graft ACL which will thereafter be installed, the router assembly will clear away only as much bone as is required to properly size the femoral notch and eliminate impingement problems. Furthermore, by properly sizing the longitudinal dimensions of router assembly 55 relative to the notch region where impingement occurs, impingement can be eliminated by just circumferential movement of router assembly 55 on guidewire 50, i.e., without requiring longitudinal movement of router assembly 55 on guidewire 50 during bone-trimming operations.
Significantly, since guidewire 50 is preferably formed out of a highly elastic material, and since the router assembly's shaft portion 70' and body portion 82' are formed so as to be flexible, it is possible to use router assembly 55 to remove impinging bone in a dynamic sense, i.e., to use the router assembly to cut away impinging bone even as the knee is flexed through a full range of natural motions. See, for example, FIGS. 19 and 20, where router assembly 55 is shown enlarging the femoral notch while the patient's leg is bent at approximately a 90° angle; FIGS. 21 and 22, where router assembly 55 is shown enlarging the femoral notch while the patient's knee is substantially straight; and FIG. 23, where router assembly 55 is shown enlarging the femoral notch while the patient's knee is bent at approximately a 140° angle. It should be noted in FIGS. 21 and 22, and again in FIG. 23, how guidewire 50 and router assembly 55 are capable of undergoing substantial elastic deformation during such knee flexing even as bone-trimming operations are under way.
Looking next at FIGS. 24-26, in another preferred embodiment of the present invention, the apparatus of the present invention comprises guidewire 50 and a router assembly 55A.
Router assembly 55A is substantially the same as router assembly 55 described above, except as is shown in the drawings and/or hereinafter described. In particular, router assembly 55A utilizes a collar 83A (FIGS. 25 and 26) rather than the collar 83 described above. Collar 83A has its hole 90 disposed off-center within the collar, whereby the router device's cutting head 67 will be clocked to one side relative to the body's hollow outer tube 82 (see FIG. 26). In particular, with router assembly 55A, collar 83A is arranged so that the router device's cutting head 67 is clocked outboard relative to the central axis of hollow outer tube 82. This permits the router device to engage impinging bone more readily. In order to accommodate such lateral displacement of router device 65, the router assembly's shield 85A has its hole 95A shifted laterally as well, in the manner shown in FIG. 26.
In operation, router assembly 55A is intended to be used in substantially the same way as router assembly 55.
Looking next at FIG. 27, in another preferred embodiment of the present invention, the apparatus of the present invention comprises guidewire 50 and a cannulated router device 65A. Router device 65A is generally similar to the router device 65 discussed above, except that with router device 65A, its cutting teeth 89 are disposed about only a portion of the periphery of its cutting head 67A, with the remainder of the cutting head being smooth and non-abrasive. Accordingly, by moving cannulated router device 65A on guidewire 50 so as to oscillate the router device through only a fraction of a complete revolution, bone can be removed adjacent to the cutting teeth 89 while the remainder (i.e., the non-cutting portion) of the cutting head 67A safely opposes any delicate structures which are to be safeguarded (e.g., the PCL). Thus, with the apparatus of FIG. 27, impinging bone may be safely removed without providing a shield assembly (e.g., such as the shield assembly 75 described above) for the router device.
In another form of the invention, the cannulated router device 65A of FIG. 27 could be replaced with a cannulated router device of the sort adapted to remove hard bone while leaving soft tissue unharmed. By way of example, the cannulated router device 65A of FIG. 27 might be replaced by the cannulated router device 65B shown in FIG. 28. More particularly, router device 65B includes a cutting head 67B having an outer configuration similar to that disclosed in U.S. Pat. No. 4,445,509 issued May 1, 1984 to David C. Auth for METHOD AND APPARATUS FOR REMOVAL OF ENCLOSED ABNORMAL DEPOSITS, which patent is hereby specifically incorporated herein by reference. Alternatively, cutting head 67B could have some other configuration of the sort well known in the art which permits cutting of hard bone without harming soft tissue. As a result of such a construction, a cannulated router device 65B having such a configuration could then be safely rotated completely about guidewire 50 so as to remove impinging bone without risking damage to delicate soft tissue. Thus, with the apparatus of FIG. 28 or with equivalent cutting apparatus, impinging bone can be safely removed without providing a shield assembly (such as the shield assembly 75 described above) for the router device.
The foregoing apparatus may be used in an ACL reconstruction procedure as follows. First, the patient's knee is extended at an angle of approximately 90°. Then, a bone tunnel 30 is formed in the tibia in ways well known in the art. Next, guidewire 50 is passed through bone tunnel 30 and up into the femur. Then a cannulated router device (in the form of either router assembly 55, or router assembly 55A, or router device 65A, or router device 65B) is loaded onto guidewire 50 and used to perform the desired notchplasty in the manner previously described. Next, the cannulated router device is dismounted from guidewire 50. Then bone tunnel 35 is formed in femur 10 in ways well known in the art. Then guidewire 50 is removed from femur 10. Finally, a graft ACL 5A is installed in femoral bone tunnel 35 and tibial bone tunnel 30 in ways well known in the art.
Looking next at FIG. 29, in another preferred embodiment of the present invention, the apparatus of the present invention comprises guidewire 50 and a marking device 100. Marking device 100 preferably comprises a resilient cannulated head 105 and a flexible cannulated shaft 110 connected to head 105. Cannulated head 105 is formed so that it can hold and release a dye without cutting bone. Marking device 100 is used by moving the device up and down guidewire 50, with or without rotation, whereby the marking head 105 will contact any bone in its way. By sizing marking device 100 properly relative to the size of the graft ACL which is to be installed, movement of marking device 100 along guidewire 50 while the knee is moved through a range of natural motions will cause the marking element to leave its dye on any portions of the femur which might impinge upon the graft ACL which will thereafter be installed in the knee. Thereafter, marking device 100 and guidewire 50 are removed from the surgical site and the surgeon may utilize a conventional cutting element to remove the marked bone. Then the graft ACL may be installed in the knee without fear of impingement.
In the foregoing description of the preferred embodiments of the invention, it was noted that guidewire 50 is preferably formed out of a pseudoelastic material so as to provide the desired characteristics of firmness and flexibility. However, it should also be appreciated that a guidewire made out of a non-pseudoelastic material can also be utilized in connection with the present invention. Of course, inasmuch as the preferred use of the present invention involves flexing the knee over a wide range of motions with the guidewire in place, limitations in wire flexibility can inhibit the range of knee movements performed with the guidewire in place. Thus, in the situation where a non-pseudoelastic guidewire is to be used, it can be helpful to mount the distal end of the guidewire in a fixture by means of a universal joint. This fixture can then be attached to the bottom surface of the femur or, more advantageously, it can be disposed in a bore formed in the bottom of the femur. Preferably this bore is the femoral bone tunnel 35 used for the ACL reconstruction procedure.
More particularly, and looking now at FIG. 30, the distal end of a non-pseudoelastic guidewire 50A can be mounted in a fixture 115 by a universal joint 120 whereby the proximal end of the guidewire can move about relative to fixture 115. As a result of this construction, when fixture 115 is positioned in the femoral bone tunnel, universal joint 120 will help guidewire 50A to accommodate the degree of deformation required as the knee is moved through a full range of natural motions. Of course, with this embodiment of the invention, the femoral bone tunnel 35 must be formed before the notchplasty procedure is performed, since fixture 115 is intended to be received in bone tunnel 35.
Modifications Of the Preferred Embodiments
It is to be appreciated that modifications may be made to the preferred embodiments described and illustrated above without departing from the scope of the present invention
Thus, for example, while in the foregoing description the present invention has been described in the context of reconstructing an ACL, it should also be appreciated that the present invention has application to the reconstruction of other ligaments as well, where similar impingement problems can occur. Thus, for example, the present invention might be used in connection with reconstructing the posterior cruciate ligament (PCL).
The present invention can also be used to clear away impinging structures in other anatomical and non-anatomical settings.
Advantages Of The Invention
Numerous advantages are achieved through the use of the present invention.
For one thing, the present invention provides improved apparatus for reconstructing a ligament.
And the present invention provides improved apparatus for reconstructing an anterior cruciate ligament (ACL).
Also, the present invention provides improved apparatus for quickly, easily and reliably eliminating impingement problems when reconstructing an anterior cruciate ligament.
And the present invention provides improved apparatus for quickly, easily and reliably removing any anatomical structures (e.g., bone) which will conflict with the location of a graft ACL at the completion of an ACL reconstruction procedure.
The present invention also provides improved apparatus for quickly, easily and reliably removing any anatomical structures (e.g., bone) which will conflict with the location of a graft ACL as the knee is moved through a full range of natural motions.
The present invention also provides an improved method for reconstructing a ligament.
And the present invention provides an improved method for reconstructing an anterior cruciate ligament (ACL).
And the present invention provides an improved method for quickly, easily and reliably eliminating impingement problems when reconstructing an anterior cruciate ligament.
Also, the present invention provides an improved method for quickly, easily and reliably removing any anatomical structures (e.g., bone) which will conflict with the location of a graft ACL at the completion of an ACL reconstruction procedure.
And the present invention provides an improved method for quickly easily and reliably removing any anatomical structures (e.g. bone) which will conflict with the location of a graft ACL as the knee is moved through a full range of natural motions. | Apparatus for removing bone from a femoral notch, or the like, which includes a guidewire and a router assembly. The router assembly comprises a cutting head fixed to a shaft rotatably disposed in a hole through a body portion of a shield assembly. A hood portion of the shield assembly extends from the body portion of the shield assembly and covers a first portion of the cutting head while leaving exposed a second portion of the cutting head. The guidewire extends through a hole in the shaft, a hole in the cutting head, and a hole in the shield assembly hood portion, such that the router assembly is movable along the guidewire. The shaft is rotatable in the shield assembly body portion such that the second portion of the cutting head is engageable with the bone and operative to remove portions of the bone. The guidewire is installed in the knee so that it extends along the length to be occupied by a graft ligament. The guidewire and router assembly are flexible so that the bone-trimming operation may be conducted dynamically as the knee is moved through a range of natural motions. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 61/233,121 filed on Aug. 11, 2009, and also claims the benefit of earlier filing date and right of priority to Korean Patent Application No. 10-2010-0076578 filed on Aug. 9, 2010, the contents of all of which are incorporated by reference in their entirety herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to wireless communications, and more particularly, to a method and apparatus for Multimedia Broadcast/Multicast Service (MBMS) in a wireless communication system.
2. Related Art
3 rd generation partnership project (3GPP) long term evolution (LTE) is an improved version of a universal mobile telecommunication system (UMTS) and is introduced as the 3GPP release 8. The 3GPP LTE uses orthogonal frequency division multiple access (OFDMA) in a downlink, and uses single carrier-frequency division multiple access (SC-FDMA) in an uplink. The 3GPP LTE employs multiple input multiple output (MIMO) having up to four antennas. In recent years, there is an ongoing discussion on 3GPP LTE-advanced (LTE-A) that is an evolution of the 3GPP LTE.
A multimedia broadcast/multicast service (MBMS) is a service which provides multimedia traffic to a user equipment (UE) in a cell. In the 3GPP LTE, the MBMS is provided through a multicast channel (MCH) which is a common transport channel in order to increase efficiency of a radio resource, and a plurality of MCHs can be used in one cell according to capacity of a multicast traffic channel (MTCH) and a multicast control channel (MCCH). The MCH serves to transmit two types of logical channels, i.e., the MTCH and the MCCH, and is mapped to a physical multicast channel (PMCH) which is a physical channel.
Only one MCCH exists in each cell, and the MCCH is a control channel used for transmission of MBMS control information. In order for the UE to receive traffic data of a certain MBMS, the MCCH for transmitting the control information of the MBMS has to be received. This is because scheduling information regarding the MTCH for the MBMS is transmitted on the MCCH. The UE first receives the MCCH to acquire information regarding an MTCH for transmitting the MBMS desired by the UE and then receives the MTCH.
As a plurality of MBMSs is simultaneously provided, the UE can receive the MBMS on an MCH in which only MTCHs are multiplexed. How to receive an updated MCCH by the UE on the MCH in which only MTCHs are multiplexed is not introduced yet.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for MBMS which enables to receive updated MBMS control information.
In an aspect, a method for a multimedia broadcast/multicast service (MBMS) includes receiving MBMS control information on a first multicast channel (MCH), receiving at least one MBMS traffic on a second MCH based on the MBMS control information, receiving a medium access control (MAC) protocol data unit (PDU) indicating a change of the MBMS control information on the second MCH, and receiving updated MBMS control information on first MCH if the change of the MBMS control information is indicated.
The MBMS control information may not be included in the MAC PDU.
The MAC PDU may include a MAC control element (CE) indicating the change of the MBMS control information.
The MAC PDU may include a MAC subheader corresponding to the MAC CE, and the MAC subheader may include a logical channel ID (LCID) for identifying the MAC CE.
If the MAC CE is included in the MAC PDU, the change of the MBMS control information may be indicated.
The MBMS control information may include a first value tag, and the MAC CE may include a second value tag. If the first value tag and the second value tag are different from each other, the change of the MBMS control information may be indicated.
In another aspect, a wireless apparatus for a multimedia broadcast/multicast service (MBMS) includes a radio frequency unit for transmitting and receiving a radio signal, and a processor operatively coupled with the radio frequency unit and configured to receive MBMS control information on a first multicast channel (MCH), receive at least one MBMS traffic on a second MCH based on the MBMS control information, receive a medium access control (MAC) protocol data unit (PDU) indicating a change of the MBMS control information on the second MCH, and receive updated MBMS control information on first MCH if the change of the MBMS control information is indicated.
Unnecessary channel switching to receive a MCCH can be minimized during MBMS. Delay of MBMS and battery consumption of the user equipment can be minimized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a wireless communication system to which the present invention is applied.
FIG. 2 is a diagram showing a radio protocol architecture for a user plane.
FIG. 3 is a diagram showing a radio protocol architecture for a control plane.
FIG. 4 shows channel mapping for an MBMS.
FIG. 5 shows a structure of a MAC PDU in 3GPP LTE.
FIG. 6 shows various examples of a MAC subheader.
FIG. 7 shows a problem caused by the conventional method.
FIG. 8 is a flowchart showing an MBMS method according to an embodiment of the present invention.
FIG. 9 shows an example of an MCCH change indication.
FIG. 10 shows another example of an MCCH change indication.
FIG. 11 is a block diagram showing a wireless communication system for implementing an embodiment of the present invention.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
FIG. 1 shows a wireless communication system to which the present invention is applied. The wireless communication system may also be referred to as an evolved-UMTS terrestrial radio access network (E-UTRAN) or a long term evolution (LTE)/LTE-A system.
The E-UTRAN includes at least one base station (BS) 20 which provides a control plane and a user plane to a user equipment (UE) 10 . The UE 10 may be fixed or mobile, and may be referred to as another terminology, such as a mobile station (MS), a user terminal (UT), a subscriber station (SS), a mobile terminal (MT), a wireless device, etc. The BS 20 is generally a fixed station that communicates with the UE 10 and may be referred to as another terminology, such as an evolved node-B (eNB), a base transceiver system (BTS), an access point, etc.
The BSs 20 are interconnected by means of an X2 interface. The BSs 20 are also connected by means of an S1 interface to an evolved packet core (EPC) 30 , more specifically, to a mobility management entity (MME) through S1-MME and to a serving gateway (S-GW) through S1-U.
The EPC 30 includes an MME, an S-GW, and a packet data network-gateway (P-GW). The MME has access information of the UE or capability information of the UE, and such information is generally used for mobility management of the UE. The S-GW is a gateway having an E-UTRAN as an end point. The P-GW is a gateway having a PDN as an end point.
Layers of a radio interface protocol between the UE and the network can be classified into a first layer (L1), a second layer (L2), and a third layer (L3) based on the lower three layers of the open system interconnection (OSI) model that is well-known in the communication system. Among them, a physical (PHY) layer belonging to the first layer provides an information transfer service by using a physical channel, and a radio resource control (RRC) layer belonging to the third layer serves to control a radio resource between the UE and the network. For this, the RRC layer exchanges a RRC message between the UE and the BS.
FIG. 2 is a diagram showing a radio protocol architecture for a user plane. FIG. 3 is a diagram showing a radio protocol architecture for a control plane. The user plane is a protocol stack for user data transmission. The control plane is a protocol stack for control signal transmission.
Referring to FIG. 2 and FIG. 3 , a PHY layer provides an upper layer with an information transfer service through a physical channel. The PHY layer is connected to a medium access control (MAC) layer which is an upper layer of the PHY layer through a transport channel. Data is transferred between the MAC layer and the PHY layer through the transport channel. The transport channel is classified according to how and with what characteristics data is transmitted through a radio interface.
Between different PHY layers, i.e., a PHY layer of a transmitter and a PHY layer of a receiver, data are transferred through the physical channel. The physical channel is modulated using an orthogonal frequency division multiplexing (OFDM) scheme, and utilizes time and frequency as a radio resource.
A function of the MAC layer includes mapping between a logical channel and a transport channel and multiplexing/de-multiplexing on a transport block provided to a physical channel over a transport channel of a MAC service data unit (SDU) belonging to the logical channel. The MAC layer provides a service to a radio link control (RLC) layer through the logical channel.
A function of the RLC layer includes RLC SDU concatenation, segmentation, and reassembly. To ensure a variety of quality of service (QoS) required by a radio bearer (RB), the RLC layer provides three operation modes, i.e., a transparent mode (TM), an unacknowledged mode (UM), and an acknowledged mode (AM). The AM RLC provides error correction by using an automatic repeat request (ARQ).
Functions of a packet data convergence protocol (PDCP) layer in the user plane include user data delivery, header compression, and ciphering. Functions of a PDCP layer in the control plane include control-plane data delivery and ciphering/integrity protection.
A radio resource control (RRC) layer is defined only in the control plane. The RRC layer serves to control the logical channel, the transport channel, and the physical channel in association with configuration, reconfiguration and release of radio bearers (RBs). An RB is a logical path provided by the first layer (i.e., PHY layer) and the second layer (i.e., MAC layer, RLC layer, and PDCP layer) for data delivery between the UE and the network. The configuration of the RB implies a process for specifying a radio protocol layer and channel properties to provide a specific service and for determining respective detailed parameters and operations. The RB can be classified into two types, i.e., a signaling RB (SRB) and a data RB (DRB). The SRB is used as a path for transmitting a RRC message in the control plane. The DRB is used as a path for transmitting user data in the user plane.
When a RRC connection exists between a RRC layer of the UE and a RRC layer of the network, the UE is in a RRC connected state, and otherwise the UE is in a RRC idle state.
Data are transmitted from the network to the UE through a downlink transport channel. Examples of the downlink transport channel include a broadcast channel (BCH) for transmitting system information and a downlink-shared channel (SCH) for transmitting user traffic or control messages. The user traffic of downlink multicast or broadcast services or the control messages can be transmitted on the downlink-SCH or an additional downlink multicast channel (MCH). Data are transmitted from the UE to the network through an uplink transport channel. Examples of the uplink transport channel include a random access channel (RACH) for transmitting an initial control message and an uplink SCH for transmitting user traffic or control messages.
Examples of logical channels belonging to a higher channel of the transport channel and mapped onto the transport channels include a broadcast channel (BCCH), a paging control channel (PCCH), a common control channel (CCCH), a multicast control channel (MCCH), a multicast traffic channel (MTCH), etc.
A multimedia broadcast/multicast service (MBMS) is a service which provides multimedia data to a UE in a cell. In the 3GPP LTE, the MBMS is transmitted through an MCH which is a common transport channel in order to increase efficiency of a radio resource, and a plurality of MCHs can be used in one cell according to capacity of an MTCH and an MCCH. The MCH serves to transmit two types of logical channels, i.e., the MTCH and the MCCH, and is mapped to a physical multicast channel (PMCH) which is a physical channel.
FIG. 4 shows channel mapping for an MBMS.
A PMCH which is a physical channel carries an MCH. The MCH which is a transport channel is broadcast in a cell.
An MTCH which is a logical channel is a traffic channel for transmitting traffic data of the MBMS. One MBMS service is transmitted through one MTCH, and thus a plurality of MTCHs may exist in one cell.
Only one MCCH exists in each cell, and the MCCH which is a logical channel is a control channel used for transmission of MBMS control information. In order for a UE to receive data of a certain MBMS, the MCCH for transmitting the control information of the MBMS has to be received. This is because scheduling information regarding the MTCH for the MBMS is transmitted on the MCCH. The UE first receives the MCCH to acquire information regarding an MTCH for transmitting the MBMS desired by the UE and then receives the MTCH.
MBMS control information on the MCCH may include at least one of an identity of the MBMS, an identify of a session of the MBMS, and scheduling information of a (P)MCH (i.e., resource allocation information for receiving the (P)MCH).
FIG. 5 shows a structure of a MAC PDU in 3GPP LTE.
The MAC protocol data unit (PDU) includes a MAC header, a MAC control element (CE), and at least one MAC service data unit (SDU). The MAC header includes at least one subheader, and each subheader corresponds to the MAC CE and the MAC SDU. The subheader represents a length and property of the MAC CE and the MAC SDU. The MAC SDU is a data block provided from a higher layer of a MAC layer (e.g., an RLC layer or an RRC layer). The MAC CE is used to deliver control information of the MAC layer similarly to a buffer status report.
FIG. 6 shows various examples of a MAC subheader.
The MAC subheader may include the following fields.
R (1 bit): a reserved field E (1 bit): an extension field. It indicates whether a following field is F and L fields. LCID (5 bit): a logical channel ID field. It indicates which type of an MAC CE is used or to which logical channel a MAC SDU belongs. F (1 bit): a format field. It indicates whether a following L field is 7 bits or 15 bits. L (7 or 15 bit): a length field. It indicates a length of the MAC CE or the MAC SDU corresponding to the MAC subheader.
The MAC subheader corresponding to a fixed-sized MAC CE does not include the F and L fields.
Subfigures (A) and (B) of FIG. 6 show examples of a MAC subheader corresponding to a variable-sized MAC CE and a MAC SDU. Subfigure (C) of FIG. 6 shows an example of a MAC subheader corresponding to a fixed-sized MAC CE.
A plurality of MTCHs can be multiplexed in one MCH. When the plurality of MBMSs is provided by a specific cell, a plurality of MCHs can be used. However, since only one MCCH exists for each cell according to current 3GPP LTE, the MCCH is transmitted only through one MCH among a plurality of MCHs.
FIG. 7 shows a problem caused by the conventional method. 15 MBMS are provided to a certain cell, and each MBMS has its corresponding MTCH. Assume that an MCCH and MTCHs 1 to 7 are transmitted by being multiplexed in an MCH 1 , and MTCHs 8 to 15 are transmitted by being multiplexed in an MCH 2 .
If a UE intends to receive a 9 th MBMS, the UE has to receive an MTCH 9 transmitted through the MCH 2 . If the UE receives only the MCH 2 to receive the MTCH 9 , the MCCH transmitted on the MCH 1 cannot be received.
If the UE also has an interest on a different MBMS, the UE needs to periodically receive the MCCH to confirm whether the different MBMS is provided. However, since the MCCH is transmitted using an MCH different from the MTCH 9 which is currently received, there is a problem in that the UE has to stop receiving the MCH 2 to receive the MCCH and has to monitor the MCH 1 .
Moreover, since the UE has to periodically monitor the MCCH, battery consumption of the UE occurs due to the monitoring.
Therefore, in order to prevent the UE from periodically receiving the MCCH unnecessarily, a method of adding an MCCH change indication to an MCH on which the MCCH is not transmitted is proposed.
FIG. 8 is a flowchart showing an MBMS method according to an embodiment of the present invention.
A UE receives MBMS control information on a first MCH (step S 810 ). A MCCH for the MBMS control information is multiplexed in the first MCH.
The UE receives at least one MBMS traffic on a second MCH based on the MBMS control information (step S 820 ). In the MCH, one or more MTCH for the at least one MBMS traffic may be multiplexed but an MCCH may not be multiplexed.
The UE receives an MAC PDU including an MCCH change indication on the second MCH (step S 830 ). The MCCH change indication indicates a change of the MBMS control information. The MCCH change indication can be added as an MAC CE in an MAC PDU and can be transmitted on the second MCH.
The UE receives updated MBMS control information on the first MCH (step S 840 ). Upon receiving the MCCH change indication while receiving the MTCH on the second MCH on which the MCCH is not transmitted, the UE switches a channel to the first MCH on which the MCCH is transmitted.
The MCCH change indication may be transmitted in various formats.
FIG. 9 shows an example of an MCCH change indication.
Only when the MBMS control information is changed, a BS can allow the MCCH change indication to be included in a MAC PDU on the MCH. Upon receiving the MCCH change indication while receiving the MTCH, a UE determines that the content of the MCCH is changed, and receives an updated MCCH by performing channel switching to the first MCH on which the MCCH is transmitted. If the MCCH change indication does not exist in the MAC PDU including the MTCH, the UE determines that the MCCH is not changed and continuously receives the second MCH.
The UE receives an MBMS # 9 on an MCH 2 through an MTCH 9 . If the MAC PDU including the MCCH change indication is received on the MCH 2 , the UE receives the MCCH on the MCH 1 .
FIG. 10 shows another example of an MCCH change indication.
An MCCH is transmitted by adding a first value tag, and the MCCH change indication is transmitted by including a second value tag. The value tag indicates whether the MCCH is changed, and may be represented in various forms such as a version number of the MCCH, a sequence number, a counter, etc. For example, whenever the content of the MCCH is changed, a value of the value tag may be incremented by 1.
If the content of the MCCH is changed, a BS increments the second value tag of the MCCH change indication. A UE compares a value of the first value tag of a previous MCCH with a value of the second value tag of a current MCCH change indication, and if the two values are different from each other, receives the MCCH by regarding that the MCCH is changed. The MCCH is transmitted always by including the value of the value tag. Even in the MCH on which the MCCH is not transmitted, the MCCH change indication is always included in transmission.
In order for the UE to receive a certain MBMS service, the UE first receives the MCCH. The UE stores the first value tag of the received MCCH in a memory. Then, when the MTCH is received afterwards, the second value tag in the MCCH change indication is checked. If the second value tag and the first value tag are different from each other, the UE determines that the content of the MCCH is changed, and receives the changed MCCH by switching a channel to the MCH on which the MCCH is transmitted. Otherwise, if the second value tag and the first value tag are equal to each other, the UE determines that there is no change in the MCCH and continuously receives the MTCH.
Since the MCCH change indication is always transmitted on the MCH on which the MCCH is not multiplexed, advantageously, the UE can easily know whether the MCCH is changed even if there is a loss in the MCH.
Meanwhile, the MCCH change indication is included in a MAC PDU as a MAC CE. A specific identify can be used to configure a MAC subheader corresponding to the MAC CE for the MCCH change indication. A logical channel ID (LCID) may be defined to identify the MAC CE for the MCCH change indication.
The following table shows an example of the LCID for the MAC CE.
TABLE 1
Index
LCID values
00000
CCCH
00001-01010
Identity of the logical channel
01011-11010
Reserved
11011
MCCH Change Indication
11100
UE contention Resolution Identity
11101
Timing Advance Command
11110
DRX Command
11111
Padding
As a MAC SDU, MTCH traffic is multiplexed with the MCCH change indication in a MAC PDU. The MCCH change indication MAC CE may be multiplexed in the MAC PDU prior to the MTCH traffic. This is to allow the UE to receive this MAC CE before other MTCH traffic so as to more rapidly know changes in the MCCH.
The MCCH change indication may consist of only an MAC subheader. That is, if only an R/R/E/LCID MAC subheader representing ‘LCID=MCCH change indication’ is included in the MAC PDU, the UE knows that there is a change in the MCCH and thus receives the MCCH. In this case, a length of the MAC CE is regarded as 0.
If the MCCH change indicator includes a value tag, a MAC subheader representing ‘LCID=MCCH change indication’ and a MAC CE including a value tag can be included in the MAC PDU. If a size of the value tag is fixed, a fixed-sized MAC subheader can be used, and if the size of the value tag is variable, a variable-sized MAC subheader can be used.
FIG. 11 is a block diagram showing a wireless communication system for implementing an embodiment of the present invention.
A BS 1110 includes a processor 1111 , a memory 1112 , and a radio frequency (RF) unit 1113 .
The processor 111 implements the proposed functions, processes, and/or methods. The aforementioned operation of the BS may be implemented by the processor 1111 . The processor 1111 may transmit MBMS control information and/or MBMS traffic on a MCH. The processor 1111 may construct a MAC PDU to indicate a change of the MBMS control information and may transmit the MAC PDU on the MCH.
The memory 1112 is coupled to the processor 1111 , and stores a protocol or parameter for the operation. The RF unit 1113 is coupled to the processor 1111 , and transmits and/or receives a radio signal.
A UE 1120 includes a processor 1121 , a memory 1122 , and an RF unit 1123 .
The processor 1121 implements the proposed functions, processes, and/or methods. The aforementioned operation of the UE may be implemented by the processor 1121 . The processor 1121 may receive the MBMS control information and/or the MBMS traffic on the MCH. The processor 1111 may receive the MAC PDU to indicate a change of the MBMS control information and may receive updated MBMS control information.
The memory 1122 is coupled to the processor 1121 , and stores a protocol or parameter for the operation. The RF unit 1123 is coupled to the processor 21 , and transmits and/or receives a radio signal.
The processors may include application-specific integrated circuit (ASIC), other chipset, logic circuit and/or data processing device. The memories may include read-only memory (ROM), random access memory (RAM), flash memory, memory card, storage medium and/or other storage device. The RF units may include baseband circuitry to process radio frequency signals. When the embodiments are implemented in software, the techniques described herein can be implemented with modules (e.g., procedures, functions, and so on) that perform the functions described herein. The modules can be stored in memories and executed by processors. The memories can be implemented within the processors or external to the processors in which case those can be communicatively coupled to the processors via various means as is known in the art.
In view of the exemplary systems described herein, methodologies that may be implemented in accordance with the disclosed subject matter have been described with reference to several flow diagrams. While for purposed of simplicity, the methodologies are shown and described as a series of steps or blocks, it is to be understood and appreciated that the claimed subject matter is not limited by the order of the steps or blocks, as some steps may occur in different orders or concurrently with other steps from what is depicted and described herein. Moreover, one skilled in the art would understand that the steps illustrated in the flow diagram are not exclusive and other steps may be included or one or more of the steps in the example flow diagram may be deleted without affecting the scope and spirit of the present disclosure.
What has been described above includes examples of the various aspects. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the various aspects, but one of ordinary skill in the art may recognize that many further combinations and permutations are possible. Accordingly, the subject specification is intended to embrace all such alternations, modifications and variations that fall within the spirit and scope of the appended claims. | A method and apparatus of allocating a resource for a plurality of logical channels is provided. A transmitter acquires a plurality of available resources for a plurality of component carriers, and allocates the plurality of available resources to the plurality of logical channels based on priority of each of the plurality of logical channels. | 8 |
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to an ignition control apparatus for controlling the ignition energy for igniting the mixture supplied to the internal combustion engine, in accordance with the flow velocity of the mixture flowing around the spark plug, and in particular, to an ignition control apparatus for detecting the flow velocity of the mixture in response to the rotational speed of the engine so that the ignition energy is controlled by the duration of energization of the ignition coil.
It is well known that in order to ignite the mixture supplied to the internal combustion engine, a spark plug is provided in the engine and supplied with a spark ignition voltage from the ignition coil. It is also well known that in order to accomplish highly-efficient combustion of mixture in the engine, the timing of generation of a spark ignition voltage i.e., the timing of ignition of the internal combustion engine is changed in accordance with the pressure in the engine intake pipe and the rotational speed of the engine. As one method for generating a spark ignition voltage from the ignition coil, electric power is supplied to the ignition coil from a power supply such as a battery thereby to store electric energy in the ignition coil, so that the ignition coil is de-energized at a timing in accordance with the engine operating conditions. According to this method, the spark ignition voltage is changed with the electric energy stored in the ignition coil, and therefore the ignition energy generated at the spark plug is also changed with the electric energy stored in the ignition coil. In other words, the ignition energy increases with the duration of energization of the ignition coil. If the duration of energization of the ignition coil is short, the amount of heat generated by the ignition coil is desirably small while ignition energy large enough to ignite the mixture fails to be produced. If the duration of energization of the ignition coil is long, on the other hand, a sufficiently large ignition energy is obtained while the amount of heat generated is large. One of the methods for obviating the problems associated with the duration of energization is by maintaining the ignition energy constant by maintaining the duration of energization constant.
The air-fuel mixture supplied to the internal combustion engine flows in the combustion chamber in the compression stage at a flow velocity which is higher, the higher the rotational speed of the engine. Especially in the case of an internal combustion engine having a main combustion chamber of large capacity and an auxiliary combustion chamber of smaller capacity communicating with each other, in which the mixture ignited in the auxiliary combustion chamber is spouted into the main combustion chamber, the flow velocity of the mixture transferred from the main combustion chamber into the auxiliary combustion chamber is greatly increased with the increase in the rotational speed of the engine.
The experiments conducted by the inventors show that the minimum ignition energy required for igniting completely the mixture in the combustion chamber is changed with the flow velocity of the mixture in the combustion chamber. Therefore, the above-mentioned method in which the ignition energy is maintained constant by maintaining the duration of energization constant regardless of the operating conditions of the internal combustion engine is not proper for preventing the overheating of the ignition coil and power loss by limiting the ignition energy to a required minimum.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an ignition control apparatus in which the ignition energy is controlled in accordance with the flow velocity of the air-fuel mixture supplied to the internal combustion engine, in the neighborhood of the spark plug.
Another object of the invention is to provide an ignition control apparatus in which the control of the ignition energy in accordance with the flow velocity of the mixture is accomplished by control of the duration of energization of the ignition coil in accordance with the rotational speed of the internal combustion engine.
According to the present invention, there is provided an ignition control apparatus in which the timing of de-energization of the ignition coil that constitutes the timing of generation of a spark at the spark plug is changed in accordance with the operating conditions of the internal combustion engine, characterized in that the period of energization of the ignition coil prior to the de-energization of the ignition coil is changed in accordance with the rotational speed of the internal combustion engine. The duration of energization of the ignition coil corresponding to the rotational speed of the engine is generally determined to be lengthened more as the engine rotational speed decreases below or increases above a predetermined value. The predetermined value of the engine rotational speed is depending on the type of the internal combustion engine involved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing a general configuration of an embodiment of the apparatus according to the present invention.
FIG. 2 is a diagram showing the characteristics of mixture flow at the spark plug of the engine with an auxiliary combustion chamber shown in FIG. 1.
FIG. 3 is a characteristics diagram showing the relation between the air oversupply rate and the mixture flow velocity in the engine shown in FIG. 1.
FIG. 4 is a characteristics diagram showing the relation between the ignitable limit energy and the mixture flow velocity in the engine of FIG. 1.
FIG. 5 shows a detailed configuration of the angle detector 16 shown in FIG. 1.
FIG. 6 is a diagram showing the detailed electric wiring of the ignition control calculation device 30 and the ignition device 40 in FIG. 1.
FIG. 7 is a time chart for explaining the operation of the ignition control calculation device.
FIG. 8 is a diagram showing the program for ROM in FIG. 6.
FIG. 9 is a characteristics diagram showing the relation between engine speed and mixture flow velocity in the engine shown in FIG. 1.
FIG. 10 is a characteristics diagram showing the relation between the ignition timing and mixture flow velocity.
FIG. 11 is a characteristics diagram showing the relation between the engine speed and the amount of ignition energy to be supplied.
FIG. 12 is a characteristics diagram showing the amount of ignition energy to be supplied, in terms of energization angle.
FIG. 13 is a diagram showing the detailed electric wiring of the constant circuit in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described below with reference to an embodiment applied to an internal combustion engine with an auxiliary combustion chamber shown in FIG. 1. Reference numeral 1 shows a cylinder, and numeral 2 a piston inserted into the cylinder 1. A cylinder head 3 is fastened to the top of the cylinder 1 through a gasket 4. A main combustion chamber 7 is defined by the top surface 5 of the piston 2 at the top dead center of compression and the internal surface 6 of the cylinder head. An intake port 8 opens to the internal surface 6 of the cylinder head in the neighborhood of the outer periphery of the main combustion chamber 7 and is so arranged that the axis thereof is directed toward substantially the center of the cylinder 1 in the neighborhood of the opening in the main combustion chamber i.e., the neighborhood of the intake valve 9. An auxiliary combustion chamber 11 communicated with the main combustion chamber 7 through the path 10 is provided in the neighborhood of the top of the main combustion chamber 7. The path 10 is provided in such a position and direction as to open toward the downstream of the circulating flow of the mixture in the main combustion chamber 7. Further, a spark plug 13 is mounted in such a manner that the discharge electrode 12 thereof is located in the neighborhood of the opening of the path 10 to the main combustion chamber 7. Numeral 14 shows an exhaust valve, and numeral 15 a valve seat. In the intake stage of the internal combustion engine of this type, the piston 2 moves down whereupon the intake valve 9 opens so that a comparatively thin mixture gas is introduced into the cylinder from the intake port 8. Next, the piston 2 moves up and the intake valve 9 closes, thus entering the compression stage. In the compression stage, the mixture gas flows toward the auxiliary combustion chamber 11 as shown by the arrow A. This gas flow is very great in the neighborhood of the discharge electrode 12 of the spark plug 13. And at a timing in accordance with the engine operating conditions, the discharge electrode 12 ignites the mixture gas. As a result, combustion takes place in the auxiliary combustion chamber 11, and the combustion gas of high temperature and high pressure generated by combustion of the mixture gas in the auxiliary combustion chamber 11 is spouted at high speed into the main combustion chamber 7 through the path 10, so that this torch effect causes rapid ignition and combustion of the thin mixture gas in the main combustion chamber 7.
The flow velocity of the mixture gas in the neighborhood of the spark plug of the internal combustion engine and the amount of ignition energy required for ignition of the mixture gas are shown in FIGS. 2 to 4. As obvious from FIG. 2, the flow velocity of the mixture gas increases substantially in proportion to the rotational speed of the engine regardless of the load, and the velocity of flow is maximum at a piston position about 30 degrees before the top dead center regardless of the rotational speed. In FIG. 3, the air-fuel ratio is shown by use of the air oversupply rate λ, the shadowed parts showing an ignition limit area. As seen from this characteristics diagram, the required ignition energy gradually decreases in the range of flow velocity from 0 to 5 m/s, while it increases exponentially in the range beyond 5 m/s. With the air-fuel ratio maintained constant (λ=1.29), it is noted from FIG. 4 that a very large ignition energy is required at a flow velocity higher than 15 m/s. It will be thus understood that the minimum amount of the required ignition energy varies with the gas flow velocity.
Turning back to FIG. 1, numeral 16 shows an angle detector mounted on the distributor shaft coupled to the piston 2 of the internal combustion engine for generating four reference signals T's per rotation, each signal T having a predetermined angular width Tθ, and for generating 720 angular signals CLθ's per rotation. Numeral 17 shows an intake pressure detector for detecting the intake negative pressure of the engine, numeral 18 an engine temperature detector including a temperature switch for detecting the temperature of the engine-cooling water, and numeral 30 an ignition control calculation device connected to the angle detector 16 and the pressure detector 17 for determining the amount of ignition energy and ignition timing in accordance with the engine operating conditions. Numeral 40 shows an ignition device including an ignition coil for supplying ignition energy to each of the spark plugs of the cylinders of the engine in the amount and timing calculated.
As shown in FIG. 5, the angle detector 16 is mounted on the distributor shaft and includes a rotor 161 with four protrusions adapted to rotate in synchronism with the rotation of the distributor shaft, a rotor 162 with 720 protrusions also adapted to be rotated in synchronism with the rotation of the distributor shaft, electromagnetic position detectors 163, 164, and a waveform shaper circuits 165, 166 for shaping the waveforms of the signals produced by the electromagnetic position detectors 163, 164. The angle detector 16 produces a reference signal T having a certain angular width Tθ from the top dead center of each cylinder and produces an angular signal CLθ for each one degree of crank angle of the crank shaft which makes two rotations for every rotation of the distributor shaft.
The ignition control calculation device 30 includes a first converter circuit 31 for converting the engine speed into a binary code, a second converter circuit 32 for converting the intake negative pressure into a binary code, an ignition timing determining circuit 33 for determining the ignition timing, an ignition energy amount determining circuit 34 applied with the outputs of the first converter circuit 31 and the engine temperature detector 18, and a primary coil control circuit 35 for supplying and cutting off the current in the primary side of the primary coil of the ignition coil in the ignition device 40 in response to the outputs of the ignition timing determining circuit 33 and the ignition energy amount determining circuit 34.
The ignition control calculation device 30 and the ignition device 40 are illustrated in detail in the circuit diagram of FIG. 6. Also, FIG. 7 is a time chart for explaining the operation thereof. The first converter circuit 31 includes an AND circuit 311 applied with the reference signal T of (a) in FIG. 7 provided from the angle detector 16, a well-known oscillator circuit 312 for generating high-frequency pulses, a binary counter 313, a counter 314 impressed with the reference signal T as a reset signal and the output of the oscillator circuit 312 as a clock signal and which produces a decode signal for generating clock pulses sequentially from the rise point of the reference signal T (such as CD4017 made by RCA and hereinafter referred to as "the decade counter"), and a memory element 315 (hereinafter referred to as "the latch"). As seen from (c) and (d) of FIG. 7, the decade counter 314 produces timing signals R1 and R2 in response to the first and third clock pulses applied from the oscillator circuit 312 as counted from the fall point of the reference signal T. Under this condition, the time from the fall point of the reference signal T to the rise point of the signal R2 is sufficiently short as compared with the crank angle of 1 degree over the whole rotational range, i.e., one cycle of the angular signal CLθ of (b) in FIG. 7. The clock pulses and the reference pulse T are applied to the AND circuit 311 to generate a logic product thereof. The clock pulses applied at a certain angle Tθ are counted by the binary counter 313 and the count thus obtained is stored in the latch 315 at the time of fall of the reset signal R1. Thus the value stored in the latch 315 represents the engine rotational speed N and increases with the decrease in revolutions.
The second converter circuit 32 includes 324 resistors 321, 322 and 323, an operational amplifier 324 for amplifying the analog signal voltage of the intake pressure detector 17, an A/D converter for converting the amplified output signal into a parallel digital value, and a latch 326 for storing the output of the A/D converter 325. The latch 326, like the latch 315, stores the output of the A/D converter 325 at the fall of the timing signal R1 of the decade counter 314. As a result, the value stored in the latch 326 represents the intake negative pressure P.
The value associated with the engine rotational speed N stored in the latch 315 of the first converter circuit 31 and the value associated with the intake negative pressure P stored in the latch 326 of the second converter circuit 32 are applied to the program means of the ignition timing determining circuit 33. The value associated with the engine rotational speed N stored in the latch 315, on the other hand, is applied to the program means of the ignition energy amount determining circuit 34.
The ignition timing determining circuit 33 includes a read-only memory element 331 having a program means (hereinafter referred to as ROM), a constant setting circuit 332 for setting the constant "A" (for instance, having a switch for setting a binary code representing the number 180 of the rotational angle pulses CLθ generated during the crank rotational angle of 180 degrees), a well-known subtractor circuit 333 for subtracting the output nα of ROM 331 from the output "A" of the constant circuit 332, and an up-down counter 334 (such as CD4029 of RCA) impressed with the output "A-nα" of the subtractor circuit 333 as a jam input, the angular pulse CLθ as a clock input signal and the output of the decade counter 314 as a reset input signal for counting down the number equal to "A-nα". When the value associated with the engine speed N stored in the latch 315 and the value associated with the intake negative pressure P stored in the latch 326 are applied to the ROM 331 constituting the program means, the ROM 331 produces the value "nα" predetermined for the two values as an ignition advance angle. As shown in FIG. 8, ROM 331 is such that values positioned in the map divided by the engine speed N and the intake negative pressure P are programmed as advance angles nα. If the intake negative pressure P is from 0 to -60 mmHg at the engine speed N from 1200 to 1400 r.p.m. for instance, the advance angle is 8 degrees BTDC; at 1400 to 1600 r.p.m., 9 degrees BTDC; at 1600 to 1800 r.p.m., 10 degrees BTDC; and so on. In similar fashion, when the intake negative pressure P is from -120 to -180 mmHg, the advance angle is 10 degrees BTDC at the engine speed of form 1200 to 1400 r.p.m.; 11 degrees BTDC at 1400 to 1600 r.p.m.; and so on.
The ignition energy amount determining circuit 34 is for controlling the energy amount in accordance with the coil energization period and includes the ROM 341 making up program means for determining the duration of energization, a constant setting circuit 345 for producing a constant Kl or 0 of parallel digital signal in response to the signal from the engine temperature detector means 18, an adder circuit 342 for adding the output Ca of ROM 314 to the output Kl or 0 of the constant circuit 345, a well-known subtractor circuit 343 for subtracting the output nd (=Ca+Kl) of the adder circuit 342 from the output "A-nα" of the subtractor circuit 333 of the ignition timing determining circuit 33, and an up-down counter 346 impressed with the "A-nα-nd" of the subtractor circuit 343 as a jam input, the angular pulse CLα as another input and the output of the decade counter 314 as a reset signal for counting down. When the value associated with the engine speed N stored in the latch 315 is applied to ROM 341 making up the program means, ROM 341 produces a value "Ca" predetermined against the applied value, as the amount of ignition energy.
A method for setting the ignition energy amount will be described below. The ignition coil used in the above-mentioned test for confirming the relation between the flow velocity of the mixture and the ignition limit energy amount has the specification as shown in Table 1 below.
Table 1______________________________________Specifications of Coil Used Coil Resistance Self-inductance______________________________________Primary winding 250 T 1.48 Ω 7.8 mHSecondary winding 26000 T 12.0 KΩ 75.0 H______________________________________
The characteristics of FIGS. 3 and 4 of course depend somewhat on the specification of the ignition coil, i.e., energy patterns but it is confirmed that the characteristics remain substantially the same in any case. The velocity of flow (m/s) at a given crank angle, say, 30 degrees BTDC, of the internal combustion engine has a substantially linear relation with the rotational speed as shown in FIG. 9. Actually, however, the ignition timing varies with the rotational speed and therefore it must be noted that the flow velocity is based on the linear relation taking into consideration the variations in ignition timing. As shown in FIG. 10, for example, the optimum ignition timing with the throttle fully opened is realized in the form of the characteristic curve of the solid line. Under this condition, the flow velocity of the mixture gas changes non-linearly with the engine rotational speed although it clearly increases with rotational speed. The optimum period of energization (ignition energy) for the flow velocity shown in FIG. 10 as based on FIGS. 3 and 4 is represented in the characteristics curve of FIG. 11. It is obvious from FIG. 11 that the period of energization of the ignition coil is required to decrease with the rise in the rotational speed up to the engine speed of 1000 r.p.m. from 0 r.p.m., while it is required to increase proportionately with the rise in rotational speed beyond 1000 r.p.m. The reason why the turning point of the duration of energization of the ignition coil as against the engine rotational speed lies around the rotational speed of 1000 r.p.m. (idling rotational speed) is that the rotational speed of 1000 r.p.m. almost corresponds to the flow velocity of 5 m/s of the mixture gas where as shown in FIG. 3 the minimum ignition energy required to ignite the mixture gas is minimum. In the rotational speed range from 4000 to 5000 r.p.m., the stored energy of the ignition coil is saturated and therefore the period of energization is shown constant, but the period of energization may be lengthened by increasing the stored energy amount of the ignition coil. Beyond 5000 r.p.m. in rotational speed, the period of energization is shortened taking into consideration the fact that the ignition timing is advanced or the advance angle is enlarged.
The ignition energy amount, i.e., the period of energization determined as above, as converted into the rotational angle of the crank shaft, is represented in the characteristics curve of solid line in FIG. 12. This energization crank angle is determined preliminarily in the form of map by the ROM 341.
The characteristics curve of solid line in FIG. 12 represents the crank angle for ignition coil energization after the engine is warmed. In order to compensate for the ignition energy at low engine temperatures, however, a certain value of crank rotational angle, say, Kl=10 degrees (dashed line in FIG. 12) is added, with the result that the ignition energy amount as shown by the dashed line in FIG. 11 is obtained, thus making possible an ideal engine-temperature compensation in which a great amount of energy is discharged at low engine rotational speeds but substantially does not work at high speeds. The constant circuit 345 for this engine-temperature compensation comprises switches 3451 and resistors 3452 for converting the value Kl into a binary code and AND gates 3453 operated in response to the operation of the engine-temperature detecting switch 18. For this purpose, the engine-temperature detecting switch 18 produces "1" and "0" signals at the temperature of cooling water below 60° C. and over 60° C. respectively.
To the extent of the foregoing description, a calculated value "A-nα" corresponding to the advance angle is produced at the output of the subtractor circuit 333, and the crank rotational angle "A-nα-nd" corresponding to the period of energization defining the ignition energy amount is produced at the output of the subtractor circuit 343. Both calculated values are converted into an actual coil energization angle corresponding to the crank angle as mentioned below. The up-down counter 334 counts the angular pulses CLθ by the number "A-nα" from the fall point of the timing signal R2 as shown in (f) of FIG. 7, and generates a negative pulse which falls at the end of counting as shown in (h) of FIG. 7. Similarly, the up-down counter 346 counts the angular pulses CLθ by the number "A-nα-nd" from the fall point of the timing signal R2 as shown in (e) of FIG. 7, and at the end of counting, generates a negative pulse falling as shown in (g) of FIG. 7.
The primary coil control circuit 35 includes a flip-flop having NAND circuits 355, 356, resistors 351, 352, and transistors 353, 354. In response to the output of the flip-flop as shown in (i) of FIG. 7, the current in the primary winding of the ignition coil is interrupted as desired. When the output signal of the flip-flop is "0", the transistor 353 is turned off and the transistor 354 is turned on, so that current flows from the battery 20a on the primary side of the ignition coil 401 through the key switch 20b. At the rise point from "0" to "1" level, the current is cut off, thus generating a spark ignition high voltage on the secondary side, so that ignition energy is supplied to the spark plugs 13a, 13b, 13c and 13d of the cylinders sequentially through the distributor 402. In the process, the angular pulse CLθ is the signal associated with the crank angle of 1 degree, and therefore the count thereof directly represents the crank rotational angle.
Although the foregoing description of the present invention is concerned with the internal combustion engine with an auxiliary combustion chamber, the present invention is also applicable to other types of internal combustion engines. In a well-known internal combustion engine having a single combustion chamber per each cylinder, for instance, the flow velocity of the mixture gas flowing in the neighborhood of the spark plug increases substantially in proportion to the rotational speed, but the variation in flow velocity is limited to about 0 m/s to several m/s. Therefore, the period of energization of the ignition coil is required to be set in such a manner as to decrease with the increase in the rotational speed until it reaches several thousand r.p.m., and after reaching several thousand r.p.m., increase with the increase in the rotational speed, or alternatively, it is required to be set in such a manner as to increase with the increase in rotational speed over the whole range of the engine rotational speeds. | An ignition control apparatus for an internal combustion engine is disclosed in which the ignition energy for igniting by means of a spark plug the air-fuel mixture supplied to the internal combustion engine is controlled in accordance with the flow velocity of the air-fuel mixture flowing in the neighborhood of the spark plug. An ignition coil for supplying a spark ignition voltage to the spark plug is energized by a power supply and de-energized at the desired timing of spark generation in accordance with the operating conditions of the internal combustion engine. The rotational speed of the engine representing the flow velocity of the mixture is detected and on the basis of this detected rotational speed, the duration of energization of the ignition coil is variably controlled. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of Korean Patent Application No. 10-2014-0021779, filed on Feb. 25, 2014, the disclosure of which is hereby incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a window/door system with a flat track and more particularly, to a window/door system with a flat track having a “ ”-shaped roller support in which the roller support in a cross sectional shape of “ ” having one side being open is used, to provide a nice appearance and to improve air-tightness and water-tightness by reducing the number of grooves shown on a window/door frame when a window/door is opened.
2. Description of the Related Art
Generally, a window or door (hereinafter, referred to as a window/door) installed in a building enables people inside to view the outside and has the functions of blocking noise, air and heat flow between the inside and outside. Further, a window/door ventilates polluted indoor air when it is open. A window/door is installed in a window/door frame in a certain size in the form of a sliding or hinged window/door. Following the trend that buildings have been luxurious, many different window/door systems have been developed for use to be easily maintained and managed, to be nice in appearance and to have functionality such as a security function.
In a conventional window/door system, a window/door frame exposes rail grooves where rails are installed and protrude, to allow a window/door to be opened or closed in a sliding motion. However, when people walk passing the rail grooves formed in the door frame, the rail grooves may be a dangerous obstruction causing them to stumble. Furthermore, since dust or any other foreign materials collect in the rail grooves, it is not easy to clean such dirty rail grooves. Specially, in a case where the window/door system is installed in a veranda, since a draft or rainwater easily comes into through the exposed rail grooves, the flow-tightness (air tightness, soundproof and drainage) is greatly reduced. When typhoon or heavy rain occurs, rainwater may flow inward.
Technology to solve the aforementioned problems has been presented in Korean Patent Nos. 167124 and 324496. However, since the structures presented in these patents are complicated, it is very difficult to connect and separate the window/door to and from the rail grooves. Further, since no structure to drain rainwater is specially provided, drainage is not good and rainwater flows backward to the inside. Furthermore, since the structure to block a draft is too simple, it is difficult to block drafts.
The applicant (inventor) of the present invention has repeated the research and development to solve not only the aforementioned problems but also many problems indicated during directly building window/door systems. As a result, the applicant (inventor) obtained Korean Patent Nos. 901994, 1055326 and 1216681 on the technology developed in relation to a rail-covered window/door system wherein a rail covering panel is mounted above rails giving a flat track look. According to this technology, the rails on which a window/door is sliding are not exposed to the outside. Furthermore, while the applicant (inventor) is now directly constructing a window/door system, he continues to develop a window/door system to improve air tightness, water tightness and heat insulation property and to be nice in appearance. The present invention has been also drawn during a series of such research and development.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to solve the above problems and to provide a window/door system with a flat track having “ ”-shaped roller supports in which the roller support is structured to have a cross sectional shape of “ ” having one side being open, thereby providing a nice appearance and improving air tightness and water tightness by reducing the number of grooves exposed between a window/door frame and a rail covering panel when the window/door is opened.
In accordance with an embodiment of the present invention, there is provided a window/door system with a flat track which comprises; a rail unit stably positioned lengthwise in a window/door frame, the rail unit including a rail panel in a flat shape, rails to allow the window/door to move in the sliding motion on the rail panel, and a rail cover joining channel expending to protrude upward from a top surface of the rail panel; a “ ”-shaped roller support including rollers, a roller mounting section in a lower position under which the rollers are mounted, a window/door connecting section in a upper position, and a connection section connecting one end of the roller mounting section and one end of the window/door connecting section to each other, thereby forming a cross sectional shape of “ ” which is open at one side, wherein a pair of the roller supports is installed such that the open sides of the “ ” shapes face each other and the rollers are stably positioned on the rails of the rail unit; a rail cover having: a rail covering panel and rail cover joining flanges extending to protrude downward under the rail covering panel and to securely fit into the rail cover joining channel of the rail unit, wherein the rail cover is poisoned between in each “ ”-shaped roller support installed to face each other such that the rail covering panel is positioned within each roller mounting section and each window/door connecting section; and a window/door to be securely connected by mounting a lower part of a window/door sash on the window/door connecting section.
Preferably, a pair of the window/door frames is installed, an insulator is integrally inserted between the pair of the window/door frames, and an insulation cap above the insulator is inserted to fit into the pair of the window/door frames.
Preferably, each window/door frame comprises: a pair of side parts positioned vertically, a connection part connecting lower ends of the side parts, rail unit connecting protrusions extending to protrude inward from the side parts above the connection part such that both ends of the rail panel of the rail unit are secured, and gasket receiving grooves formed to face each other in inner surfaces of upper ends of the side parts.
Preferably, the window/door connecting section of the roller support includes a mounting opening where mohair or a gasket is inserted to be mounted, and the top surface of the rail covering panel includes an indent formed at the position where the mohair or the front end of the gasket is in contact.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and advantages of the present invention will become more apparent to those of ordinary skill in the art by describing in detail preferred embodiments thereof with reference to the attached drawings in which:
FIG. 1 is a cross-sectional profile view of a window/door system according to an embodiment of the present invention, which is applied to a double window/door structure;
FIG. 2 is a top-down view of the window/door system of FIG. 1 with the upper railing removed; and
FIG. 3 is an exploded view of a lower part of the window/door system of FIG. 1 ;
FIG. 4 is a cross-sectional profile view of the window/door system according to the embodiment of the present invention, which is applied to a single window/door structure.
[Description of numbers for constituents in drawings]
10: window/door frame
13: rail unit connecting protrusion
14: gasket receiving groove
15: gasket
16: insulator
17: insulation cap
20: rail unit
21: rail panel
22: window/door weight support
23: rail
24: rail cover joining channel
30: roller support
31: roller
32: roller mounting section
33: window/door connecting section
34: guide protrusion
35: gasket supporting
protrusion
38: mohair
40: rail cover
41: rail covering panel
42: rail cover joining flange
50: window/door
51: window/door sash
52: glass
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which the preferred embodiments of the invention are shown so that those of ordinary skill in the art can easily carry out the present invention.
The greatest technical characteristic of a window/door system with a flat track according to the present invention is that a roller support is manufactured to have a cross sectional shape of “ ”. According to the present invention, the appearance is nice and the air tightness and water tightness are improved by decreasing the number of grooves (gaskets) exposed to be shown between a window/door frame and a rail covering panel to one (1) per window/door when the window/door is opened.
In this application of the present invention, the “flat track” means a rail covering structure in that rails on which the window/door slides are not shown in the window/door system since the rails are covered by the rail covering panel. According to this structure, the rails are never shown to the outside and only the top surface of the rail covering panel in a flat shape is shown when the window/door is open.
The window/door system according to the present invention has a basic constitution comprising: a window/door frame 10 fixedly installed in a building; a rail unit 20 fixedly connected to an inside of the window/door frame 10 ; a roller support 30 stably held and slid on the rail unit 20 ; a rail cover 40 connected to the rail unit 20 and secured in position to cover a rail; and a window/door 50 secured on the rail cover 40 and the roller support 30 .
The window/door frame 10 is fixedly installed in the building. The window/door frame 10 to be vertically positioned includes a pair of side parts 11 forming both side walls, and a connection part 12 connecting lower ends of the side parts 11 to each other. A cross section of the window/door frame 10 has a rectangular shape which is open upward. Gasket receiving grooves 14 are formed to face each other in the inner surfaces of the upper ends of the side parts 11 . Rail unit connecting protrusions 13 each extend to protrude inward from the side parts 11 lengthwise, above the connection part 12 , so that both ends of a rail panel 21 of the rail unit 20 are connected to the rail unit connecting protrusions 13 , respectively.
In the case of a double window/door structure, as shown in FIG. 1 , one pair of the window/door frames 10 is installed inside and the other pair of the window/door frames 10 is installed outside. An insulator 16 is integrally inserted between each pair of the window/door frames 10 lengthwise. An insulation cap 17 is inserted to be secured on the insulator 16 between the window/door frames 10 , so that the insulator 16 is not exposed upward.
The rail unit 20 is stably positioned lengthwise and fixedly secured inside the window/door frame 10 . The rail unit 20 comprises: the rail panel 21 in a flat shape, rails 23 positioned on the rail panel 21 to allow the window/door 50 to slide, and a rail cover joining channel 24 extending to protrude upward from the rail panel 21 to be connected to rail cover joining flanges 42 of the rail cover 40 . The rail unit 20 further comprises a pair of window/door weight supports 22 to safely support the weight of the window/door 50 to be mounted on and to be connected to the rail unit 20 . The window/door weight supports 22 extend downward from the under surface of the rail panel 21 lengthwise and are spaced apart from each other at a proper distance. It is desirable that the window/door weight supports 22 are supported on the connection part 12 of the window/door frame 10 .
The rails 23 are positioned lengthwise an either side of the rail cover joining channel 24 . It is preferable that one pair of the rails 23 is positioned at one side of the rail cover joining channel 24 and the other pair of the rails 23 is positioned at the other side of the rail cover joining channel 24 in consideration of safety. The cross section of the rail cover joining channel 24 has an “H” shape. The opposite inner surfaces of the rail cover joining channel 24 include notches, respectively. Protrusions formed on the outer surfaces of the rail cover joining flanges 42 of the rail cover 40 are fit into the notches of the rail cover joining channel 24 by a one-touch manner (see FIG. 2 ).
The roller support 30 comprises: a window/door connecting section 33 , a roller mounting section 32 ; and a connection section (not indicated by a drawing reference number) connecting one end of the window/door connecting section 33 and one end of the roller mounting section 32 to each other. Accordingly, the window/door connecting section 33 , the roller mounting section 32 and the connection section between the window/door connecting section 33 and the roller mounting section 32 forms a cross sectional shape of “ ” which is open at one side. In the roller support 30 , rollers 31 are mounted, at equal intervals, under the roller mounting section 32 . A pair of the roller supports 30 is mounted in one window/door frame 10 such that the open sides of the “ ” shapes face each other and the rollers 31 are stably positioned on the rails 23 of the rail unit 20 . The rollers 31 may be mounted in one (1) row (single roller) under the roller mounting section 32 but it is desirable that the rollers 31 are mounted in two (2) rows (a plurality of rollers) in consideration of safety.
The roller support 30 includes a gasket supporting protrusion 35 extending outward from an outer surface of the connection section positioned between the window/door connecting section 33 and the roller mounting section 32 . A gasket 15 has an upper end being bent in the form of “ ” The gaskets 15 are connected in the gasket receiving grooves 14 formed in the inner surfaces of the upper ends of the side parts 11 of the window/door frame 10 . When the window/door system is assembled, the bent end of the gasket 15 is positioned on the gasket supporting protrusion 35 to be locked with each other. Accordingly, the end of the gasket 15 is prevented from slipping into the gap between the side part 11 and the roller support 30 , thereby improving the seal, air tightness and water tightness between the side parts 11 of the window/door frame 10 and the roller support 30 .
When the window/door system with the flat track is assembled, the grooves where the gaskets 15 are positioned are exposed lengthwise between the side parts 11 of the window/door frame 10 and the ends of the roller supports 30 . In the present invention, since the roller supports 30 in the “ ” shape are used, only two (2) lines of the grooves which are formed at both ends lengthwise are shown per window/door frame 10 , thereby providing a nice appearance and improving the water tightness and air tightness. However, in a case where a “□”-shaped roller support is used, the grooves in two (2) lines are shown along the both ends of each roller support and therefore, a total of four (4) lines of the grooves are shown per window/door frame 10 . In this case, the appearance is not good and the water tightness and air tightness are lowered since the number of the grooves is increased.
The rail cover 40 comprises: a rail covering panel 41 in a flat shape; and a pair of rail cover joining flanges 42 extending downward from the rail covering panel 41 . The rail cover joining flanges 42 are stably connected with the rail cover joining channel 24 of the rail unit 20 so that the rail cover 40 is secured to cover the rails 23 not to be shown upward. The rail covering panel 41 is positioned between and in each roller supports 30 which are installed such that the opening sides of the roller supports 30 face each other. That is, the rail covering panel 41 is positioned within the window/door connecting sections 33 and the roller mounting sections 32 (see FIG. 1 ).
The window/door connecting section 33 of the roller support 30 includes mounting openings where mohair 33 or gaskets are inserted to be mounted. On the rail covering panel 41 , indents 41 a are formed at the places where the mohair 36 or the front ends of the gaskets are in contact. When the window/door system is assembled, the mohair 36 or the front ends of the gaskets are inserted into the indents 41 a , thereby filling the gap between the under surface of the window/door connecting section 33 of the roller support 30 and the top surface of the rail covering panel 41 and therefore improving the seal, air tightness and water tightness. Mohair or gaskets may be mounted in one roper support 30 in one (1) or two (2) rows. When these are mounted in two (2) rows, the mohair (or gaskets) may be mounted in all of the two (2) rows or the mohair may be mounted in one (1) row and the gaskets may be mounted in the other one (1) row.
The window/door 50 is fixedly connected by mounting a lower section of a window/door sash 51 on the window/door connecting section 33 of the roller support 30 . Drawing reference number 52 not described indicates glass.
Guide protrusions 34 protrude and extend upward and obliquely at both ends of the window/door connecting section 33 of the roller support 30 , to guide a location of connecting the window/door sash 51 . Since the guide protrusions 34 are formed, the window/door 50 can be easily mounted and assembled at the correct location.
FIG. 4 shows the window/door system with the flat track according to the present invention is used in a single window/door structure. The window/door system with the flat track used in the single window/door structure is identical with that used in the double window/door structure as shown in FIG. 1 , except for only the insulator 16 and the insulation cap 17 installed between the window/door frames 10 .
In the window/door system with the flat track as characterized above, since the cross section shape of the roller support is “ ” which is opened at one side, only one (1) groove is exposed lengthwise between the window/door frame and the rail covering panel per window/door when the window/door is opened. Therefore, the appearance is nice in comparison with the conventional window/door system with the flat track where two (2) grooves are exposed per window/door. Further, since the number of the grooves to be exposed decreases, the air tightness and water tightness are improved. Additionally, since the number of the grooves to be exposed is reduced, the number of the gaskets to be inserted into the grooves is reduced, the material costs required in manufacturing and the management and maintenance costs can be reduced.
The invention has been described using preferred exemplary embodiments. However, it is to be understood that the scope of the invention is not limited to the disclosed embodiments. On the contrary, the scope of the invention is intended to include various modifications and alternative arrangements within the capabilities of persons skilled in the art using presently known or future technologies and equivalents. The scope of the claims, therefore, should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements. | There is provided a window/door system with a flat track having “ ”-shaped roller supports to provide a nice appearance and to improve air tightness and water tightness by reducing the number of grooves exposed on a window/door frame when a window/door is opened, by using the roller supports in a cross sectional shape of “ | 4 |
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method and a device for measuring, by photo-spectrometry, the concentration of harmful gases in the flue gases through a heat-producing plant of the kind that comprises a first space for the combustion of a fuel, a device placed in a second space located downstream of the combustion space, said device in the second space comprising tubes through which a medium, such as water, air or steam, may pass in order to be heated by heat transfer from the flue gases formed during the combustion, and a chimney located downstream of the tube device for letting out the flue gases from the plant.
BACKGROUND OF THE INVENTION AND PRIOR ART
Simultaneous production of heat and steam by combustion of a so-called bio-fuel, i.e., a solid fuel consisting of wood or biomass, has lately become more and more common, inter alia due to the facts that such a production is power-efficient, shows endurance in the long run, may be based on domestic raw materials and gives a minimal influence on the environment. However, it has turned out that the combustion of bio-fuel is a process that in some respects is more complicated and difficult to handle than the combustion of other solid fuels, such as coal. One complication is that the ashes from a bio-fuel has another composition and other melting properties than, e.g., coal ash. Inter alia, this difference involves costly problems with corrosion and ash deposition on the tubes included in existing superheating plants. Thus, serious high temperature corrosion has been observed in the major part of combined power and heating plants in Sweden after some years of operation with 100% bio-fuel. The problems may become particularly accentuated when to the fuel are added such materials as demolition timber and sorted waste of different types. In practice, the corrosion manifests itself in that the usually high-alloyed, and thereby expensive, superheater tubes are coated with stout, strongly adhering layers or deposits of ash, at the same time as the tube surface underneath is exposed to corrosive melts which give rise to a loss of metal.
Among experts, unanimity reigns that chlorine constitutes the main corrosion accelerator in the above-mentioned context. A conventional theory is that chlorine is transported into the ash deposit on the superheater tubes in the form of gas phase potassium chloride (KCl), alternatively as very small aerosols of potassium chloride that have condensed immediately upstream of the superheater device. Thereafter, a reaction with sulphur takes place on the tube surface in the ash deposit, thereby forming potassium sulphate and free chlorine, which in this form is very corrosive. Albeit this theory is plausible, in practice great difficulties exist not only to verify this theory but also to take measures to solve the problem, above all due to the lack of a suitable measuring technique. It is true that in SE 8502946-0, it is in general terms described how photo-spectrometry may be utilized to determine certain parameters, e.g., the concentration, for gaseous substances that occur in such combustion processes that are performed at high temperatures, but in this case the technique is primarily focussed on measuring in flames, and the document does not contain any instructions as to how the technique would, in practice, be used for measurements in plants of the type presented in the preamble.
Quite generally, in heat-producing plants occur, besides the above-mentioned corrosion problems, also other similar problems that are caused by the presence of gaseous metal chlorides or metals in elementary form. Hence, in the plants may be included also other arrangements than merely superheater devices comprising sets or packages of tubes, through which for instance air is circulated in order to be heated (in practice, such arrangements usually consist of air pre-heaters or so-called economizers). When metals, such as heavy metals in the form of zinc and lead in gaseous form, are carried by the flue gases and hit the arrangements, they are deposited on the surfaces of the tubes, thereby forming deposits that are not necessarily corrosive, but that deteriorate the heat transfer from the flue gases to the medium that circulates within the tubes.
OBJECTS AND FEATURES OF THE INVENTION
The present invention aims at overcoming the shortcomings associated with previously known measuring technique and in a purposeful way eliminating or counteracting the corrosion and deposit problems that arise in tube-including devices for heat transfer, e.g., superheater devices, economizers or air pre-heaters that exist downstream of the combustion space in combustion plants. Therefore, a primary object of the invention is to create a process as well as a device which in practical operation at difficult external conditions manage to specifically determine the presence and concentration of exactly those gaseous substances in the flue gases of the combustion process which give rise to serious corrosion or harmful deposits on the tubes that are included in said devices. Another object is to provide a process, by means of which the very creation of corrosive or harmful gases in the flue gases that shall pass through the tube devices may be restrained.
According to the invention, at least the primary object is attained by the characteristics given in the characterizing clauses of claims 1 and 5 . Advantageous embodiments of the invention are further defined in the dependent claims.
BRIEF DESCRIPTION OF THE APPENDED DRAWINGS
In the drawings
FIG. 1 is a schematic illustration showing the general construction of a combined heat and power plant, in which the invention is applicable,
FIG. 2 is an enlarged planar detail view showing a device included in an arrangement according to the invention for sending and receiving light, which device cooperates with a spectrometer,
FIG. 3 is a schematic illustration of said spectrometer and an equipment for calibrating the spectrometer, and
FIG. 4 is a schematic illustration, shown on a reduced scale, of an alternative embodiment of a combined heat and power plant, and an arrangement according to the invention connected thereto.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 is shown a steam-producing combustion plant that may consist of an industrial steam boiler with the main purpose of producing steam, e.g., for the production of electricity, but that may also consist of a combined power and heating plant of the type that produces not only steam but also heat. As main components, the plant comprises a boiler 1 and a chimney 2 . In the boiler 1 is included a first space 3 in the form of a combustion chamber, in which fed-in fuel is burnt. In practice, the boiler may work with conventional fluidized bed technique (among experts called BFB=“Bubbling Fluidized Bed”). In larger plants, the boiler may have a height within the range of 10 to 40 meters. In another space 4 serving as a flue gas duct, downstream of the combustion chamber 3 , are provided one or several superheater devices. In the example according to FIG. 1 , three such superheater devices 5 are shown. Each one of these devices comprises a set of tubes or tube loops, through which steam may pass in order to be overheated by heat transfer from the flue gases that are created during the combustion and that pass through the space 4 . Between the spaces 3 and 4 extends an oblique wall 6 included in a separator, whose purpose is to collect solid particles falling down from the flue gases and to return those to the combustion chamber. After the flue gases having passed the superheater devices 5 , they are cooled in one or several so-called economizers 5 ′ and pass further through an air pre-heater 5 ″ to finally be emitted via the chimney 2 (usually after first having penetrated through one or several filters, not shown).
In FIG. 1 , reference numeral 7 designates a light-emitting and light-receiving device that is comprised in the arrangement according to the invention. As may be clearly seen in FIG. 1 , this device 7 is placed in the immediate proximity of a superheater device 5 , viz. the superheater device that first comes in contact with the passing flue gases.
Reference is now made to FIG. 2 , which illustrates how the device 7 comprises a light-emitting unit 7 ′ that is mounted in one of the two opposite walls 8 that delimit the flue gas duct 4 , and a light-receiving unit 7 ″ placed in the opposite wall. As radiation source in the emitting unit 7 ′ is advantageously used a xenon bulb 9 , that has the capability of emitting ultraviolet light with a broad wavelength spectrum within the range of about 200 nm–3 μm. Alternatively, a deuterium bulb may also be used for the same purpose. The light from the bulb is collimated, e.g., through a lens 10 , whereafter it passes through the flue gases in the duct 4 as a beam 11 and farther into the receiving unit 7 ″, where the light is focused on an optical fiber 12 . This optical fiber carries the light to a spectrometer designated 13 in its entirety, in which the intensity of the light is analyzed as a function of the wavelength of the light. A computer 14 cooperates with the spectrometer. In the spectrometer is included a light wavelength separating unit 15 , whose purpose is to separate the different wavelengths of the incoming light, so that the intensity of different wavebands may be measured with a non-wavelength-selective detector 15 ′. In practice, the light wavelength separating unit may consist of a monochromator or a spectrograph. The monochromator lets through only a narrow waveband of the incoming light and may as a wavelength-separating element utilize, e.g., a grating, a prism or an optical band passfilter. The spectrograph projects a continuous band of wavelengths within a given range of wavelengths in its focal plane where the detector is mounted. As a wavelength-separating element in the spectrograph a grating, a prism or a so-called “Michaelson-interferometer” may be used.
For the spectrograph is normally used a multi-channel detector, e.g., a photo-diode array (PDA), or an extended one-channel detector, e.g., a photo multiplicator, in combination with a thin slot that moves sequentially over the surface of the detector and is mounted in such a way that it coincides with the focal plane of the spectrograph. From a practical point of view, this slot may be arranged radially on a rotating disk according to the embodiment described in Platt & Perner 1983 (Platt U & Perner P., “Optical and laser remote sensing”, eds. Killinger, D K, and Mooradian, A., “Springer ser”. Optical Sci. 39, 97, 1983). The photo-diode array consists of a row of photo diodes (cf. camera) which simultaneously measure the intensity distribution of the light over the surface of the array, whereafter this spectrum is read off electronically after a certain exposing time. In combination with a monochromator, a one-channel light detector is normally used, e.g., a photo diode.
In the embodiment according to FIG. 2 , a spectrograph is used in combination with a photo-diode array, which is an advantageous embodiment. The invention may also be realized by utilizing monochromator technique, but in such a case at least two monochromators would be needed, which are adjusted to different wavelengths to make the measuring system specific for the searched gas components, e.g., alkali metal chlorides, and which are not influenced by broad band damping of the light.
The signal from the photo detector is read by means of a specially constructed PC measuring card, and software for PC-Windows, that is especially adapted for the purpose, evaluates the integrated spectrum.
The evaluation of registered measuring spectra in the software of the computer takes place in accordance with the principles suggested in the above-mentioned article by Platt & Perner, 1983. According to algorithms given in this article, quantitative data are calculated for the searched gas components out of the spectral information by correlating measured spectra to referential spectra for different gas components by multivariate analysis. These calculations may be performed continuously in the computer (calculation time <2 s), which enables on-line presentation of measuring data, e.g., on a screen 16 , and updating of analogous out-signals on a D/A card in the computer unit.
Among experts, the above described measuring technique is denominated DOAS technique (Differential Optical Absorption Spectroscopy). This technique is also described in general terms in the previously mentioned SE 8502946-0.
The present invention is based on the insight that DOAS technique may be specifically utilized for measuring the concentration of gaseous metals and/or metal chlorides and in particular alkali metal chlorides (potassium chloride as well as sodium chloride) in the flue gases. More specifically, this is realized by calibrating the spectrometer 13 for registration of the spectral intensity distribution of the light within the wavelength range 200–310 nm. For this purpose, a calibration equipment of the type shown in FIG. 3 is used. This equipment comprises an oven 17 , in which may be placed a gas cuvette 18 with two quartz windows 19 , to which cuvette gas may be led from a source 20 via a supply conduit 21 and evacuated via an evacuation conduit 22 . Light-emitting and light-receiving units, respectively, 7 ′, 7 ″ are placed on both sides of the oven, so that the light beam 11 can pass through the cuvette, more precisely via its windows 19 . The oven is regulated to a certain temperature, preferably a temperature at which gas-measuring in space 4 is to be performed afterwards. Gas of a given composition containing the gas component, e.g., potassium chloride or sodium chloride, that is intended to be measured in the flue gas duct 4 , is dosed from the gas source 20 via a control valve 23 that keeps the gas flow constant, and further through the gas cuvette 18 . In the case when potassium chloride or sodium chloride is to be measured, then a salt of the respective compound is placed in a spoon 24 , that is introduced into the inlet conduit 21 to the cuvette. By adjusting the temperature of the oven, different vapour pressures are obtained above the salt, and alkali metal chloride vapours with a given partial pressure will stream through the measuring cuvette. When the gas concentration of the gas component in question (and other possible gas components that have light absorption in the wavelength range that shall be utilized for the measuring) has stabilized, then the absorption spectrum of the component is measured and stored according to the same principle as in the regular measuring in the flue gas duct 4 . Here, a reference spectrum is obtained that is used as the basis for the automatic spectral evaluation that takes place later when measuring the unknown gas concentration in the flue gas duct.
The spectral structure of KCl and NaCl has such a broad band (=the range of 230–280 nm) and is located at such a wavelength that a simple and inexpensive type of spectrometer may be used for performing the measurement. More precisely, one may advantageously use a modern type of inexpensive minispectrometer that is based on the above-mentioned use of a diode array (semi-conductor sensor) integrated in the optical bench.
Although it is of considerable value per se, only being capable of detecting the concentration in situ of gaseous alkali metal chlorides in the fumes, more specifically continuously during the operation of the plant, it is particularly interesting to utilize registered data to control the course of the fuel combustion. FIG. 4 schematically illustrates a plant in which this possibility has been realized. In this case, an alternative embodiment is exemplified of a combined power and heating plant, in which the boiler 1 of the plant cooperates with a cyclone separator 25 that is installed between the combustion space 3 and the flue gas duct 4 in which a number of superheater devices 5 are mounted (in this example the chimney of the plant has been left out due to spacetechnical reasons). In practice, this type of boiler is denominated CFB (=“Circulating Fluidized Bed”). Also in this plant is included at least one economizer 5 ′ and an air pre-heater 5 ″. Similar to the gas measuring arrangement according to FIGS. 1 to 3 , the arrangement according to FIG. 4 comprises a light emission unit 7 ′ and a light reception unit 7 ″ that via an optical fiber 12 is connected to a spectrometer 13 and a computer 14 cooperating therewith. Via a cable 26 , an out-signal from the computer may be sent to a central control unit designated 27 , by means of which different parameters that determine the combustion course may be controlled.
In connection with the fire-place space 3 of the boiler is shown a fuel feed stack 28 , to which fuel may be fed by means of a suitable fuel feeder, that is schematically indicated in the form of a conveyor belt 29 . Over the conveyor belt are shown a number of containers 30 , 31 , 32 , which either comprise a fuel out-feed means 33 , e.g., in the form of a feed screw. In the two former containers 30 , 31 , two different types of fuel may be kept, e.g., bio-fuel and burnable waste, respectively. In the third container 32 is stored a chlorine-reducing material, which, when needed, may be supplied to the fuel or the fuel mixture to the combustion chamber. Thus, the material in the container 32 constitutes an additive, whose primary purpose is to reduce the amount of alkali metal chlorides in the flue gases. In practice, this substance may consist of sulphur or a sulphur-containing material, although it is also feasible to use minerals, such as kaolinite. The operation of the three out-feed devices may be controlled individually by means of separate control devices 34 that are connected to the central control unit 27 . By means of these control devices, the feed devices 33 may on one hand be activated or inactivated in order to initiate or finish the out-feeding of the material in question on the conveyor belt 29 , and on the other hand control the working speed of the out-feed device and, thereby, the amount of the respective material that is fed out on the conveyor per time unit.
The so-called air register is also to a high degree determining for the course of the combustion process, which register is included in a conventional way into the combustion plants of the type in question. In practice, such air registers may comprise several consecutive air inlets to the boiler. However, in the example only two such inlets are shown, namely a first inlet 35 for primary air to the lower part of the combustion chamber, and an inlet 36 for secondary air, which is placed downstream of the fuel inlet 28 . A central fan 37 may via conduits 38 , 39 supply air to the inlets 35 , 36 , more precisely via flies 40 , 41 in the conduits 38 , 39 . The function of these flies 40 , 41 may be controlled by means of separate control means 42 , 43 , which in turn are controlled by the central control unit 27 . Depending on the measurement data in question regarding the existence and concentration, respectively, of alkali metal chlorides in the flue gases, the supply of air to the interior of the boiler may thus be regulated, more precisely in order to reduce the amount of alkali metal chlorides in the region of the superheater arrangements to the utmost possible extent. In this context, it should be pointed out that the relation between the adjusting of the air registers and the content of alkali metal chlorides varies from one plant to another, depending on the design and the combustion principle of the boiler.
FUNCTION AND ADVANTAGES OF THE INVENTION
Initially, the present invention is based on the insight that metal chlorides may be spectral-analyzed with ultraviolet light at high temperatures. By placing the light-emitting and light-receiving units of the described measuring arrangement in the immediate proximity of the superheater device(s) that is/are submitted to corrosion and where the temperature of the flue gases lies within the range of 600 to 1400° C., the existence and concentration of alkali metal chlorides may be established in situ specifically at that place, where the existence of chlorides is critical, namely immediately before they hit the surfaces of the superheater tubes and react with sulphur under the formation of alkali metal sulphate and free chlorine. This is of considerable importance in so far as if gas samples would be taken for extractive analysis, or if measurements would take place downstream of the superheater devices—where the flue gas temperature is lower—then the very reactive chlorides would have the time to condense and/or react with other compounds and, therefore, it would not be possible to measure them in a proper way. Thus, the measurement would entirely lose its relevance if the chlorides had condensed. It should also be underlined that it is also not expedient to measure the chloride content earlier in the process, i.e., in the combustion chamber, in that the chlorides react on their way towards the superheater device. Further, it is of great importance that the survey of the alkali metal chloride concentration in the flue gases of the plant takes place essentially continuously. It is true that it is possible to make individual measurings intermittently, in so far as time breaks between recurrent measuring occasions are allowed. However, by making these breaks short, e.g., within the range of 10 to 60 seconds, an essentially continual survey of the existence and concentration of the corrosion-initiating chlorides is secured. Moreover, by utilizing continually obtained measuring data relative to the chloride concentration in the flue gases, in accordance with the preferred embodiment of the invention, in order to control the combustion process, an effective means is obtained during practical operation for counteracting corrosion attacks on the superheater tubes. Controlling the different parameters that determine the combustion course and the alkali metal chloride amounts developed in the gases may be accomplished in different ways. One effective way is—as described above in connection with FIG. 4 —to add a chlorine reducing additive, e.g., in the form of sulphur or a sulphur-containing material. By supplying moderate, albeit effective amounts of sulphur to the fuel, a reaction is attained already during the combustion process between the sulphur and the alkali metal chlorides, thereby, inter alia, forming hydrogen chloride, something that involves that free chlorine is not evolved in the region of the superheater devices. At least the chlorine amounts are reduced in this region to an absolute minimum. Another way is to alter the composition of the fuel mixture, e.g., by reducing the fuel component(s) that turn out to give rise to high contents of alkali metal chlorides. In combination with these measures, the air register may also be adjusted in order to minimize the amount of reactive chlorides in the region of the superheater tubes.
FEASIBLE MODIFICATIONS OF THE INVENTION
The arrangement according to the invention may also be utilized for measuring the existence and concentration of sulphur dioxide (SO 2 ) within the given wavelength range (200 to 310 nanometers), more specifically in order to avoid or counteract overdosing of sulphur additives or sulphur-containing fuels, respectively, or, alternatively, counteract the taking of other operative measures that may increase the SO 2 content in the flue gas duct to values above the stipulated limits. It should also be mentioned that the invention may be used for measuring the concentration of other gaseous metal chlorides than just potassium and sodium chlorides, e.g., heavy metal chlorides, such as zinc and lead chloride, respectively, in that also these have a characteristic light absorption within the wavelength range of 200 to 310 nanometers. Within the scope of the invention, it is also feasible to measure the concentration of gaseous metals in elementary form, e.g. elementary zinc. Different existence forms of zinc and lead are foreseen to be present especially frequently in the combustion of waste-related fuels. Zinc and lead chlorides may form ash deposits of a relatively low melting point, e.g., 300° C., on the heat-transferring tube device; this enhances corrosion as well as deposit growth. In particular, they may form deposits on the tubes making part of an economizer. By installing a measuring arrangement according to the invention in the proximity of this type of tube-containing devices, the concentration of these substances may be measured in an appropriate way, whereafter the measuring results may be utilized for taking measures in order to reduce the amount of harmful substances, e.g., by altering the composition of the fuel.
In this context, it may also be mentioned that experts in the field in question attest the theory that a possible existence of dioxines in the fumes is dependent on the amount of alkali metal chlorides. Therefore, within the scope of the invention it is possible to utilize the described measuring arrangement to indirectly—namely by establishing the concentration of alkali metal chlorides—measure the existence and concentration of dioxines that are dangerous to the environment.
It should also be mentioned that the invention may be applied independently of whether the heat-producing plant comprises superheater devices or not. Thus, the invention may, as outlined above, be utilized exclusively for measurements in connection with an economizer or an air pre-heater.
Although the invention in the drawings has been illustrated in connection with two conventional types of combined power and heating plants, viz. plants with fluidized bed boilers of the types BFB and CFB, respectively, it is also applicable on other types of combustion plants, e.g., such that make use of grate firing technique or burners for burning pulverized fuels. | A method for measuring the concentration of harmful gases in flue gases through a heat-producing plant that includes a combustion space and a device located downstream of the combustion space, the device includes tubes, through which for instance water, steam or air may pass in order to be heated by heat transfer from flue gases formed during the combustion. In a region near the tube device, at least one beam of ultraviolet light is emitted from a light emitter at one side of a flue gas duct to a light receiver located at the opposite side of the duct, which light emitter is connected to a spectrometer cooperating with a computer unit, in which spectrometer the light is divided spectrally. | 8 |
BACKGROUND OF THE INVENTION
Trauma to the brain or spinal cord caused by physical forces acting on the skull or spinal column, by ischemic stroke, arrested breathing, cardiac arrest, Reye's syndrome, cerebral thrombosis, cerebral embolism, cerebral hemorrhage, encephalomyelitis, hydrocephalus, post-operative brain injury, cerebral infections, various concussions and elevated intracranial pressure results in edema and swelling of the affected tissues. This is followed by ischemia, hypoxia, necrosis, temporary or permanent brain and/or spinal cord injury and may result in death. The tissue mainly affected are classified as grey matter, more specifically astroglial cells. The specific therapy currently used for the treatment of the medical problems described include various kinds of diuretics (particularly osmotic diuretics), steroids (such as, 6-α-methylprednisolone succinate) and barbiturates. The usefulness of these agents is questionable and they are associated with a variety of untoward complications and side effects. Thus, the compounds of this invention comprise a novel and specific treatment of medical problems where no specific therapy is available.
Recent publications entitled "Agents for the Treatment of Brain Injury" 1. (Aryloxy)alkanoic Acids, Cragoe et al, J. Med. Chem., (1982) 25, 567-569, and "Agents for the Treatment of Brain Edema: ,2[(2,3,9,9a-tetrahydro-3-oxo-9substituted-1H-fluoren-7-yl)oxy] Alkanoic Acids and Some of Their Analogs", Cragoe et al., J. Med. Chem. (1986), 29, 825-841, report on recent experimental testing of agents for treatment of brain injury and review the current status of treatment of brain injury. Additionally, U.S. Pat. Nos. 4,316,043, 4,317,922, 4,337,354, 4,356,313 and 4,356,314 disclose certain alkanoic and cycloalkanoic acids for the treatment of grey matter edema.
The compounds of the invention have the added advantage of being devoid of the pharmacodynamic, toxic or various side effects characteristic of the diuretics, steroids and barbiturates.
DESCRIPTION OF THE INVENTION
The compounds of the instant invention are best characterized by reference to the following structural Formula (I): ##STR1## wherein: ##STR2##
R 1 is lower alkyl, branched or unbranched, containing from 1 to 5 carbon atoms such as methyl, ethyl, n-propyl, isopropyl and the like, aryl such as phenyl, halo substituted aryl such as p-fluorophenyl, o-fluorophenyl, p-chlorophenyl and the like, aralkyl such as benzyl, cycloalkyl containing from 3 to 6 nuclear carbon atoms such as cyclopropyl, cyclobutyl, cyclopentyl and the like, or cycloalkyl-lower alkyl containing from 4 to 7 total carbon atoms such as cyclopentylmethyl and the like;
X and Y are halo or lower alkyl, such as methyl;
x is 1 to 4; and
y is 1 to 3.
Since the 9acarbon atom in the molecule is asymmetric, the compounds of the invention are racemic. However, these compounds or their precursors can be resolved so that the pure enantiomers can be prepared, thus the invention includes the pure enantiomers. This is an important point since some of the racemates consist of one enantiomer which is much more active than the other one. Furthermore, the less active enantiomer generally possesses the same intrinsic toxicity as the more active enantiomer. In addition, it can be demonstrated that the less active enantiomer depresses the inhibitory action of the active enantiomer at the tissue level. Thus, for three reasons it is advantageous to use the pure, more active enantiomer rather than the racemate.
Likewise, since certain products of the invention are acidic, the invention also includes the obvious pharmaceutically acceptable salts such as the sodium, potassium, ammonium, trimethylammonium, piperazinium, 1-methylpiperazinium, guanidinium, bis(2-hydroxyethyl)ammonium, N-methyl-glucosammonium and the like salts.
It is also to be noted that the compounds of Formula I, as well as their salts, often form solvates with the solvents in which they are prepared or from which they are recrystallized. These solvates may be used per se or they may be desolvated by heating (e.g. at 70° C.)in vacuo.
Although the invention primarily involves novel [(5,6-dichloro-3-oxo-9-apropyl-2,3,9,9a-tetra hydrofluoren-7-yl)oxy]ethanol and their salts, it also includes their derivatives, such as oximes, hydrazones and the like. Additionally, this invention includes pharmaceutical compositions in unit dosage form containing a pharmaceutical carrier and an effective amount of a compound of Formula I, its R or S enantiomer, or the pharmaceutically acceptable salts thereof, for treating brain injury. The method of treating a person with brain injury by administering said compounds or said pharmaceutical compositions is also a part of this invention.
PREFERRED EMBODIMENT OF THE INVENTION
The preferred embodiments of the instant invention are realized in structural Formula II ##STR3## wherein: ##STR4##
R 3 is lower alkyl, branched or unbranched, containing from 1 to 5 carbon atoms; and
x is 1 or 2.
Also included are the enantiomers of each racemate.
A preferred compound is R(+) [(5,6-dichloro1,2,9,9a-tetrahydro-9a-propyl-1H-fluoren-7-yl)oxy]ethanol.
Also preferred is R(+) [(5,6-dichloro-1,2,9,9a-tetrahydro-9a-propyl-1H-fluoren-7-yl)oxy]ethyl 4-(dimethylamino)butyrate hydrochloride.
Also preferred is R(+) [(5,6-dichloro-1,2,9,9a-tetrahydro-9a-propy-1H-fluoren-7-yl)oxy]ethyl (dimethylamino)acetate hydrochloride
Also preferred is R(+) [(5,6-dichloro-1,2,9,9a-tetrahydro-9a-propy-1H-fluoren-7-yl)oxy]ethyl 3-carboxypropionate.
Also preferred is R(+) [(5,6-dichloro-1,2,9,9a-tetrahydro-9a-propyl- 1H-fluoren-7-yl)oxy]ethyl 3-carboxyacrylate.
Especially preferred are the pure enantiomers since, in most instances, one enantiomer is more active biologically then its antipode.
Included within the scope of this invention are the pharmaceutically acceptable salts of basic or acidic esters of [(5,6-dichloro-3-oxo-9a-propyl-2,3,9,9a-tetrahydrofluoren-7-yl)oxy]ethanol (Ib) and its derivatives since a major medical use of these compounds is solutions of their soluble salts which can be administered parenterally.
Thus, the acid addition salts can be prepared by the reaction of the acidic esters of [(5,6-dichloro-3-oxo-9a-propyl-2,3,9,9a -tetrahydrofluoren-7-yl)oxy]ethanol and its derivatives with an appropriate alkali metal hydroxide, carbonate or bicarbonate such as sodium hydroxide, potassium hydroxide, sodium carbonate, sodium bicarbonate and the like or an organic base, such as ammonium hydroxide, piperazine, 1-methylpiperazine, guanidine, bis-(2-hydroxyethyl)amine, N-methylglucosamine and the like salts. The salts of the basic esters of this invention may be prepared by reaction with an appropriate pharmaceutically acceptable mineral acid or organic carboxylic acid, such as hydrochloric acid, sulfuric acid, hydrobromic acid, isethionic acid, methanesulfonic acid, maleic acid, succinic acid, acetic acid and the like. The salts selected are derived from among the nontoxic, pharmaceutically acceptable acids.
The compounds of this invention, such as: ##STR5##
The compounds of Formula I can serve as prodrugs of the corresponding carboxylic acids of Formula IIIa known to be agents for the treatment of brain injury (see U.S. Pat. Nos. 4,316,043 4,317,922, 4,337,354, 4,356,313, 4,356,314). ##STR6## Compound IIIa is obtained from compound I by well-known metabolic processes. Thus, when R=H, an oxidative metabolism occurs and when R= other than H a hydrolytic and oxidative metabolism occurs to produce IIIa.
Since it is convenient to administer the compounds parenterally, particularly intravenously, it is convenient to make a derivative of Ib which can be converted to a watersoluble salt. Thus, with the compound where ##STR7## a salt can be formed from a organic or inorganic acid which is water soluble. Likewise, with the compound where ##STR8## a salt can be formed from an organic or inorganic base which is water soluble.
The compounds of this invention are prepared as follows: ##STR9##
Phenol IV is prepared from pure III by heating with molten pyridine hydrochloride. The reaction is generally carried out using 25 to 35 moles of pyridine hydrochloride to one of III. The stirring mixture is heated preferably at 190° C. for 15 minutes. Somewhat longer periods are required at lower temperatures. However, excess heating leads to excessive decomposition products.
Reaction of compound IV with 2-iodoethanol (V) in a solvent such as acetone in the presence of a base such as potassium carbonate leads to compound Ib. It is convenient to heat the reaction mixture at the reflux temperature of acetone for periods of 18-36 hours to complete the reaction. Other solvents such as 2-butanone or dimethylformamide can be used, however, the temperature of the reaction should be kept in the range of 50°-60° C. Other bases such as sodium carbonate may be used.
The reaction of compounds Ib with compound VIII leads to the formation of compound (Ic). Compound VIII is formed by the reaction of compound VI with carbonyldiimidazole (VII) in the presence of a base such as 1,5-diazabicyclo[4.3.0]nonane (DBN) or 1, -diazabicyclo[5.4.0]undecane (DBU) in a solvent such as tetrahydrofuran (THF) or dioxane. The reaction is completed in 1 to 5 hours.
The addition of compound Ib to a preformed solution of VIII in THF and stirring the mixture at a temperature of 20°to 35° C. for 12 to 16 hours leads to the formation of the desired product. Acidification of Ib with an acid such as hydrochloric acid leads to the formation of compound Ib in the form of its hydrochloride salt.
The reaction of compound Ib with compound IX upon acidification produces compound Id if A=--(CH 2 ) 2 --and compound Ie if A=--CH═CH--. Compound IX is prepared from either succinic acid or maleic acid (1 mole) by treatment with imidazole sodium followed by reaction with carbonyldiimidazole (VII) (1 mole). The reaction is carried out in the presence of dimethylformamide and the reaction is complete at ambient temperature within about 15 to 30 minutes. Compound Ib is added to the reaction mixture along with a catalytic amount of sodium methoxide (CH 3 ONa) (0.05 mole equivalent). The product (compound Id or Ie) is isolated by evaporation of the solvent, adding water and acidification of the solution with hydrochloric acid.
It is to be noted that the compounds described above consist of the pure R-enantomer since they are derived from compound IIIb, which is a pure R-enantiomer.
It is to be recognized that these compounds of Formula I possess an asymmetric carbon atom at position 9a and, therefore, consist of racemates composed of two enantiomers. However, an appropriate intermediate phenol (i.e. Compound IV) which consists of one pure enantiomer, permits the synthesis of pure enantiomeric products of Formula I.
Inasmuch as there are a variety of symptoms and severity associated with grey matter edema, particularly when it is caused by head trauma, stroke, cerebral hemorrhage or embolism, post-operative brain surgery trauma, spinal cord injury, cerebral infections, various brain concussions and elevated intracranial pressure, the precise treatment is left to the practioner. Generally, candidates for treatment will be indicated by the results of the patient's initial general neurological status, findings on specific clinical brain stem functions and findings on computerized axial tomography (CAT), nuclear magnetic resonance (NMR) or positron emission tomography (PET) scans of the brain. The sum of the neurological evaluation is presented in the Glascow Coma Score or similar scoring system. Such a scoring system is often valuable in selecting the patients who are candidates for therapy of this kind.
The compounds of this invention can be administered by a variety of established methods, including intravenously, intramuscularly, subcutaneously, intracisternally or orally. The parenteral route, particularly the intravenous route of administration, is preferred, especially for the very ill and comatose patient. Another advantage of the intravenous route of administration is the speed with which therapeutic brain levels of the drug are achieved. It is of paramount importance in brain injury of the type described to initiate therapy as rapidly as possible and to maintain it through the critical time periods. For this purpose, the intravenous administration of drugs of the type of Formula I in the form of their salts is superior.
A recommended dosage range for treatment is expected to be from 0.01 mg/kg to 20 mg/kg of body weight as a single dose, preferably from 0.05 mg/kg to 10 mg/kg. An alternative to the single dose schedule is to administer a primary loading dose followed by a sustaining dose of half to equal the primary dose, every 4 to 24 hours. When this multiple dose schedule is used, the dosage range may be higher than that of the single dose method. Another alternative is to administer an ascending dose sequence of an initial dose followed by a sustaining dose of 1.5 to 2 times the initial dose every 4 to 24 hours. For example, 3 intravenous doses of 4, 6 and 8 mg/kg of body weight can be given at 6 hour intervals. If necessary, 4 additional doses of 8 mg/kg of body weight can be given at 12 hour intervals. Another effective dose regimen consists of a continuous intravnous infusion of from 0.05 mg/kg/hr to 2.0 mg/kg/hr. Of course, other dosing schedules and amounts are possible.
One aspect of this invention is the treatment of persons with grey matter edema by concomitant administration of a compound of Formula I or its salts, and an anti-inflammatory steroid. These steroids are of some, albeit limited, use in control of white matter edema associated with ischemic stroke and head injury. Steroid therapy is given according to established practice as a supplement to the compound of Formula I as taught elsewhere herein. Similarly, a barbiturate may be administered as a supplement to treatment with a compound of Formula I.
The compounds of Formula I are utilized by formulating them in a pharmaceutical composition such as tablet, capsule or elixir for oral administration. Sterile solutions or suspensions can be used for parenteral administration. A compound or mixture of compounds of Formula I, or its physiologically acceptable salt, is compounded with a physiologically acceptable vehicle, carrier, excipient, binder, preservative, stabilizer, flavor, etc. in a dosage form as called for by accepted pharmaceutical practice.
Illustrative of the adjuvants which may be incorporated in tablets, capsules and the like are the following: a binder such as gum tragacanth, acacia, corn starch or gelatin; an excipient such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid and the like; a lubricant such as magnesium stearate; a sweetening agent such as sucrose, lactose, or saccharin; a flavoring agent such as peppermint, oil of wintergreen or cherry. When the dosage unit form is a capsule, it may contain in addition to materials of the above type a liquid carrier such as a fatty oil. Various other materials may be present as coatings or to otherwise enhance the pharmaceutical elegance of the preparation. For instance, tablets may be coated with shellac, sugar or the like. A syrup or elixir may contain the active compound, sucrose as a sweetening agent, methyl and propyl parabens as preservatives, a dye and a flavoring such as cherry or orange flavor.
Sterile compositions for injection or infusion can be formulated according to conventional pharmaceutical practice by dissolving the active substance in a conventional vehicle such as water, saline or dextrose solution by forming a soluble salt in water using an appropriate acid, such as a pharmaceutically acceptable carboxylic acids or mineral acids. Alternatively, a suspension of the active substance in a naturally occurring vegetable oil like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or a synthetic fatty vehicle like ethyl oleate or the like may be formulated for injection or infusion. Buffer, preservatives, antioxidants and the like can be incorporated as required.
The basic premise for the development of agents for the treatment of brain injury of the types described is based on the studies in experimental head injury by R. S. Bourke et. al. (R. S. Bourke, M. A. Daze and H. K. Kimelberg, Monograph of the International Glial Cell symposium, Leige, Bel. Aug. 29-31, 1977 and reference cited therein) and experimental stroke by J. H. Garcia et. al. (J. H. Garcia, H. Kalimo, Y. Kamijyo and B. F. Trump, Virchows Archiv. [Zellopath.], 25, 191 (1977).
These and other studies have shown that the primary site of traumatic brain injury is in the grey matter where the process follows a pattern of insult, edema, ischemia, hypoxia, neuronal death and necrosis followed, in many instances, by irreversible coma or death. The discovery of a drug that specifically prevents the edema would obviate the sequalae.
Experimental head injury has been shown to produce a pathophysiologcal response primarily involving swelling of astroglial as a secondary, inhibitable process. At the molecular level, the sequence appears to be: trauma, elevation of extracellular K + and/or release of neurotransmitters, edema, and necrosis Astroglial swelling results directly from a K + -dependent, cation-coupled, chloride transport from the extracellular into the intracellular compartment with a concomitant movement of an osmotic equivalent of water. Thus an agent that specifically blocks chloride transport in the astroglia is expected to block the edema caused by trauma and other insults to the brain. It is also important that such chloride transport inhibitors be free or relatively free of side effects, particularly those characteristics of many chloride, transport inhibitors, such as diuretic properties. Compounds of the type illustrated by Formula I exhibit the desired effects on brain edema and are relatively free of renal effects.
That this approach is valid has been demonstrated by the correlation of the in vitro astroglial edema inhibiting effects of chloride transport inhibitors with their ability to reduce the mortality of animals receiving experimental in vivo head injury. As a final proof, one compound (ethacrynic acid) which exhibited activity both in vitro and in vivo assays was effective in reducing mortality in clinical cases of head injury. These studies are described in the Journal of Medicinal Chemistry, Volume 25, page 567 (1982), which is hereby incorporated by reference.
Three major biological assays can be used to demonstrate biological activity of the compounds. The (1) in vitro cat cerebrocortical tissue slice assay, (2) the in vitro primary rat astrocyte culture assay and (3) the in vivo cat head injury assay. The first assay, the in vitro cat cerebrocortical tissue slice assay has been described by Marshall, L. F.; Shapiro, H. M.; Smith, R. W. In "Seminars in Neurological Surgery: Neural Trauma"; Popp, A. J.; Bourke, R. S.; Nelson, L. R. ; Kimelberg, H, K,. Eds.; Raven Press: New York, 1979; p. 347, by Bourke, R. S.; Kimelberg, H, K.; Daze, M. A. in Brain Res. 1978, 154, 196, and by Bourke, R. S.; Kimelberg, H. K,; Nelson, L. R. in Brain Res. 1976, 105, 309. This method constitutes a rapid and accurate method of determining the intrinsic chloride inhibitory properties of the compounds of the invention in the target tissue.
The second assay method involves the in vitro primary rat astrocyte assay. The method has been described by Kimelberg, H. K.; Biddlecome, S.; Bourke, R. S. in Brain Res. 1979, 173, 111, by Kimelberg, H. K.; Bowman, C.; Biddlecome, S.; Bourke, R. S., in Brain Res. 1979, 177, 533, and by Kimelberg, H. K.; Hirata, H. in Soc. Neurosci. Abstr. 1981, 7, 698. This method is used to confirm the chloride transport inhibiting properties of the compounds in the pure target cells, the astrocytes.
The third assay method, the in vivo cat head injury assay has been described by Nelson, L. R.; Bourke, R. S.; Popp, A. J.; Cragoe, E. J. Jr.; Signorelli, A.; Foster, V. V. ; Creel, in Marshall, L. F.; Shapiro, H. M.; Smith, R. W. In "Seminars in Neurological Surgery: Neural Trauma"; Popp, A. J.; Bourke, R. S.; Nelson, L. R.; Kimelberg, H. K., Eds.; Raven Press: New York, 1979; p. 297.
This assay consists of a highly relevant brain injury in cats which is achieved by the delivery of rapid repetitive acceleration-deceleration impulses to the animal's head followed by exposure of the animals to a period of hypoxia. The experimental conditions of the assay can be adjusted so that the mortality of the control animals falls in the range of about 25 to 75. Then, the effect of the administration of compounds of this invention in reducing the mortality over that of the control animals in concurrent experiments can be demonstrated.
Using the in vitro cat cerebrocortical tissue slice assay, described in Example 1, compounds of the present invention are tested for activity. This test provides the principal in vitro evaluation and consists of a determination of concentration vs. response curve. The addition of HCO 3 31 to isotonic, K + -rich saline-glucose incubation media is known to specifically stimulate the transport of Cl - coupled with Na + and an osmotic equivalent of water in incubating slices of mammalian cerebral cortex. Experiments have demonstrated that the tissue locus of swelling is an expanded astroglial compartment. Thus, the addition of HCO 3 - to incubation media stimulates statistically significant and comparable increases in cerebrocortical tissue swelling and ion levels. After addition of drug to the incubation media, detailed drug concentration-reponse curves are then obtained. The data are expressed as percent HCO 3 - -stimulated swelling vs. drug concentration, from which the concentration of drug providing 50% inhibition of HCO 3 - -stimulated swelling (I 50 in molarity) is interpolated.
The following examples are included to illustrate the in vitro cerebrocortical tissue slice assay, the preparation of representative compounds of Formula I and representative dosage forms of these compounds. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being indicated by the following claims. All temperatures in the examples are in Centigrade unless otherwise indicated.
EXAMPLE 1
In Vitro Cerebrocortical Tissue Slice Assay
Adult cats of 2-3 kg body weight are employed in tissue slice studies. Prior to sacrifice, the animals are anesthetized with ketamine hydrochloride gassed for (Ketaset), 10 mg/kg intramuscularly. Eight (three control, five experimental) pial surface cerebrocortical tissue slices (0.5-mm thick; approximately 150 mg initial fresh weight) are cut successively with a calibrated Stadie-Riggs fresh tissue microtome without moistening and weighed successively on a torsion balance. During the slice preparation all operations except weighing are confined to a humid chamber. Each slice is rapidly placed in an individual Warburg flask containing 2 ml of incubation medium at room temperature. The basic composition of the incubation media, in millimoles per liter, is as follows: glucose, 10; CaCl 2 , 1.3; MgSO 4 , 1.2; KHSO 4 , 1.2; Hepes (N2hydroxyethyl-piperazine-N'-2-ethanesulfonic acid, titrated with NaOH to pH 7.4), 20. Except when adding HCO 3 - , the osmolarity of the media is maintained isosmotic (approximately 285 mOsm/L) by reciprocal changes of Na + or K + to achieve a concentration of K + of 27 mM. The basic medium was saturated with oxygen by bubbling pure oxygen through the solution for 30 minutes before use. When added, NaHCO 3 or triethylammonium bicarbonate (TEAB) is initially present in the sidearm of each flask at an initial concentration of 50 mM in 0.5 ml of complete medium. Nonbicarbonate control slices are incubated at 37° C. in 2.5 ml of basic medium for 60 minutes. Bicarbonate control slices are similarly incubated for an initial 20 minutes at 37° C. in 2.0 ml of basic medium to which is added from the sidearm an additional 0.5 ml of incubation medium containing 50 mM HCO 3 - , which, after mixing, results in a HCO 3 - concentration of 10 mM and a total volume of 2.5 ml. The incubation is continued for an additional 40 minutes. The various compounds to be tested are dissolved by forming the hydrochloride salts in water. When only the free bases are available, the hydrochloride salts are formed by treating the free base with a molar equivalent of hydrochloric acid and diluting to the appropriate concentrations. Just prior to incubation, all flasks containing HCO 3 - are gassed for 5 minutes with 2.5% CO 2 /97.5% O 2 instead of 100% O 2 .
Following the 60-minute incubation period, tissue slices are separated from incubation medium by filtration, reweighed, and homogenized in 1N HCiO 4 (10% w/v) for electrolyte analysis. The tissue content of ion is expressed in micromoles per gram initial preswelling fresh weight. Control slice swelling is expressed as microliters per gram initial preswelling fresh weight. The effectiveness of an inhibitor at a given concentration is measured by the amount of HCO 3 - -stimulated swelling that occurred in its presence, computed as a percent of the maximum possible. Tissue and media Na + and K + levels are determined by emission flame photometry with Li + internal standard; Cl - levels are determined by amperometric titration. Tissue viability during incubation is monitored by manometry.
EXAMPLE 2
R(+) 5,6-Dichloro-1,2,9,9a-tetrahydro-7-hydroxy-99-propyl-3H-flouren-3-one
R(+) (5,6-Dichloro-2,3,9,9a-tetrahydro-3-oxo-9a-propyl-1H-fluoren-7-yl)oxy]acetic acid (7.38 g, 20 mMole) was added to a stirring melt of pyridine hydrochloride (73.8 g, 630 mMole) at 190° C. and heated for 15 minutes. The mixture was quickly poured, with stirring, into crushed ice (400 g) and the resulting solid was separated by filtration, washed with H 2 O, resuspended in H 2 O, refiltered, thoroughly washed with H 2 O and dried. The yield of product was 6.4 g (100%); this product was purified by extraction with ethyl acetate via a Soxhlet, the solvent evaporated and the residue washed with ether to give material, mp 253°-255° C. [α] D 25 +177.4 (c=1 THF).
Analysis for C 16 H 16 Cl 2 O 2 : Calculated: C, 61.75; H, 5.18. Found: C, 61.96; H, 5.41.
EXAMPLE 3
R(+) [(5,6-Dichloro-1,2,9,9a-tetrahydro-9a-propyl-1H-fluoren-7-vl)oxy]ethanol
R(+) 5,6-Dichloro-1,2,9,9a-tetrahydro-7-hydroxy-9a-propyl-3H-fluoren-3-one (3.3 g, 10.6 mMole), 2-iodoethanol (2.74 g, 15.9 mMole), potassium carbonate (2.19 g, 15.9 mMole) and acetone (500 ml) were stirred and refluxed for 24 hours. The mixture was filtered and the filtrate evaporated to dryness in vacuo. The residue was treated with water, the water layer removed and the residue dissolved in acetone. Evaporation of the acetone solution produced a residue which was chromatographed on a silica gel column. The material was placed on the column in a little acetonitrile and eluted with a butyl chloride-acetonitrile 7:3 mixture. Evaporation of the appropriate cuts gave 2.82 g of product, which after recrystallization from butyl chloride melted at 125°-127° C.
Analysis for C 18 H 20 Cl 2 O 3 : Calculated: C, 60.85; H, 5.67. Found: C, 61.10; H, 5.82.
EXAMPLE 4
R(+)[(5,6-Dichloro-1,2,9,9a-tetrahydro-9a-propyl-1H-fluoren- 7-yl)oxy]ethyl 4-(dimethylamino)butyrate hydrochloride
4-(Dimethylamino)butyric acid hydrochloride (603 mg, 3.36 mMole) and 1,5-diazabicylco [4.3.0]nonane (DBN) (447 mg, 3.36 mMole) in tetrahydrofuran (100 ml) were stirred under anhydrous conditions for 2 hours. Then, R(+) [(5,6-dichloro-1,2,9,9a-tetrahydro-9a-propyl-1H-fluoren-7-yl)oxy]ethanol was added and the mixture stirred for 16 hours.
The reaction mixture was evaporated in vacuo and the residue extracted with dichloromethane. The dichloromethane extract was washed with a brine solution and then with a 0.1 normal hydrochloric acid solution. The dichloromethane solution was dried over MgSO 4 and evaporated to dryness in vacuo. The residue was treated with boiling ethyl acetate which gave the solid product 1.03 g m.p. 146°-148°.
Analysis for C 24 H 31 Cl 2 NO 4 ·HCl: Calculated: C, 57.09; H, 6.39; N, 2.77. Found: C, 56.81; H, 6.51; N, 2.74.
EXAMPLE 5
R(+) [(5,6-Dichloro-1,2,9,9a-tetrahydro-9a-propyl-1H-fluoren-7-yl)oxy]ethyl (dimethylamino)acetate hydrochloride
By conducting the reaction as described in Example 4 except that the 4-(dimethylamino)butyric acid hydrochloride was replaced by an equivalent amount of N,N-dimethylglycine, there was obtained R(+) [(5,6-dichloro-1,2,9,9a-tetrahydro-9a-propyl-1H-fluoren-7-yl)oxy]ethyl (dimethylamino)acetate hydrochloride.
EXAMPLE 6
R(+) [(5,6-Dichloro-1,2,9,9a-tetrahydro-9a-propyl-1H-fluoren. 7-yl)oxy]ethyl 3-carboxypropionate
Succinic acid (1.3 g, 11 mMole) in dimethylformamide (50 ml) was treated with imidazole sodium (991 mg, 11 mMole) and then carbonyldiimidazole (1.78 g, 11 mMole) added. After stirring for 20 minutes, [(5,6-dichloro-1,2,9,9a-tetrahydro-9a-propyl-1H-fluoren-7-yl)oxy]ethanol (3.55 g, 10 mMole) was added followed by sodium methoxide (27 mg) and the mixture stirred for 20 hours at ambient temperature.
The solvent was removed by evaporation at reduced pressure and the residue treated with water (20 ml). The mixture was extracted with dichloromethane and the water layer separated and acidified with hydrochloric acid. The mixture was extracted with dichloromethane and the extract dried over MgSO 4 . Evaporation of the solvent gave the product.
EXAMPLE 7
(Z) R(+) [(5,6-Dichloro-1,2,9,9a-tetrahydro-9a-propyl-1H-fluoren-7-yl)oxy]ethyl3-carboxyacrylate
By carrying out the reaction as described in Example 6 except that the succinic acid was replaced by an equimolar amount of maleic acid, there was obtained (Z) R (+) [(5,6-dichloro-1,2,9,9a-tetrahydro-9a-propyl-1H-fluoren- 7-yl)oxy]ethyl 3-carboxyacrylate.
EXAMPLE 8
Parenteral solution of R(+) [(5,6-Dichloro-1,2,9,9a-tetrahydro-9a-propyl -1H-fluoren- 7-yl)oxy]ethanyl4 4-(dimethylamino)butyrate hydrochloride
The parenteral solution of R(+) [(5,6-dichloro-1,2,9,9a-tetrahydro-9a-propyl-1fluoren-7-yl)Oxy]ethanyl 4-(dimethylamino)butyrate hydrochloride (Example 4) (542 mg) is dissolved by stirring and warming with sufficient water to bring the total volume to 10 ml and the solution is sterilized by filtration. All the water that is used in the preparation is pyrogen-free. The concentration of the active ingredient (calculated as free base) in the final solution is 5%.
Similar parenteral solutions of the basic esters of this invention can be prepared by replacing the active ingredient of this Example by any of the other basic ester compounds of this invention.
EXAMPLE 9
Parenteral solution of the Sodium Salt R(+) [(5,6-Dichloro-1,2,9,9a-tetrahydro-9a-propyl-1-fluoren-7-yl)oxy]ethyl 3-carboxypropionate
The parenteral solution of the Sodium Salt R(+) [(5,6-Dichloro-1,2,9,9a-tetrahydro-9a-propyl-1H-fluoren-7-yl)oxy]ethyl 3-carboxyproprionate (Example 6) (500 mg) is dssolved by warming with a solution of 0.25 N sodium bicarbonate (4.53 ml). The solution is diluted to 10 ml with water and sterilized by filtration. All the water used in the preparation is pyrogen-free. The concentration of the active ingredient (calculated as free acid) in the final solution is 5%.
Similar parenteral solutions of the acidic esters of the compounds of this invention can be prepared by replacing the active ingredient of this Example by any other acidicester compounds of this invention.
EXAMPLE 10
Dry-Filled Capsules Containing 100 mg of Active Ingredient Per Capsule
______________________________________ Per Capsule______________________________________R(+) [(5,6-dichloro-1,2,9,9a-tetra- 108.4 mghydro-9a-propyl-1H--fluoren-7-yl)-oxy]ethyl 4-(dimethylamino)-butyrate hyrochlorideLactose 90.6 mgMagnesium Stearate 1 mgCapsule (Size No. 1) 200 mg______________________________________
The R(+) [(5,6-dichloro-1,2,9,9a-tetrahydro-9a-propyl-1H-fluoren-7-yl)oxy]ethyl 4-(dimethylamino)butyrate hydrochloride (Example 3) is reduced to a No. 60 powder and then the lactose and magnesium stearate are passed through a No. 60 bolting cloth onto the powder and the combined ingredients admixed for 10 minutes and then filled into a No. 1 dry gelatin capsule.
Similar capsules can be prepared by replacing the active ingredient of this Example by any of the other compounds of this invention. | The invention relates to novel [(5,6-dichloro-3-oxo-9a-propyl-2,3,9,9a-tetrahydrofluoren-7-yl)oxy]ethanol, its derivatives, and their salts. The compounds are useful for the treatment and prevention of injury to the brain and of edema due to head trauma, stroke (particularly ischemic), arrested breathing, cardiac arrest, Reye's syndrome, cerebral thrombosis, cerebral embolism, cerebral hemorrhage, cerebral tumors, encephalomyelitis, spinal cord injury, hydrocephalus, post-operative brain injury trauma, edema due to cerebral infections including that due to AIDS virus, various brain concussions and elevated intracranial pressure. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/681,097 filed on Aug. 8, 2012, which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to apparatuses and methods for treating or filtering fluids, and more particularly to apparatuses and methods for use in conjunction with box culverts to collect and filter storm water runoff.
BACKGROUND OF THE INVENTION
[0003] Impervious surfaces and other urban and suburban landscapes generate a variety of contaminants that can enter storm water, polluting downstream receiving waters. These contaminants can include heavy metals, oils, and greases, organic toxins, as well as trash and debris. In response to tighter guidelines imposed by environmental and regulatory agencies, the control of pollution, silt and sediment found in storm water runoff and other sources of water is receiving ever-increasing attention at all levels of federal, state, and local government. Federal and state agencies have issued mandates and developed guidelines regarding the prevention of non-point source (storm water caused) pollution that require action by governmental entities. These mandates affect the management of water runoff from sources such as storms, slopes, and construction sites. In addition, there are many other laws and regulations in place that restrict the movement or disposal of significant amounts of water. Such laws and regulations have a significant impact on, for example, the ways that states, municipalities, highway authorities and other responsible bodies can drain or otherwise dispose of storm water runoff or other water falling on or passing over highways, roadways, parking lots and the like.
[0004] Typical storm water filtration systems used to reduce pollutant loading in runoff from urban developments include known filter devices housed in a vault configuration. The filter devices capture and retain sediment, oils, metals and other target constituents close the source and reduces the total discharge load. As illustrated in FIG. 1 , the filter devices can include cylindrical filter cartridges with filter media, housed within upright walls, such as the Perk Filter™ (KriStar Enterprises, Inc.; Santa Rosa, Calif.). A filter device is also described in U.S. Pat. No. 6,241,882, which is entitled “Sump & Filter Device For Drainage Inlets” and is assigned to KriStar Enterprises, Inc.
[0005] Referring to FIG. 1 , storm water can enter the filtration system via an inlet opening 101 through an outer wall 102 into a first chamber of the vault. The first chamber includes a gallery floor 103 and a floor slab 104 beneath the gallery floor. The storm water then flows through one or more bypass manifold assemblies 105 , past an internal wall 106 that is poured such that it is monolithic with the outer wall or outer walls. The bypass manifold assembly includes an inlet bypass floatable weir 107 at an upper portion that obstructs the flow of gross pollutants in the water. The bypass manifold assembly also includes an inlet bypass manifold weir 108 located at a lower portion that allows fluid to accumulate. During periods of routine flow, storm water moves through the bypass manifold assembly into an adjacent filter chamber, where it is filtered by one or more known devices, such as filter cartridges 109 containing filter media. Filtered flows then move through an outlet opening 110 along an outer wall 111 . During periods of peak flow, storm water is allowed to accumulate in the first chamber until it reaches the height of the lower bypass weir, also called an inlet bypass manifold weir. Bypass flows pass over the weir and are directed to a lower annular space, separate from the chamber with filter media, before the storm water exits the system. Angled brackets support 112 acts as a support frame for the platform on which the filter media rests. Expansion bolts 113 are used to join the angled bracket to the platform.
[0006] Because the vault and the components must be separately constructed, time and effort is required to size and manufacture different vaults and components for different flow capacities. Moreover, the platform on which the filter devices rest must be sized and designed to securely fit these different vault structures. In practice, the filtration capacity is often limited by the size of an individual vault. Installation of the various components in the system may require additional effort, particularly for larger systems with a large number of filter devices and increased treatment capacities.
[0007] Thus, there exists a need for practical and economical storm water filtration methods and apparatuses that can be easily manufactured and installed at a site. There is also a need for a storm water filtration system that can efficiently handle bypass flows during peak events. There is also a need for a storm water filtration system that can be configured to handle different levels of storm water flows.
SUMMARY OF THE INVENTION
[0008] The present invention provides more effective methods and apparatuses for filtering and treating polluted or dirty water, such as storm water runoff, using existing box culverts. The invention relies on the support structures in the box culvert to install a “false floor” that supports the filter media and allows filtered flows to pass along the top. The false floor also creates an annular space below to allow for unfiltered bypass flows from the system.
[0009] A conventional box culvert includes a rectangular-shaped drain or pipe that channels water flow under roads, parking lots, railroads, or similar obstructions. Other shapes such as arched, round, circular, or curved culverts are also available. Box culverts are generally available as precast units that can be manufactured before installation. They provide both load bearing strength and structural integrity. Because they are readily available and easily sourced for construction applications, box culverts provide a versatile, structurally strong, and cost effective structure to support storm water filtration systems. Box culverts are available in various standard sizes and known materials, such as precast concrete. Thus, one advantage of the use of a box culvert in the present invention is the ability to use existing structures that are available and manufactured according to standard industry sizes. This allows for ease of manufacture, as well as quicker and more economical installation.
[0010] Another advantage of the present invention is the use of one or more false floors installed in an existing box culvert to provide a separate, alternate path for storm water flow. A false floor is set within the box culvert. It provides a platform or mounting surface on which filter devices may rest. It also creates an annular space beneath the floor through which unfiltered flows moving from the bypass assembly can move. In this way, the false floor separates filtered and unfiltered storm water flowing through the same system.
[0011] Another advantage of the present invention is the flexibility to configure and use additional filter sections in box culverts, as needed for a given site or filtration capacity. Because the box culverts are modular, a plurality of box culverts may be used in different configurations, depending on the needs of a given site or construction project. The system can be expanded to accommodate multiple units. In addition, filter units can be added or removed as needed.
[0012] Another advantage of the present invention is the use of one or more internal bypass assemblies disposed within one or more walls of the inlet section. The internal bypass assembly provides an alternate path for storm water during peak flow events by diverting storm water from a filter section into an annular space below the filter section.
[0013] A further advantage of the present invention is the reduction of the workload required of one more particular filter unit in terms of the amount of sedimentation, silt and pollution that they are required to remove over the course of its life span. These advantages can be accomplished by installing multiple filter banks, such that at least a portion of storm water runoff or other passing fluids can be processed through multiple banks during high flow events.
[0014] Another advantage of the present invention is the ability to retain gross pollutants, such as trash, debris, and coarse sediment, within a filtration system, without impeding peak flow bypass needs. The present invention allows for trash capture through the use of a bypass manifold assembly located within a box culvert.
[0015] Yet another advantage of the present invention is the provision of more effective methods and apparatuses for filtering and treating polluted or dirty water, such as storm water runoff, that passes over highways, roadways, parking lots and the like, such that whatever fluid eventually makes its way into a final drainage infrastructure or destination is likely to be cleaner. This advantage is realized by providing an apparatus and method for processing water runoff or other fluid when such fluid enters a water treatment system. These and other useful objects are achieved by the improved apparatuses and methods disclosed herein.
[0016] One embodiment of the present invention provides an apparatus adapted to cooperatively engage with a box culvert, comprising: an inlet section disposed within a box culvert; at least two outer walls shared with the box culvert; at least one internal bypass assembly disposed within a wall of the inlet section comprising two substantially vertical weirs; at least one filter section in fluid communication with the bypass assembly comprising at least two inner walls and filter media; at least one bottom platform disposed within the box culvert and under at least a portion of the filter section, wherein the space between a lower surface of the platform and an upper surface of the box culvert forms an annular space through which unfiltered fluid is allowed to flow; and an outlet section in fluid communication with the filter section, wherein said outlet section comprises at least two outer walls shared with a box culvert.
[0017] Optionally, the apparatus may comprise an access riser along a top surface of the box culvert, wherein the access riser includes a moveable access cover. The apparatus may further comprise multiple filter sections, wherein a substantially vertical separation plate is disposed between adjacent filter sections. The apparatus may further comprise multiple bottom platforms, wherein a closure plate separates adjacent platforms. The platform of the apparatus may optionally comprise concrete.
[0018] In another embodiment, the present invention provides a method of processing fluid comprising the steps of selecting an inlet of a box culvert; selecting a filter device; coupling said box culvert and said filter device; installing a platform disposed within the box culvert and under the filter device, wherein the surface of the platform rests on a surface of the box culvert; and passing fluid through said box culvert and filter device. The space between a lower surface of the platform and an upper surface of the box culvert forms an alternate route for fluid flow.
[0019] In some embodiments, it is contemplated that the dimensions and structural configurations of the box culvert and filter elements can vary with a range dependent on one or more design factors including but not limited to: desired water volume capacity, desired weight of each modular unit, desired load-bearing tolerance for each unit, desired amount of water flow to be managed, size and structure of overall assembly in which the system is to be used, and/or the desired access space for inspection and maintenance purposes. Other apparatuses, methods, features and advantages of the invention will be apparent to one with skill in the art upon examination of the following figures and detailed description. All such additional apparatuses, methods, features and advantages are included within this description and are encompassed within the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The included drawings are for illustrative purposes and provide examples of possible structures for the disclosed inventive storm water filtration system. These drawings in no way limit any changes in form and detail that may be made to the invention by one skilled in the art without departing from the spirit and scope of the invention.
[0021] FIG. 1 illustrates a side cut-away view of a known filtration system using a vault configuration.
[0022] FIGS. 2A through 2C illustrate in top plan view, side cut-away view, and end view, respectively, a filtration system using box culverts with five treatment bays, an inlet section, and an outlet section. FIG. 2D illustrates in side cut-away view of an embodiment of a bypass assembly shown in FIGS. 2A through 2C .
[0023] FIG. 3 illustrates a top plan view of an exemplary filtration system with four banks
[0024] FIG. 4 illustrates in side cut-away view of a bank of the filtration system described in FIG. 3 .
[0025] FIG. 5 illustrates schematically a section placement diagram showing the filter units described in FIGS. 3 and 4 .
[0026] FIGS. 6A through 6D provide isometric views of one embodiment of a false floor of the present invention with recesses for four substantially cylindrical filter devices.
[0027] FIGS. 7A through 7D provide isometric views of another embodiment of a false floor of the present invention with recesses for eight substantially cylindrical filter devices.
[0028] FIGS. 8A through 8D provide isometric views of a further embodiment of a false floor of the present invention with recesses for sixteen substantially cylindrical filter devices.
[0029] FIGS. 9A through 9D illustrate one unit, a short end cap, made of standard concrete.
DETAILED DESCRIPTION
[0030] In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments of the present invention. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the invention, these examples are not limiting. Other embodiments may be used, and changes may be made without departing from the spirit and scope of the invention.
[0031] One embodiment of the present invention includes a filtration system with multiple filter sections, each section containing filter media that forms a treatment bay for incoming storm water. The filtration system is incorporated into a precast box culvert with a standard industry design. The box culvert is shown as a large pipe structure having a rectangular cross section, but in practice, the box culvert may have any other size and shape common known in the art, such as round, elliptical, circular or curved.
[0032] As shown in FIGS. 2A through 2C , storm water may enter the system from an inlet, for example, an opening with an entrance pipe 201 , and flow through an inlet section 202 . The ordinary artisan will recognize that all or a portion of the top faces of each box culvert unit (alone or as part of a larger assembly) can be fitted with or easily adapted for fitting with a cover panel, plug, plate, grate, fitting or valve system well known in the art of water management systems. As illustrated, the inlet section includes a bolted and gasketed access cover 203 and access riser 204 with a ladder. The presence of this port allows for inspection, clean-out, monitoring, and maintenance of the inlet section.
[0033] One or more inlet bypass assemblies 205 are located within the inlet section. The bypass assembly includes two substantially vertical weirs. A first weir is located at a lower portion of the assembly and forms a barrier to the flow of storm water entering the inlet section and against which storm water can accumulate. The second weir is behind the first weir, preferably positioned such that the top edge of the second weir is higher than the top edge of the first weir. The first weir can be located in front of the second weir to first capture gross pollutants such as trash or debris. A floatables weir, which can also take the form of a gross pollutant hood, can be optionally located at a top portion of the assembly and at least partially obstructs the passage of trash and floatables to the adjacent chambers. One or more steel plates may be used for or as part of one or more weirs. In addition, one or more pipes or flow thru tubes may be positioned through slots in the weirs to convey fluid to the filter sections. In a preferred embodiment, two flow thru tubes may be incorporated to direct flow in a given bypass assembly. One or multiple bypass assemblies can be positioned within the interior of a box culvert, downstream from the inlet opening. One or multiple bypass assemblies can be placed side by side along a wall in the inlet section. One or more filter sections 206 are placed downstream from the inlet section. An equalization port 207 is placed in the inlet section (and in the outlet section, as well).
[0034] During periods of normal flow, storm water flows from the inlet section through the bypass assembly and toward downstream filtration media, where it is treated using filtration methods known in the art, including filter devices with filter cartridges or perforated sand pipes. In one embodiment, the filter devices may be cylindrical in shape and manufactured from durable polymeric components with a polymer-coated steel support screen and stainless steel hardware. Its base construction allows use with a wide variety of media chose to address site-specific pollutants of concern. Additional access covers 209 and access risers with steps 210 or ladder 211 can be included in the filter sections. The presence of these additional ports allows for inspection, clean-out, monitoring, and maintenance of the filter sections.
[0035] Subsequent filter sections of the system may be built into individual box culverts or culvert segments placed side by side. To connect the segments, tongue and groove joints 212 are sealed with asphalt mastic and non shrink grout on the inside surfaces. An outlet section 208 is located at an end of the filtration system and includes an outlet 213 for storm water to exit the system.
[0036] As shown in FIG. 2C , the cross section of box culvert may be rectangular in shape. The box culvert has opposing sides and curved haunches 214 at the corners. When positioned along one or more lower corners, the haunches or shoulders of the box culvert provide a load-bearing surface to support a concrete slab that creates a false floor 215 . The false floor may be made of concrete or other suitable materials. It is placed substantially horizontally above the bottom of the box culvert and creates an annular space between the bottom of the false floor and the bottom surface of the box culvert. During periods of routine water flow, storm water moves through the three openings from the bypass assemblies to one or more filter sections for treatment. But during periods of high flow, storm water that has accumulated above the height of the second weir travels from the entrance of the inlet section into the space between the two weirs, bypasses the filter section, and exits through the outlet section or an alternative external bypass structure (such as a separate pipe).
[0037] When multiple filter sections are included, as shown in FIG. 2A and 2B , stainless steel false floor connector plates 216 can be used to connect false floors placed in adjacent filter segments.
[0038] An embodiment of the bypass assembly is shown in more detail in FIG. 2D . Under normal flow conditions, storm water from an entrance of the system flows toward the first weir 216 and second weir 217 . The storm water rises to the level of one or more flow thru tubes 218 . A floatables weir 219 is positioned in front of an upper portion of the first weir and captures gross pollutants from the incoming storm water. Storm water—i.e., “low flows”—passes through one or more of the tubes to the filter medium 220 . The floatables weir may be particularly advantageous in a system because allows the use of cartridges in the filter section without protection from floatable debris. During increased flow events, storm water passes over the first weir, into the space between the first and second weirs, and underneath the false floor. In a preferred embodiment, a perforated drain-down feed-thru tube is placed along or near one of the upwardly extending weirs. Because the lowest flow path from the inlet section to either the filter section or the bypass assembly can be above the floor, there is the potential for standing water. The perforated drain-down feed-thru tube allows that water to drain down into the filter section after the rain event has passed.
[0039] The design of the filtration system of the present invention is scalable. Because the box culverts are modular and can be added as needed, the filtration system can be assembled in various configurations to accommodate relatively high fluid flow along a space. FIG. 3 illustrates one embodiment of the present invention that uses three hundred and sixty-eight (368) filter cartridges, each standing about 18 inches tall. The system includes box culverts with an internal space in the shape of cubes that houses the inlet and filter sections. The box culverts are configured to form four substantially rectangular filter banks, 301 , 302 , 303 , and 304 , each receiving storm water from inlet 305 . As a non-limiting example, each bank can be about 55 feet (660 inches) long and 9.33 feet (112 inches) wide. The footprint of the system can be about 55 feet long (660 inches) and 37.33 feet (448 inches) wide.
[0040] Storm water enters through an inlet section 306 . One or more inlet bypass assemblies 307 are located downstream from the entrance of each bank. In a preferred embodiment, three bypass assembles are placed in each of the four banks, providing for a total of twelve bypass assemblies. The inlet sections include equalizing boot couplers, 308 and 309 . During periods of routine flow, storm water moves from the inlet section through the bypass assembly, after which it is filtered by filter cartridges 310 placed in the filter sections 311 . The filtered flows are directed to one or more outlet sections 312 , which also include one or more equalizing boot couplers 313 , and exit the system through an outlet 314 located on one side. False floors disposed within the box culverts under the filter cartridges provide a secondary route for unfiltered bypass flows during period of high storm water flow. Stainless steel connecting plates 315 join false floors from adjacent filter sections. By way of example, a filtration system configured in this way may be designed to handle a treatment flow rate of about 6,624 gallons per minute (14.76 cubic feet per second) and a bypass flow rate of about 15.9 cubic feet per second.
[0041] In this embodiment, storm water enters through a single inlet; filtered and unfiltered exits through a single outlet. However, the system can be configured to accept flow from additional inlets and additional outlets, such as external pipes or other structures. For example, unfiltered bypass flow can be directed to a separate pipe or manifold, from which it would then exit the system.
[0042] Notably, the system of the present invention allows for flexibility in the event that additional capacity is needed after installation. Although the filter banks are shown in the figures to be populated, in practice, some of the filter banks may be left vacant. Plugs, such as stainless steel separation plates or other dividers, can be provided to isolate those unused banks during operation. As the filtration needs of a particular site increases, filter devices with additional media may be added in the previously unused banks, and the plugs can be removed to increase the filtration capacity of a given system.
[0043] FIG. 4 shows an assembled side cut-away view of an installed system, as described in FIG. 3 . The system is placed on bedding 401 that conforms to American Public Works Association (“APWA”) Standard Specification, Section 306 -1.121, except that the minimum bedding depth shall be 12-inches or greater. Backfill added around the side and top 402 , conforms to APWA Standard Specification, Section 306 -1.121, except that the minimum side backfill width shall be as required to allow sufficient room for compaction but no less than 6-inches and the minimum final backfill depth should be 12-inches. Compacted soil 403 may be placed above the filtration system.
[0044] For cleanout and maintenance, bolted and gasketed access covers 404 may be integrated using field poured concrete collar. The access covers may be lifted to allow for maintenance, clean-out, or monitoring of a filter section. In this way, the filtration system will not be clogged. Additional access risers with steps 405 or a ladder 406 can also be included to facilitate access into and out of a particular unit.
[0045] Between individual filter sections, tongue and groove joints 407 are sealed with asphalt mastic and non-shrink grout on one or more inside surfaces. It is contemplated that in some embodiments, further connecting means or fastening means may be provided for securing the box culverts. For example, wires, plastic ties, fasteners (e.g., screws, rivets, nails, snap-clips, and the like) or adhesive means (e.g., tape, glue, and the like) may be used to secure box culverts. FIG. 5 is a diagram showing the section placement of the units in each filter bank.
[0046] The present invention uses the haunch or shoulder of the box culvert as a load-bearing surface, to support a false floor. This assembly provides for a more economical design, as available standard precast concrete box culverts may be used. It can also eliminate the need for separate piping and the accompanying hydraulic issues that may arise, as bypass flows can be directly to the annular space under the false floor.
[0047] As shown in more detail in FIG. 6 , a false floor can be made of one or more slabs of suitable material, such as concrete. The pre-existing structure of the box culvert provides a supporting surface that can be used to support a false floor. At the two ends, the false floor includes top and bottom chamfers located along the shorter top and bottom sides 601 and 602 . Each chamfer is set at about a 45-degree angle to the adjacent face. The angles of the chamfers match those of the corresponding haunches in the box culvert. During installation, the chamfers are aligned with the haunches of the box culvert to slide the false floor so that it rests in within the box culvert. Epoxy can be used to fill in the annular space between the false floor and box culvert to create a seal and prevent leakage. When a system includes multiple false floors, closure plates can be used to fill in the gaps between adjacent false floors.
[0048] The false floor includes one or more cartridge impression forms 603 that create recesses, on which filter cartridges can rest. Threaded insert forms 604 are also included to be used with threaded inserts. Because of it relatively compact size, this false floor with four filter recesses may be placed at an outlet section, next to an outlet pipe.
[0049] Another embodiment of the false floor of the present invention is shown in FIGS. 7A through 7D . The false floor is made of standard concrete. Chamfers 701 and 702 located at the ends of the false floor can be designed to align with the haunches of a box culvert (not shown). Cartridge impression forms 703 located on the upper surface of the false floor create eight circular indentations on which eight circular filter cartridges can securely rest. Insert forms 704 are located along a side for threaded inserts. A through hole 705 can be placed at the center of the slab to secure the bypass assembly. Four standard lift eyes 706 can be placed along a wall to facilitate transport. This false floor, which includes eight filter recesses, may be placed next to one or more bypass assemblies in an inlet section of a filtration system.
[0050] Yet another embodiment of the false floor with additional filter cartridges is shown in FIGS. 8A through 8D . Chamfers 801 and 802 located at the ends can be designed to align with the haunches of a box culvert (not shown). Cartridge impression forms 803 located on the surface of false floor create sixteen circular indentations on which sixteen circular filter cartridges can securely rest. Threaded insert forms 804 and 805 are located along two sides for threaded inserts. Through holes 806 and 807 can be placed at the center of the slab to secure one or more bypass assemblies. Four standard lift eyes 808 can be placed alone a wall to facilitate transport. This false floor may span the length, or at least the partial length, of a filter section.
[0051] FIGS. 9A through 9D shows an embodiment of a short end cap unit that can be installed in a box culvert, for use in the filtration system of the present invention. Installation of this unit can involve a series of concrete pours to secure components of the system. In the first pour, the walls and end slabs 901 are secured. In the second pour, the internal wall 902 is set in place. In the third pour, a gallery wall along the bottom (not shown) can be set. Heavy-duty lift eyes 903 are placed along the side walls to facilitate transport of the systems. The walls surrounding the aperture along a side, which can be offset to form a “stepped can,” may include two layers resulting in outside 904 and inside 905 walls.
[0052] The components of the present filtration system, including the bypass assemblies, false floor, filter sections, and banks can be placed in different positions and configurations to address storm water management needs along different surfaces and around different surface structures. For example, the false floor can be installed along side walls or underneath vertical walls. Different filter media known in the art may be used. In addition, the filtration system may be used alone or in connection with other storm water management devices to increase the capacity and improve processing of storm water. The box culverts may be attached to a retention or detention system for water storage. As a further embodiment, a method of telemetric monitoring can be incorporated into the systems to better manage water flows.
[0053] Although the foregoing invention has been described in detail by way of illustration and example for purposes of clarity and understanding, it will be recognized that the above described invention may be embodied in numerous other specific variations and embodiments without departing from the spirit or essential characteristics of the invention. Certain changes and modifications may be practiced, and it is understood that the invention is not to be limited by the forgoing details, but rather is to be defined by the scope of the appended claims. Various modifications, alternative constructions, design options, changes and equivalents will readily occur to those skilled in the art and may be employed, as suitable, without departing from the true spirit and scope of the invention. Such changes might involve alternative materials, components, structural arrangements, sizes, shapes, forms, functions, operational features or the like. | An apparatus and method for use in conjunction with box culverts to collect and filter or otherwise treat dirty or polluted storm water runoff or other fluid is disclosed. One or more filter devices with filter media is used in connection with a box culvert. One or more internal bypass assemblies is disposed along a vertical surface in the box culvert. One or more concrete slabs is installed within the box culvert and forms a false floor below the filter devices. The false floor provides an annular space through which fluid can bypass the filter devices and be released to a drainage system. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates, for example, to a communication system such as a portable communication system, and more particularly relates to a communication apparatus for offering information such as personal information with reference to a transmitter and periphery environment information to a receiver side and further relates to its control method.
[0003] 2. Description of the Related Art
[0004] In a portable wireless communication terminal, a transmitter appoints a transmission receiver and communicates with a receiver by having a telephone call or by transmitting a message which is created in an e-mail or the like. At that time, the receiver can confirm the telephone number and the like of the transmitter at the time point when an electric wave from the transmitter is received so that can recognize the partner before a telephone call and the like is actually conducted.
[0005] In recent years, it is known a method where a person identification is made by transmitting personal information of a user by means of a portable wireless communication terminal to an objective transmission receiver and the like or a method where bio-information of a user is managed and utilized for a medical treatment at home and the like by transmitting the bio-information of the user to a management center.
[0006] With respect to this bio-information managing system using a portable wireless communication terminal, the system is constituted such that a measuring device for measuring the bio-information is connected to the portable wireless communication terminal and bio-information is transmitted to and save in the management center by means of the portable wireless communication terminal so as to make it possible to transmit a measured result from a management center to a portable wireless communication terminal of a user and to display it therein. Further, a medical stuff registered beforehand is to inspect the bio-information saved in the management center and to write in his remarks in the management center such that it is possible to transmit the remarks to the portable wireless communication terminal of the user to be displayed therein and the like.
[0007] In a patent reference 1, there is shown with respect to bio-informationmanage system using a portable wireless communication terminal of a use.
[heading-0008] <Patent Reference 1>
[heading-0009] Japanese Laid-open Patent No. 2002-215810
[0010] However, these are one way information transmission only a telephone number of a transmitter and the like can be confirmed before the reception when receiving an electric wave from a transmitter. Further, even after the reception, there are no means for a receiver to understand the occasional physical condition of a transmitter or an ambient environment other than the information of telephone sounds, characters, videos and the like which a transmitter transmits, and as a result, it cannot be said that a request of a receiver for understanding the actual state of the transmitter more deeply and more earlier is to be satisfied.
[heading-0011] In addition, there was a problem also for a transmitter that he cannot understand the situation of a receiver.
SUMMARY OF THE INVENTION
[0012] In view of the aforesaid problem, an object of the present invention lies in that situations and feelings each other is made to be understood more deeply and more early by offering bio-information of both the users and environment information. In addition, it lies in proposing a new communication means for exchanging situations and feelings each other without conducting optional communicating operations such as telephone calls and e-mails.
[0013] According to the present invention, the condition/situation of the transmitter side is judged and notified to the receiver side by inputting bio-information such as breathing, pulse-beats and heartbeats of the transmitter or the environment information such as weather, date and hour and ambient temperature and alternatively by comparing, synchronizing and making a relation between the bio-information of the transmitter or the environment information at the present time and the past bio-information or environment information. In addition, also with respect to the situation of the receiver side, it is similarly notified to the transmitter side.
[0014] In this manner, it becomes possible for both of a transmitter and a receiver to comprehend the situation of the partner side easily by a method other than an actual communication operation. In addition, even in a situation where a telephone call and the like cannot be conducted for the reason of a transmitter or a receiver, it is possible to transmit the situation to the transmitting and receiving partner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a block diagram showing a constitution of a wireless communication apparatus using a portable wireless communication terminal according to one exemplified embodiment of the present invention;
[0016] FIG. 2 is a schematic view showing a measure method of bio-information according to one exemplified embodiment of the present invention;
[0017] FIG. 3 is a flowchart showing a transmission process according to an exemplified embodiment of the present invention;
[0018] FIG. 4 is an explanatory diagram showing a data construction example of utilized data according to an exemplified embodiment of the present invention;
[0019] FIG. 5 is an explanatory diagram showing a data construction example of transmission data by output device according to an exemplified embodiment of the present invention;
[0020] FIG. 6 is a flowchart showing a receiving process according to an exemplified embodiment of the present invention;
[0021] FIG. 7 is a flowchart showing a transmission process according to another exemplified embodiment of the present invention; and
[0022] FIG. 8 is a flowchart showing a transmission process according to still another exemplified embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Hereinafter, one exemplified embodiment of the present invention will be explained with reference to FIG. 1 to FIG. 8 . It should be noted in the example of the present invention that information showing heartbeats, pulse-beats, breathing, blood pressure, SpO2 (Blood Oxygen Saturation), electrocardiograms, brain waves, sweating of skin, GSR (Galvanic Skin Response), body movement, MEG (Magnetoencephalography), EMG (Electro-Myography), body surface temperature, diameter size of a pupil, micro-vibration, biochemical reaction and the like will be designated as bio-information. Also, natural information such as date and hour, lunar age, ambient temperature, humidity, weather, atmospheric pressure and the ebb and flow of tide and environment information such as ambient noise, room temperature and a smell will be designated as circumference environment information.
[0024] FIG. 1 is a block diagram showing a rough outline of an apparatus constitution according to an example of the present invention. In this example, an explanation will be done with reference to FIG. 1 by taking an example where a portable wireless communication terminal is used as a communication apparatus. This apparatus is composed of a portable wireless communication terminal 1 , a bio-information sensor 2 for measuring bio-information of a user and for inputting the information to the portable wireless communication terminal 1 and environment information sensor 3 for measuring ambient environment information and for inputting the information to the portable wireless communication terminal 1 .C
[0025] The portable wireless communication terminal 1 is composed of an input unit 11 to which a user inputs information, an output unit 12 for outputting information, a data converter 13 for converting input information from a bio-information sensor 2 and an environment information sensor 3 from analog to digital, a CPU (Central Processing Unit) 14 executing processes according to information inputted from the data converter 13 , a ROM (Read Only Memory) 15 , a RAM (Random Access Memory) 16 and a communication control unit 17 for performing a communication through a network 18 according to results processed by the CPU 14 .
[0026] Here, the input unit 11 includes, for example, buttons and a keyboard for inputting character information, a microphone (sound collecting device) for inputting sounds, a camera (imager device, picture taking device) for inputting pictures or videos, and the like. The output unit 12 includes, for example, a display (display device) for displaying characters, pictures and videos, a speaker for outputting sounds, a lighting device (LCD picture screen, LED or the like) for lighting various kinds of lights, a driving device for shaking the main body, and the like. Also, there are recorded in the ROM 15 with respect to data to be used for programs which describe processing contents of this invention and for processing thereof and the like. Further, there are recorded in the RAM 16 with respect to environment information and bio-information which are contents utilized in the past, setting contents of a user and the like.
[0027] The bio-information sensor 2 is a device for measuring bio-information and is, for example, a heartbeat gauge, a blood pressure gauge, a brain wave measuring device and the like. There are types for these sensors such as a type to be mounted onto a portion of a user's body for measuring bio-information thereof and for transmitting the measured result to the portable wireless communication terminal 1 and a type to be installed onto the main body of the portable wireless communication terminal 1 for measuring bio-information of a user when the portable wireless communication terminal is held by a body portion of the user such as his hand and the like.
[0028] FIG. 2 shows one example of a case where bio-information of a user is measured by the bio-information sensor 2 . A brain wave measuring device 21 , for example, is constituted by installing electrodes onto a head band and measures brain waves by mounting it on a head portion of a user where it is connected to the portable wireless communication terminal 1 by means of a signal line connected to the head band and the measured result can be transmitted thereto. Also, a blood pressure measuring device 22 is constituted by installing a blood pressure gauge onto a wrist band and measures blood pressure by mounting it on a wrist of a user where the measured result is transmitted to the portable wireless communication terminal 1 similarly as the brain wave measuring device. With respect to these devices, a method was explained as one example where they are mounted onto respective regions of the body for measuring, but it is possible to mount onto other regions of the body for measuring. Further, with respect to a method for transmitting measured results from respective measuring devices to the portable wireless communication terminal 1 , it was explained as a method for connecting a signal line directly, but it is needless to say that a wireless transmission is also possible. In addition, there is also a method where a fever thermometer, a heartbeat measuring device and the like are installed onto the portable wireless communication terminal 1 and body temperature and heartbeats are measured when a user grips the terminal by his hand.
[0029] An environment information sensor 3 is a device for measuring environment information and is, for example, a clock device, a temperature gauge, a barometer and the like. There are methods for measuring environment information such as a method where measurement is performed by installing these sensors onto the portable wireless communication terminal 1 and a method in a case when it is used indoors or in a vehicle under movement where the, results measured by environment information sensors which are installed in the indoor or in the vehicle are transmitted to the portable wireless communication terminal by means of a signal line, wireless and the like.
[0030] A specific first process example using an apparatus explained in the above will be explained with reference to a flowchart shown in FIG. 3 . with reference to a flowchart shown in FIG. 3 . The process shown in FIG. 3 is a process performed mainly in the CPU 14 in a case when a transmitter transmits a situation on the side of the transmitter to a receiver using the present apparatus by telephone.
[0031] First, a power supply of the apparatus is switching on by a user (step S 101 ) and a process starts. A desirable utilized content is inputted by a user from the input unit 1 (step S 102 ). Inputted items are such as a user ID for identifying a user, bio-information to be measured, information to be used in the environment information, output devices which a user desires, their setting contents and the like. It should be noted that it is possible to proceed to a subsequent step S 103 by skipping this step S 102 in a case when these utilized contents were already set beforehand and they are to be utilized directly.
[0032] Next, CPU 14 instructs the bio-information sensor 2 and the environment information sensor 3 about the measuring start of the bio-information of a user and the environment information and the measuring is made to start. Then, measured results are inputted from the bio-information sensor 2 and the environment information sensor 3 to the CPU 7 through the data converter 13 (step S 103 ). At that time, it is desirable to apply averaging processing of the bio-information and the environment information along a certain period in the data converter 13 or the CPU 14 . The above is an initial setting before a telephone call, an e-mail or the like is initiated.
[0033] Next, with respect to a process in case of performing a communication such as a telephone call and an e-mail actually, it will be explained about a case of having a telephone call as an example. First, a transmitter determines a telephone call partner and inputs a telephone number and the like from the input unit 11 (step S 104 ). Then, the CPU 14 compares bio-information and environment information at present with the bio-information and the environment information recorded in the past utilized data which are accumulated in the RAM 16 and searches whether or not there is a history of a telephone call which was performed in a similar condition in the past (step S 105 ). It is judged according to the result whether or not there are similar utilized data in the past accumulated information (step S 106 ), and in a case when similar utilized data exist, transmission data are produced based on the contents recorded in the utilized data (step S 107 ). In a case when it is judged in step S 106 that similar utilized data do not exist, transmission data are newly produce based on the bio-information and the environment information at present (step S 108 ).
[0034] With respect to a method for producing transmission data based on the past utilized data, it will be explained with reference to FIG. 4 . FIG. 4 is one example of a data construction indicating the past utilized data. It will be explained with respect to a case where, for example, ambient temperature is selected as environment information and a speaker is selected as an output device. In a case when, for example, the ambient temperature at present is 0° C., an item is searched in the past utilized data accumulated in the RAM 16 where the measured value of the environment information is 0° C. with respect the ambient temperature. It is supposed as the result that there are 2 affairs of records for having telephone calls at 10 past 10 on Jan. 10, 2003 in a condition of an ambient temperature 0° C. and supposed that contents are recorded as transmission data at that time such that sounds of “cold and cold” are outputted with respect to a speaker of an output device for the first affair and characters of “cold!” are outputted with respect to a display device of an output device for the second affair. According to the present example, since a speaker is selected as an output device, the data of the first affair are employed as the transmission data and transmission data for outputting sounds of “cold and cold” from the speaker are produced.
[0035] It should be noted in step S 105 that the comparison of the bio-information and environment information at present with the past bio-information and environment information was performed such that it was judged whether or not there are records which coincide with each other in the example mentioned above, but it is possible to judge it by providing a predetermined amount of a permissible range with respect to each information. For example, in a case when the present ambient temperature is 0° C., it will be judged that records included in a range of ±1° C. of the past ambient temperature coincide therewith. According to the aforementioned practical example, ambient temperature was used as a searching key for the environment information, but it is needless to say that bio-information can be further added thereto so as to select transmission data which coincide therewith. Further, it is also possible to add a telephone call partner (transmission receiver) to the items of utilized data so as to select transmission data in response to environment information, bio-information and a transmission receiver.
[0036] Next, it will be explained relating to a method for newly producing transmission data with reference to FIG. 5 . FIG. 5 is one example of a data construction defining transmission data by output device. Similarly as mentioned above, it will be explained with respect to a case where ambient temperature is selected as environment information and a speaker is selected as an output device. In a case when utilized data for the ambient temperature 0° C. do not exist in the past utilized data accumulated in the RAM 16 , the CPU 14 produces transmission data of ambient temperature 0° C. newly based on the database saved in the ROM 15 or the RAM 16 . For example, it is supposed that a database as shown in FIG. 5 is saved in the ROM 15 or the RAM 16 . Here, the CPU 14 searches data relating to a speaker as an output device and ambient temperature as environment information. As a result, an item in which the contents of the measured values of the environment information are “10° C. or lower” are detected for data corresponding to the ambient temperature 0° C. at present and the definition of the transmission data “cold and cold” for that item is produced as transmission data.
[0037] In this manner, transmission data are produced and thereafter the transmission data are transmitted to a transmission receiver by means of the communication control unit 17 (step S 109 ). The CPU 14 saves the transmission data in the RAM 16 together with the bio-information and the environment information at that time (step S 110 ). Thereafter, a transmission partner will have a telephone communication by receiving a telephone call (step S 111 ). Finally, it is judged whether or not the shut-off of the power supply is instructed by the transmitter (step S 112 ) and the process will end at the time point when the shut-off of the power supply is instructed by switching off the power supply, and in case of not the shut-off of the power supply, the measurement of the bio-information of a user and the environment information is performed until a next telephone call.
[0038] As explained above, a process is performed in the portable wireless communication terminal of the transmitter side such that a situation of the transmitter at the time of a telephone call is transmitted to the transmission partner place. On the other hand, an embodiment of a process on the receiving side relating to the first process example will be explained with reference to a flowchart shown in FIG. 6 . The process shown in FIG. 6 is a process performed mainly in the CPU 14 in a case when a receiver receives a telephone call from a transmitter by using the present apparatus.
[0039] First, the power supply is switched on for the apparatus according to the present example by a user (step S 201 ) and the process starts. When transmission data from the transmitter are received by the Communication control unit 17 (step S 202 ), the CPU 14 identifies the transmitter from the received data and analyzes the received data (step S 203 ). When the transmitter is identified, it is possible to display icon and the like on the display device of the output unit 12 corresponding to the name of the transmitter and the transmitter. With respect to the receiving data, contents relating to data which are outputted to output devices and their output devices are defined and in this example, the information transmitted from the transmitter is assumed to be contents for outputting sounds like “cold and cold” with respect to a speaker of the output device. Therefore, the CPU 14 produces a control signal with respect to the speaker of the output device according to the received data so as to generate a reception sound of a voice like “cold and cold” (step S 204 ). Receiving that control signal, the speaker of the output unit 12 generates the reception sound (step S 205 ).
[0040] It is possible for the receiver to understand that the transmitter has a telephone call from a cold place, because the reception sound is generated from the speaker. The receiver judges at that time point whether or not a telephone communication will be possible (step S 206 ) and as a result if a telephone communication is possible, he receives the telephone call by pushing down a reception button and the like so as to execute the telephone communication (step S 207 ), and if it is a case of a situation that a telephone communication cannot be accepted, he will refuse the reception of the telephone call by pushing down a button and the like for sending a reply to the transmitter that the telephone communication cannot be executed (step S 208 ). Finally, it is judged whether or not the shut-off of the power supply is instructed by the receiver (step S 209 ) and the process will end at the time point when the shut-off of the power supply is instructed by switching off the power supply, and in case of not the shut-off of the power supply, a next telephone call will be waited for.
[0041] By processing in this manner, it is possible to understand the physical condition and the ambient environment situation before an actual telephone communication with the transmitter when the receiver receives a telephone call and the like.
[0042] Further, also with respect to the receiver side, it becomes possible in case of using the present apparatus to transmit the situation of the receiver side to the apparatus of the transmitter side according to the bio-information and the environment information at the time point when the receiver receives a telephone call. By performing in this manner, in a case of a situation when, for example, a receiver cannot have a telephone communication, because he is running in the direction of a destination for an urgent affair, if his heartbeats reaches 100 or more, it becomes possible to transmit transmission data corresponding to heartbeats of 100 or more simultaneously when a refusal of a telephone call reception is sent as a reply to the transmitter. Consequently, it becomes possible for a transmitter not only to recognize the information of the telephone call refusal but also to guess the reason thereof to a certain degree so that it is possible to understand the situation of the partner more deeply and better communication is realized compared with a case where a telephone call is simply refused.
[0043] As a second process example using the present apparatus, it will be explained with respect to a process of a case where a notification is made in an emergency with reference to a flowchart shown in FIG. 7 . The process shown in FIG. 7 is a process performed mainly in the CPU 14 in a case when an emergent notification is sent to a predetermined notifying place when an emergent situation occurs.
[0044] Here, from the switching on of the power supply to the measuring start shown as step S 301 to step S 303 are just similar as the step S 101 to the step S 103 of FIG. 3 explained previously. However, according to this example, it will be explained with respect to a case where ambient temperature and illumination (brightness) are selected as environment information and heartbeats are selected as bio-information. When the power supply is switched on for the present apparatus and an initial setting is performed, measuring by the bio-information sensor 2 and the environment information sensor 3 will be made to start. During a period when a communication such as a telephone call and an e-mail is not performed, selected information is measured periodically by time and compared with the average value of the past measured information which is accumulated in the RAM 16 (step S 304 ). It is judged whether or not there is a departure of a predetermined amount or more from the average value according to the compared result (step S 305 ) and in a case when there is a departure, it is judged that an emergent situation occurred and transmission data are produced in tune with its content to be transmitted to an emergency dial place (step S 306 ). After the transmission data are produced, the transmission data are transmitted automatically to an emergency dial place which was set up beforehand (step S 307 ). In a case when it is judged that there is no departure by a result of a judgment in step S 305 , the measured bio-information and environment information will be saved in the RAM 16 and the average value will be re-calculated (step S 308 ). Finally, it is judged whether or not the shut-off of the power supply can be performed and the process will end when the shut-off of the power supply is instructed, and in case of no instruction, the measurement of the bio-information and the environment information will be continued.
[0045] It will be explained specifically according to this example with respect to a judging method whether or not an emergent situation occurred. After the process starts, the CPU 14 measures the bio-information and the environment information in a constant cycle and saves the measured result in the RAM 16 in step S 308 excluding an emergent period. The average value of the measured values by time is calculated according to the saved information and this is made to be a value of a normal time. In a case, for example, where a user is running with short steps in the direction of a station for going to work in the morning, the average values of data at the start of office hours can be normally supposed such that the ambient temperature is 18° C., the illumination is 50,000-lx and the heartbeats are 95 beats/minute. In addition, in a case where he goes home on foot when going home, the average values of data at the going-home time can be supposed such that the ambient temperature is 17° C., the illumination is 3-lx and the heartbeats are 70 beats/minute. In this case, as a judging method for judging that an emergent situation occurred, it is assumed that it is defined to judge as abnormal at the going-home time in a case when the ambient temperature is within ±5° C. of the value at the normal time, the illumination is additively within ±5-lx of the value at the normal time and the heartbeats are increased further by 20 or more. At this time, in a case where the data at the going-home time on a certain day are measured such that the ambient temperature is 15° C., the illumination is 0.5-lx and the heartbeats are 110, it can be assumed that the heartbeats became abnormal in a dark place outdoors so that it is judged that there exist some kind or another dangerous condition and it is notified to the emergency dial place.
[0046] However, in a case when data of a certain day are measured in the same condition such that the ambient temperature is 23 degree, the illumination is 250-lx and the heartbeats are 92 beats/minute, it is not made as an object of an emergent notification, because the possibility that it is in a certain place having an indoor illumination is high. However, it is assumed that an action different from that of a normal time is taken in such a case so that if the data are to be included in the calculation for calculating the normal condition, the reliability of the normal time value will be lowered. Therefore, it is possible to take a process for not performing a re-calculation of the average value in a case when the measured result was apart from the average value by a fixed value or more.
[0047] Also, the example of the judgment method for the aforementioned emergent situation occurrence was related to a case of a going-home time, but it is possible to detect dangers at various stages by similarly defining judgment methods relating to time zones of going to work and others.
[0048] The definitions for judging the emergent situation occurrences used according to the present example are stored in the ROM 15 beforehand, but it is possible to constitute such that they are stored in the RAM 16 and to update them through the network or an external memory medium when it is necessary.
[0049] By processing in this manner, it becomes possible to notify dangers promptly by judging the situation and notifying it automatically according to the present apparatus in a case when emergency situations such as an encounter with a dangerous situation occur even if the user is in a situation that he cannot notify by himself.
[0050] It should be noted that according to the present embodied examples, the average value of the accumulated past information was made to be calculated in order to obtain bio-information and environment information at a normal time, but it is possible to apply predetermined operations further depending on the kind of information. For example, it becomes easier for the data such as illumination to be made to correspond to the human sense if a logarithmic operation is applied thereto and it can be assumed that a logarithmic operation is to be applied before the process of averaging.
[0051] Next, as a third process example using the present apparatus, it will be explained with respect to a process of a case where periodical communications are performed automatically with reference to a flowchart shown in FIG. 8 . The process shown in FIG. 8 is a process performed mainly in the CPU 14 in a case when a user performs periodical communications to a specific transmission partner periodically by telephone, e-mail transmission and the like and a situation that a communication cannot be performed by some kind or another reason occurs such that a communication to the transmission partner is performed automatically.
[0052] Here, from the switching on of the power supply to the measuring start shown as step S 401 to step S 403 are just similar as the step S 101 to the step S 103 of FIG. 3 explained previously. According to this example, in a case when communications such as telephone calls and e-mails are performed, it is assumed that those of the history will be stored in the RAM 16 . First, the CPU 14 searches the communication history in the RAM 16 and makes a search whether or not a periodical communication exists. The periodical communication is judged by a fact that a communication is performed to a specific transmission receiver at a certain specific time zone. For example, it is such a case that a telephone call to home is performed at approximately 18 o'clock everyday. As a result, in a case when a periodical communication exists, the present process starts at a time point when it becomes that time (step S 404 ). First, a timer is 0-cleared (step S 405 ). Next, it is judged whether or not a periodical communication was performed (step S 406 ) and in a case when a periodical communication existed, a process for a next periodical communication is performed. In a case when a periodical communication does not exist, it is judged whether or not the timer exceeds a fixed time (d) (step S 407 ) and in a case when it does not exceed it, the timer is counted up (step S 409 ) so as to judge once again repeatedly whether or not a periodical communication exists. In a case when a periodical communication is not performed even if the timer exceeds the fixed time, it is judged that a user did not perform a periodical communication and a process for performing a periodical communication is taken automatically.
[0053] In a case if a periodical communication was not performed, first, measured values of bio-information and environment information are compared with the values at a normal time and it is judged whether or not there is an abnormal situation (step S 408 ). If there is an abnormal situation, it is judged that an emergent situation occurred and a notification is transmitted to an emergency dial place (step S 412 ). If there is no abnormal situation, transmission data to the periodical communication place are produced (step S 410 ) and that content is transmitted to the periodical communication place (step S 411 ). In a case if, for example, any abnormal situation cannot be especially seen in the bio-information and the environment information when a user who has a telephone communication to his home at approximately 18 o'clock everyday does not have a telephone call for a certain fixed period, for example, for 30 minutes or more after 18 o'clock, the present apparatus produces transmission data such as a content of “I will communicate later on, because I cannot go home yet.” and transmits that automatically to his home.
[0054] With respect to the contents of the transmission data in a case when a periodical communication cannot be performed, there are methods such as a method where a user sets as an initial setting in step S 403 and a method where it is registered in the ROM 15 or the RAM 16 beforehand such that the contents thereof are to be used. In addition, they can be one kind of a sentence of a fixed format or can be set individually for each kind of the periodical communication.
[0055] Further, in the present examples, it was explained with reference to a method for communicating automatically by using the present apparatus in a case when a periodical communication cannot be performed, but it is possible to adopt a process for making a user apprehend that a periodical communication is not performed yet by outputting a notification that a periodical communication was not performed to either one of the output devices in the output unit 12 .
[0056] By processing in this manner, the present apparatus will perform a communication instead even if it becomes a situation where a communication cannot be performed with respect to the transmission receiver with which communications are performed periodically so that the transmission receiver can confirm that there is no abnormal situation and can feel safe and secure. Also, it might happen that the transmission receiver worries about non-communication and tries to make a communication to the transmitter for a confirmation, but such an activity becomes needless such that useless communications decrease.
[0057] As the above, it was explained with respect to exemplified embodiments relating mainly to a portable wireless communication terminal, but it is needless to say that a communication form by means of infrared is applicable and a wire communication form by means of conductive lines such as a public telephone line and internet or by means of an optical fiber and the like is also applicable. Also, it is possible to apply the present constitution and the processes with respect to communication systems other than the portable communication terminal. For example, it can be applied to a fixed telephone and a TV telephone, a video conference, a game and the like. These communication systems are types where communications are performed bilaterally between one to one or one to multiple communication apparatuses and with respect to them, it is possible to realize similar processes by employing similar constitutions as the exemplified embodiments already explained. Further, it is necessary that a user lies in the vicinity of the communication apparatus in a case when these communications are performed, but an occasion might happen where a receiver is missing when a transmitter wants to communicate with him. In such a case, it becomes possible to perform a process for notifying to the transmitter side by judging whether the receiver is at home or away from home based on the bio-information of the receiver and the environment information according to the communication apparatus. In this manner, it does not happen that the transmission partner has a telephone call while the receiver is away from home, waits for the receiver until he appears or the like. Further, it becomes possible to enjoy games on the network by making communications only with favorable partners after the conditions of the communication partners are comprehended beforehand.
[0058] According to the present invention, it becomes possible to recognize the physical condition and the ambient environment situation of the communication partner other than information as communication means such as telephone and possible to understand the partner much better.
[0059] Also, according to the present invention, it becomes possible to notify dangers promptly by making an emergent notification automatically in a case when an emergency situation occurs where a user encounters with a dangerous condition and the like even in a situation that the user himself cannot communicate by telephone and the like.
[0060] Further, according to the present invention, it becomes possible to confirm whether he is safe or not without a communication for confirmation from the periodical communication place by performing a communication automatically to the periodical communication place in a case where a user performed periodical communications but there occurred a situation that that communication was not performed.
[0061] Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments and that various changes and modifications could be effected therein by one skilled in the art without departing from the spirit or scope of the invention as defined in the appended claims. | By providing bio-information and/or environment information between a pair of users, it becomes possible for the users to understand the situation or the feeling of each other more deeply and earlier. A communication system for exchanging the situations and the feelings of both the users is provided without performing optional communication operations, such as a telephone call and an e-mail. The condition or the situation on the transmitter side is to be judged and to be notified to the receiver side by inputting bio-information such as breathing, pulse-beats and heartbeats or environment information such as weather, date and hour, ambient temperature, or alternatively, by comparing, synchronizing and/or relating the bio-information and/or the environment information at present with respect to the bio-information and/or the environment information in the past. With respect to the situation of the receiver side, it is also notified similarly to the transmitter side. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a hybrid vehicle (referred to as an HV) having a plurality of components such as an engine, a motor and the like, and more particularly is directed to an apparatus for promoting warm-up of the engine while cooling other components.
2. Description of the Related Arts
In a hybrid vehicle (HV) there are mounted an engine and a motor which are intended to cooperatively generate power for driving the vehicle. Among several types of HV's, there is a type called series HV (referred to as SHV hereinbelow) in which its engine, generator and motor are connected in series. In the SHV, the engine drives the generator whose output power in turn drives the motor. In the case of using a D. C. generator as the generator, a D. C. output of the generator is converted into an alternating current by means of an inverter prior to supply to the motor. In this case, a rechargeable battery may be connected between the generator and the inverter so as to store the D.C. output of the generator therein and to drive the motor with the aid of the output of the battery. Furthermore, the inverter may be controlled to derive a required output from the motor.
At the time of actuating the engine in such a vehicle, a fuel-air mixture ratio when the engine is cold is set so as to differ from that when the engine is warmed up. That is, while the engine is cold, the ratio of fuel is increased compared with the warmed-up engine. However, if actuating the engine in the cold, a larger amount of harmful materials such as CO, HC, and NO X which are contained in an exhaust gas may be produced than the engine which has been warmed up. A proper catalyst may be used to eliminate such harmful materials. In the cold, however, the temperature of the catalyst is also low. The catalyst at a relatively lower temperature generally has a poor working efficiency and adversely increases so-called emission as described hereinbefore. In addition, when the temperature of the engine is low, a lubricating oil of the engine also has a higher viscosity. If the viscosity of the lubricating oil is high, the engine itself presents a large frictional resistance, which leads to a poor fuel consumption.
A possible means of solving such problems is disclosed in Japanese Utility Model Publication No. 56-17724 in which an engine vehicle includes a heater used for warming up the engine at the time of cold start. To this end, the heater may be arranged around the engine. In this publication, a battery is provided as a power source of the heater.
Such an additional heater is applicable to the HV as well. In this case, as the HV has already been provided with the battery for the drive of the motor as described above, it may be natural to use this battery as the power source of the heater. Nevertheless, if the motor drive and the energization of the heater are carried out by the same battery, there may arise another disadvantage that the power of the battery is partly consumed due to the energization of the heater, which shortens the traveling distance per unit charge of battery.
SUMMARY OF THE INVENTION
The present invention was conceived to overcome the above problems, of which an object is to provide an apparatus capable of more efficiently promoting the warm-up of the engine without shortening the traveling distance per unit charge of battery.
A controller of the present invention is mounted on a hybrid vehicle including a plurality of heat generating components such as an engine, and a plurality of cooling conduits through which a fluid flows to cool the plurality of components. In order to achieve the above object, the controller comprises;
a) a first decision means to determine whether the engine is in a warm-up condition or not;
b) a second decision means to determine whether components whose rejected heat is utilized are in a warmed-up condition or not; the components whose rejected heat is utilized including at least one of the plurality of components to be mounted on the hybrid vehicle except the engine; and
c) a control means for creating flow passages between the cooling conduit associated with the engine and the cooling conduit associated with the component whose rejected heat is utilized in the case where it is considered that the engine is not in a warm-up condition, but the component whose rejected heat is utilized is in a warm-up condition.
In the present invention, it is first decided whether the engine is in warm-up condition or not. This decision can be made by, for example, judging the temperature of the engine. More specifically, after the detection of the engine temperature by means of a sensor or the like, the first decision means judges whether the engine is in a warm-up condition or not depending on whether the detected temperature of the engine is higher than the first predetermined temperature or not.
It is then decided whether the component whose rejected heat is utilized is in a warmed-up condition or not. This decision can be made by, for example, judging the temperature of the component whose rejected heat is utilized. More specifically, after the detection of the temperature of the component whose exhaust heat is utilized, the second decision means judges whether the components whose rejected heat is utilized are in a warmed-up condition or not depending on whether the detected temperature of the component whose rejected heat is utilized is higher than the temperature of the second predetermined temperature.
As a result of these decision, if it is considered that the engine is not in a warmed-up condition, but the component whose rejected heat is utilized is in a warmed-up condition, then flow passages between the cooling conduit associated with the engine and the cooling conduit associated with the component whose rejected heat is utilized are opened by the control means. Providing that the hybrid vehicle includes a predetermined number of valves adapted to open the flow passages between the cooling conduit associated with the engine and the cooling conduit associated with the component whose rejected heat is utilized in compliance with a signal, the control means serves to form flow passages between the cooling conduit associated with the engine and the cooling conduit associated with the component whose rejected heat is utilized by way of the valve control.
When there are established flow passages between the cooling conduit associated with the engine and the cooling conduit associated with the component whose rejected heat is utilized, the fluid which has been warmed up is allowed to pass through the cooling conduit associated with the engine, to thereby warm up the engine. Therefore, when the engine is cold, it can be warmed up by the rejected heat of these components.
In this manner, when the engine is cold, the present invention promotes the warm-up of the engine by the user of the rejected heat of the other components, thereby realizing a prompt warm-up of the engine without shortening the traveling distance per unit charge of battery and improving the emission at the time of cold start. It is to be appreciated that the flow passages may be blocked after the warm-up of the engine to separately execute the cooling of the components.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a configuration of an HV drive system controller in accordance with a first embodiment of the present invention;
FIG. 2 is a flowchart showing a valve control action of the first embodiment in FIG. 1;
FIGS. 3A and 3B depict a temperature rise curve in the first embodiment in FIG. 1, and an effect of improved emission and fuel consumption, respectively;
FIG. 4 is a flowchart showing the flow of a valve control of the HV drive system controller in accordance with a second embodiment of the present invention as well as a heat generation control action;
FIGS. 5A and 5B depict the relationship between an exciting current and a torque current in the second embodiment in FIG. 4, and the relationship between the torque current and the heat generation of the motor, respectively;
FIG. 6 is a flowchart showing a flow of a valve control in the HV drive system controller in accordance with a third embodiment of the present invention, and the heat generation control action;
FIG. 7 is a block diagram showing a configuration of the HV drive system controller in accordance with a fourth embodiment of the present invention;
FIG. 8 is a flowchart showing a flow of a valve control action in the fourth embodiment in FIG. 7;
FIG. 9 is a block diagram showing a configuration of the HV drive system controller in accordance with a fifth embodiment of the present invention;
FIG. 10 depicts the relationship between the temperature of semiconductor and the water temperature in a power controller unit;
FIGS. 11A and 11B both show an action of the HV drive system controller in accordance with a sixth embodiment of the present invention, FIG. 11A illustrating the relationship between ON/OFF of a pump and a motor output instruction, and FIG. 11B illustrating a flow of on-off control of the pump; and
FIG. 12 shows a control curve of the pump in the HV drive system controller in accordance with a seventh embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A presently preferred embodiment of the present invention will now be described with reference to the accompanying drawings.
FIG. 1 shows a configuration of a controller for HV (hybrid vehicle) drive system in accordance with a first embodiment of the present invention. Shown in this figure is a configuration of the present invention, by way of example, incorporated into an SHV (series hybrid vehicle). The present embodiment comprises an engine 10; a generator 12 driven by the engine 10 and producing a DC power; a battery 14 which is capable of being charged and discharged; a power controller unit (referred to as PCU hereinafter) 16 including therein an inverter circuit for receiving an output from the generator 12 or the battery 14 to convert into a three-phase alternating current for output; and a motor 18 driven by the output of the PCU 16. The motor 18 is drivingly linked to wheels not shown by way of a transmission 20 and the like.
This embodiment further comprises a pair of controllers 22 and 24. In particular, the controller 22 intends to control the amount of fuel injection or the like in the engine 10. The control is performed by use of information on temperature of the engine 10 from a sensor 23 arranged on the engine 10.
On the contrary, the controller 24 intends to control, in particular, the generator 12 and PCU 16. The controller 24 receives information on the revolving speed of the generator 12 and on the output voltage of the generator 12, respectively, from a sensor 25 and a sensor 27, while issuing an exciting instruction to the generator 12. The controller 24 further receives information on the temperature of the PCU 16 and on the revolving speed of the motor 18, respectively, from a sensor 29 provided on the PCU 16 and a sensor 31 provided on the motor 18. Naturally, the controller 24 may accept other information. The controller 24 further sends forth a PWM (pulse width modulated) signal to the PCU 16, thereby performing vector control of the current to be supplied to the motor 18. The controllers 22 and 24 interchange desired information such as the temperature of the engine 10.
The engine 10, PCU 16 and motor 18 are components which generate a heat to some extent when in operation. This embodiment is therefore provided with three radiators 26, 28 and 30 so as to cool the engine 10, PCU 16 and motor 18, respectively. A way of cooling is a water cooled method in which cooling ducts are arranged as shown by broken lines in FIG. 1. A cooling conduit 32 associated with the engine 10, a cooling conduit 34 associated with the PCU 16, and a cooling conduit 36 associated with the motor 18 are provided with pumps 38, 40 and 42, respectively. These pumps 38, 40 and 42 aid water in flowing between their respective cooling ducts and the corresponding radiators. Under the control of the controller 24, the pumps 38, 40 and 42 are actuated, stopped or pressure regulated.
This embodiment is characterized firstly in that the cooling ducts 32, 34 and 36 are interconnected by way of valves A through H, and secondly in that the controller 24 controls the valves A through H to correspondingly open or close fluid channels extending between the cooling ducts 32, 34 and 36 if desired. FIG. 2 diagramatically shows a flow of valve control processing in this embodiment.
First of all, an ignition switch which is not shown is turned on (100), and then the controllers 22 and 24 decide whether the temperature T E of the engine 10 exceeds a predetermined temperature T 2 (e.g., 80° C.) (102). This step 102 is a step for judging whether the engine 10 is sufficiently warmed up or not. At the time of cold start, the engine remains cool immediately after the ignition switch has been turned on, and hence the condition of the step 102 is not satisfied. In this case, the procedure advances to next step 104.
At step 104, it is decided whether or not a temperature T INV of the PCU 16 and a temperature T MOT of the motor 18 both exceed a predetermined temperature T 1 (e.g., 80° C.). This is made for the purpose of judging whether both the PCU 16 and motor 18 are sufficiently warmed up. At cold start, this condition is not satisfied either, and accordingly the advance to step 106 is permitted.
At step 106, it is decided whether the temperature T INV of the PCU 16 is higher than the predetermined temperature T 1 or not. As in the case of steps 102 and 104, the CPU 16 has not sufficiently warmed up at this point in time from the cold start. Hence, the condition of the step 106 is not satisfied and the procedure advances to step 108. At step 108, the valves E and F provided on the cooling conduit 34 associated with the PCU 16 are turned off. As a result, the cooling conduit 34 associated with the PCU 16 is connected with the radiator 28, and the water is not allowed to flow from the valves E and F toward the valves C and D.
Afterwards, step 110 is executed where it is judged whether the temperature T MOT of the motor 18 exceeds the predetermined temperature T 1 . Since this condition is not satisfied at the time of cold start, step 112 is carried out after the step 110. At the step 112, the valves G and H provided on the cooling conduit 36 associated with the motor 18 are turned off. As a result, the cooling conduit 36 is connected to the radiator 30, and the water is not allowed to flow toward the valves C and D. Afterwards, the procedure returns to step 102.
In this state, the cooling ducts 32, 34 and 36 are isolated from one another. Subsequently, the same procedure is repeated until either the PCU 16 or the motor 18 is sufficiently warmed up to exceed the predetermined temperature T 1 . The PCU (inverter) 16 normally has a tendency to be warmed up sooner than the motor 18, and accordingly the condition of the step 106 will be satisfied previous to that of the step 110. When the condition of the step 106 is established, the valves A to F are turned on (114 to 118), thus resulting in the formation of flow passages between the cooling conduit 32 associated with the engine 10 and the cooling conduit 34 associated with the PCU 16 by way of the valves A to F. Then the water within the cooling conduit 34 warmed up by the PCU 16 is allowed to flow into the cooling conduit 32 associated with the engine 10. In this state, the engine 10 is warmed up by the rejected heat of the PCU 16.
While on the contrary, when the motor 18 is warmed up earlier than the PCU 16, in other words, the condition of the step 110 is satisfied previous to that of the step 106, the valves A to D, G and H are turned on (120 to 124). In this case, these are formed fluid passages between the cooling conduit 32 associated with the engine 10 and the cooling conduit 36 associated with the motor 18. Under these circumferences, the engine 10 is warmed up by the exhaust heat of the motor 18.
After either the PCU 16 or the motor 18 has been sufficiently warmed up (in other words, the condition of either the step 106 or step 110 is satisfied), further sufficient warm-up of the remaining component establishes the condition of the step 104 to turn on the valves A to H (126 to 132). This brings about a formation of fluid passages among the cooling conduit 32 associated with the engine 10, the cooling conduit 34 associated with the PCU 16, and the cooling conduit 36 associated with the motor 18. Under these circumstances, the engine 10 is warmed up by the rejected heat of both the PCU 16 and the motor 18.
When the engine 10 is sufficiently warmed up, that is, the temperature T E of the engine 10 exceeds the predetermined temperature T 2 , steps 134 to 140 are executed where the valves A to H are all turned off. In other words, the fluid passages between the cooling conduits 32, 34 and 36 are all closed, and the engine 10, PCU 16 and motor 18 are cooled down by the radiators 26, 28 and 30, respectively.
FIGS. 3A and 3B depict the function and effect of this embodiment. FIG. 3A represents that the temperature of the engine 10 is sharply raised in the case where a valve control illustrated in FIG. 2 is carried out (shown by a broken line) as compared with the absence of the valve control (shown by a solid line), which means that the engine 10 is effectively warmed up by rejected heat of the PCU 16 and/or the motor 18. In addition, FIG. 3B represents that the emission and fuel consumption are progressively decreased as the rejected heat of the PCU 16 and motor 18 is utilized for warming up the engine 10, which means that this embodiment provides measures of promptly improving the poor emission and fuel consumption immediately after turn-on of the ignition switch.
In the HV, the motor 18 can be driven by the use of output of the battery 14 with the engine 10 at rest or idling. Accordingly, the following control can be made in cooperation with the valve control action of this embodiment.
The motor 18 is first actuated only by the use of the battery 14 with the ignition switch on, the engine 10 remaining at rest. After the progress of warming-up of the engine 10 through the action shown in FIG. 2, for example, by the rejected heat of the PCU 16, the engine 10 is started and the output of the generator 12 is produced, which ensures a remarkably effective reduction in the emission.
It is to be appreciated that the control action described above is appropriately shared between the controllers 22 and 24.
FIG. 4 shows the action of a valve control and power generation control of a system in accordance with a second embodiment of the present invention. The system of this embodiment is generally configured in substantially the same manner as in the first embodiment shown in FIG. 1, except the control action of the controllers 22 and 24. This embodiment is characterized in that the heat generation of the motor 18 is intentionally increased by a vector control on the PCU 16 so as to warm up the engine 10 more sufficiently by the heat of the motor 18.
As is clear from FIG. 4, immediately after the ignition switch is turned on (100), it is decided whether a temperature T E of the engine 10 exceeds a predetermined temperature T 2 (102). At the time of cold start, this condition is not established, which allows advance to step 106. It is judged at the step 106 whether a temperature T INV of the PCU 16 exceeds a predetermined temperature T 1 . At the cold start, this condition is not satisfied, and accordingly the procedure advances to step 108 in the same manner as the first embodiment.
In the case of this embodiment, steps 120 to 124 are carried out soon after the execution of the step 108. That is, water passages are formed between the cooling conduit 36 associated with the motor 18 and the cooling conduit 32 associated with the engine 10. Moreover, an exciting current of the motor is set to I d1' (142), and a torque current is set to I q1' (144). Afterwards, the PCU 16 undergoes a vector control based on the exciting current I d1' and the torque current I q1' which have been set (146), and the procedure returns to step 102.
Subsequently, at the time when the temperature T INV of the PCU 16 exceeds the predetermined temperature T 1 , steps 114 to 118 are executed. Furthermore, when the condition of the step 102 is satisfied, and accordingly when the engine 10 is considered to have been sufficiently warmed up, steps 134 to 140 are executed. In consequence, the exciting current and the torque current are set to I d1 and I q1 , respectively (148, 150) followed by the execution of the vector control (146).
The relationship between the exciting current and torque currents to be set at steps 142, 144, 148 and 150 is shown, by way of example, in FIG. 5A. In order to keep the output torque of the motor 18 constant, the torque current and the exciting current must be set so as to lie on a line represented as a constant torque curve in the figure. On the other hand, the torque current must be minimized so as to lessen the slip of the motor 18. In order to ensure a constant output torque and a minimum slip, a torque current represented as I q1 in the figure is requested. Correspondingly, the exciting current is represented as I d1 with a primary current I 1 . On the contrary, to maximize the slip of the motor 18 with constant output torque, a primary current I q1' and accordingly a torque current must be so set as to lie on an intersection between the constant torque curve and an arc representing a maximum primary current in FIG. 5A. The exciting torque I d1' is a value of the exciting torque corresponding to this torque current I q1' .
Consequently, through the setting such as steps 142 and 144 and vector control 146 of the primary current value of the motor 18, there can be obtained an action of the motor 18 having a maximum slip and a greater heat generation as shown by the upper curve in FIG. 5B. On the contrary, through the setting of the torque current and the exciting current as defined in steps 148 and 150 and vector control 146, there can be obtained an effective action having a minimum slip and a smaller heat generation which is represented by the lower curve in FIG. 5B. In other words, the motor 18 is actuated with a larger slip and a larger heat generation due to primary copper loss under the condition where the engine 10 has not been sufficiently warmed up, while the motor 18 is actuated with normal operational condition, that is, with a smaller slip and a smaller heat generation under the condition where the engine 10 has been sufficiently warmed up. Therefore, this embodiment employs an intentionally increased heat generation of the motor 18 only while the engine 10 is cold, thereby ensuring an effective warm-up of the engine 10.
FIG. 6 shows an action of a valve control and a power generation control of a system in accordance with the third embodiment of the present invention. The system of this embodiment is also configured in the same manner as the first embodiment shown in FIG. 1. In this embodiment, the heat generation of the motor 18 is not intentionally increased, but instead the heat generation of the PCU 16 is intentionally increased.
More specifically, this embodiment carries out step 110 immediately after step 102, and then either of step 112 or steps 120 to 124 is selectively carried out based on the result of decision. After the step 112 or steps 120 to 124 steps 114 to 118 are carried out. After the execution of the step 118, a switching frequency f associated with the PCU 16 is set higher than the ordinary operational condition (152), and then the procedure advances to a vector control 144. Providing that the engine 10 has been sufficiently warmed up and the criterion of the step 102 is satisfied, the frequency f is returned to an ordinary value (154) after the execution of the valve control action at steps 134 to 140.
This control depends on the fact that the heat generation of the PCU 16 which includes an inverter is decided by the switching frequency f associated with the PWM control. More specifically, the higher the switching frequency f associated with the PWM control, the larger the heat generation of the PCU 16 is, and vice versa. Accordingly, in this embodiment, the heat generation of the PCU 16 is intentionally increased to accelerate the warm-up of the motor 10. When the motor 10 is fully warmed up, the PCU 16 returns to the ordinary action.
FIG. 7 depicts a configuration of a system in accordance with a fourth embodiment of the present invention. This embodiment differs from the foregoing embodiments in the provision of members corresponding to the battery 14 such as a radiator 44, a cooling conduit 46, a pump 48 and valves I and J.
FIG. 8 diagramatically shows the processing flow of the valve control action of the controller 24 in this embodiment.
The action illustrated in this figure is different from the action of the first embodiment in that steps 156 to 162 are carried out after the execution of steps 112, 124, 132 and 140. It is decided at step 156 whether a temperature T E of the engine 10 is lower than a temperature T BA of the battery 14, and unless this condition is satisfied, the valves I and J provided on the cooling conduit 46 are turned off (158). The valves I and J are arranged between the valves A and C, and between the valves B and D, respectively. With these valves off, the cooling conduit 46 is connected with the radiator 44 to form no flow passage directed toward the valves A to D. That is, if the condition of the step 156 is not satisfied, the rejected heat of the battery 14 does not contribute to the warm-up of the engine 10.
Provided that the condition of the step 156 is satisfied, the valves A, B, I and J are all turned to on (160, 162). With these valves on, water passages are formed between the cooling conduit 46 associated with the battery 14 and the cooling conduit 32 associated with the engine 10, which allows water warmed by the rejected heat of the battery 14 to flow into the cooling conduit 32 associated with the engine 10. The engine 10 is thus warmed up by virtue of the rejected heat of the battery 14. According to the present embodiment in this manner, the rejected heat of the battery 14 is also utilized to warm up the engine 10, thereby remarkably promoting the warm-up of the engine 10.
In lieu of the steps 156 to 162 in FIG. 8, the following processing, for example, may be carried out. More specifically, the criterion of the step 104 is replaced by T INV >T 1 and T MOT >T 1 and T BA >T 1 , using nesting similar to the steps 106, 108, and 114 to 118. For such a control procedure, the procedure shown in FIG. 8 is advantageous when the battery 14 produces less heat than the PCU 16 and the motor 18.
FIG. 9 diagramatically shows a configuration of a system in accordance with a fifth embodiment of the present invention. This embodiment shown in FIG. 9 differs from the first embodiment in the provision of a heater 50 to assist in the warm-up of the engine 10. In this embodiment, the heater 50 is supplimentarily used to accelerate the warm-up of the engine 10 in addition to the exhaust heat of the PCU 16 and the motor 18.
It is to be noted that the PCU 16 includes a variety of semiconductors such as switching transistors. Consequently, the PCU 16 has a small heat capacity and is liable to sharply rise in temperature due to a load such as the motor 18 (refer to FIG. 10). It is therefore difficult to perform satisfactory cooling merely by water cooling with the aid of the cooling conduit 34. Up to now, in order to eliminate or reduce such disadvantages, a thick aluminum plate has been used to increase the heat capacity, or the pump 40 was rotated at all times. However, the addition of the aluminum plate and the like inconveniently leads to an increase in weight and cost, and further to a reduction in radiation properties due to a poor heat transfer. Moreover, the rotation of the pump 40 at all times increases the power consumption.
It is therefore conceivable to put the pump 40 under the control of the controller 24 as shown by a long and short dash line in FIG. 9 so as to switch the status of the pump 40 in response to the output status of the PCU 16.
FIGS. 11A and 11B show an action of the control over the pump 40 in the form of an ON/OFF control.
The pump control action of this embodiment or a sixth embodiment of the present invention is as follows The controller 24 decides whether an output instruction to the motor 18 exceeds a predetermined value P 2 or not (164). When this condition is satisfied, the PCU 16 activates the pump 40 (166). It is then judged whether the output instruction to the motor 18 is not more than P 1 (168). The pump 40 remains on until this condition is satisfied. The pump 40 is deenergized when this condition is established (170). Subsequently, the procedure returns to step 164. On the contrary, the pump 40 is turned off (172) from when it is judged that the output instruction to the motor 18 is smaller than P 2 (164).
Accordingly, this embodiment permits the pump 40 to be turned on only in the case of larger output instruction to the motor 18 (than P 2 ), thereby presenting water circulation within the cooling conduit 34 associated with the motor 18. Hence, the relationship between ON/OFF of the pump 40 and the motor output instruction is provided as shown in FIG. 11A.
FIG. 12 further shows an action of on-off control of this embodiment in the form of a continuous-variation control. In this embodiment i.e. a seventh embodiment, the output of the pump 40 is gradually decreased responsive to the output instruction to the motor 18 rising. This also ensures a suitable quantity of water for cooling the PCU 16 while restraining power consumption, in the same manner as the sixth embodiment.
It is desirable that these actions described as the sixth and seventh embodiments be incorporated into the first to fifth embodiments, thereby utilizing the rejected heat for warming up the engine 10 while preferably cooling the PCU 16.
It is to be understood that the valve control described hereinbefore is not exclusively confined to the application to warm-up of the engine 10. For example, in case where the vehicle is used in a cold area and the engine 10 is sufficiently warmed up and the other components are cold, the rejected heat of the engine 10 can be utilized for the warm-up of the other components.
According to the present invention as detailed hereinabove, the engine is warmed up by making use of rejected heat of components such as the motor, thus realizing a prompt warm-up of the engine without shortening the traveling distance per charge of the battery, to consequently improve the emission at the time of cold start. | Disclosed is a controller mounted on a hybrid vehicle. The hybrid vehicle has a plurality of heat generating components such as an engine, and a plurality of cooling conduits through which a fluid flows for cooling said plurality of components. A controller decides whether or not the engine is in a warmed-up condition and the components whose rejected heat is utilized are in a warmed-up condition. The components whose rejected heat is utilized comprise at least one of a plurality of components mounted on the hybrid vehicle except the engine. The controller serves to form flow passages between the cooling conduit associated with the engine and the cooling conduit associated with the components whose rejected heat is utilized in the case where it is considered that the engine is not in a warmed-up condition, but the components whose rejected heat is utilized are in a warmed-up conditions. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority of German application No. 10 2010 062 975.8 filed Dec. 14, 2010, which is incorporated by reference herein in its entirety.
FIELD OF INVENTION
The invention relates to a method for generating a four-dimensional representation of a target region which is subject to periodic motion, wherein a motion-compensated three-dimensional image dataset is determined from a plurality of two-dimensional projection images that have been recorded from different projection directions, wherein estimation parameters which describe a non-periodic motion and are derived from a motion model that is formulated independently of the phase of the periodic motion with respect to the recording instants of the projection images are determined on the basis of the projection images, such that the three-dimensional image dataset represents a static reconstruction for a specific instant, said static reconstruction being based on all projection images.
BACKGROUND OF INVENTION
Image reconstruction methods in which a three-dimensional image dataset is determined from a multiplicity of two-dimensional projection images that were recorded in different recording geometries, i.e. from different projection directions, are well known in the prior art. Iterative reconstruction methods or filtered back-projection methods can be used, for example. Problems always occur when the recording volume (i.e. the target region) moves, as in the case of target regions surrounding the heart, for example.
After originally using motion estimation methods that already include in principle the assumption of periodicity in the case of target regions of a body that are subject to periodic motion, satisfactory reconstruction quality was still found to be lacking. This is explained by the fact that the various instances of periodic motion nonetheless exhibit small differences, which have a negative influence on the reconstruction quality.
Surprisingly, it was found that the reconstruction quality can be significantly improved using non-periodic motion models, i.e. it is taken as a starting point that a non-periodic motion will be estimated, wherein said non-periodic motion can be used in a dynamic reconstruction algorithm (such as those that are already well known) in order to obtain a significantly improved reconstruction image, i.e. an artifact-free three-dimensional image dataset of higher quality. A method of the type cited in the introduction is disclosed in EP 2 242 023 A1, for example. This describes a method for the motion-compensated reconstruction of a three-dimensional definitive reconstruction dataset of a recording volume (which moved during a recording period) from two-dimensional projection images, using a dynamic and in particular analytical reconstruction algorithm, wherein for the purpose of determining the in particular location-dependent non-periodic motion during the recording time, an initial parameter set describing a possible motion in at least one motion model, in which the time dependency is described by the recording time, is first defined as a current parameter set, whereupon, in the context of an optimization method relating to the parameter set, a current reconstruction dataset is determined by means of the dynamic reconstruction algorithm with reference to the possible motion described by the current parameter set and is evaluated on the basis of a target function which comprises an evaluation measure, such that when a convergence criterion for the target function is finally satisfied, the optimization method can be terminated and the current reconstruction dataset can be used as the definitive reconstruction dataset. The definitive reconstruction dataset, which was already reconstructed during the optimization method, therefore corresponds to the three-dimensional image dataset of the present invention.
The method disclosed in EP 2 242 023 A1 therefore uses a parameterizable non-periodic motion model, which is therefore not defined by phases of a periodic motion but by the current time, such that recording times or the recording instant can be used immediately, without requiring a periodic motion as a basis. Various embodiments are conceivable in respect of the target function, wherein both comparison with a three-dimensional reference dataset and comparison with the recorded projection images are possible, wherein forward-projection images can be determined from the current reconstruction dataset using dynamic forward projection, and their similarity to the actual recorded projection images can be evaluated. As mentioned above, the overall result is a significant improvement in quality of the three-dimensional image dataset of the target region. Optimal image quality is achieved when the generated static three-dimensional image correlates to a heart phase in which the heart is almost at rest, usually the end-diastolic phase, and also in the systolic rest phase in the case of rapid heartbeats. A non-periodic approach to the motion makes it possible at least significantly to reduce those serious impairments to the image quality that are caused by heart phases involving pronounced motion, e.g. the systolic contraction or the early diastolic dilatation.
The resulting three-dimensional image datasets, which can show e.g. the coronary arteries and the heart, are an extremely useful tool, e.g. in the planning of minimally invasive interventions, in particular using a catheter, but also for image monitoring during an intervention, when the three-dimensional image dataset is superimposed by fluoroscopy images. However, there is also considerable demand in general for four-dimensional information in this context, i.e. for a moving representation of a target region, in particular the heart region, since such four-dimensional information is useful for functional analyses and dynamic overlapping. In interventions for clearing a chronic total occlusion, for example, such moving superimpositions of images therefore provide an extremely useful aid for the navigation of a catheter through the occluded part in order to clear the occlusion by means of ablation, for example, and reduce the risk of harming or even rupturing the vessel.
Previously disclosed are merely methods in which dynamic information is generated by an electrocardiogram gating for a corresponding heart phase. The image result of the ECG gating is post-processed, e.g. by compensating for the residual motion, wherein a 4D animation of a heartbeat is provided by separate three-dimensional reconstruction of various heart phases. Due to the problems cited above in respect of the assumption of a periodic motion, and the fact that a separate three-dimensional image dataset must be specified at considerable computing cost for each heart phase, the resulting pictures are of extremely poor quality and suffer from all manner of artifacts and other quality deficiencies, and are therefore very difficult to read.
The article “High-quality 3-D coronary artery imaging on an interventional C-arm x-ray system” by Eberhard Hansis et al., Med. Phys. 37 (4), April 2010, pages 1601 to 1609, concerns the projection-based motion compensation for the reconstruction of coronary arteries in a single heart phase using a gating.
The article “ECG-Gated Interventional Cardiac Reconstruction for Non-periodic Motion” by Rohkohl et al., MICCAI 2010, Part I, LNCS 6361, pages 151 to 158, likewise describes an electrocardiogram-gated reconstruction algorithm, in which a weighting factor is used for the images of a specific heart phase. The result is a three-dimensional image dataset in a specific heart phase.
The article “Reconstruction of Coronary Arteries From a Single Rotational X-Ray Projection Sequence” by Christophe Blondel et al., IEEE TRANSACTIONS ON MEDICAL IMAGING, Vol. 25, No. 5, May 2006, pages 653 to 663, discloses a reconstruction of coronary arteries from a single projection sequence, wherein an estimation of the motion of the coronary arteries is carried out. The tomographic reconstruction of the coronary arteries includes motion compensation and is three-dimensional.
SUMMARY OF INVENTION
The invention therefore addresses the problem of specifying an improved method for depicting the three-dimensional motion of a target region.
In order to solve this problem, it is inventively proposed that, in the context of a method of the type cited in the introduction, the three-dimensional image dataset should be animated on the basis of the estimation parameters of the non-periodic motion model that were used in its reconstruction, wherein the motion information that is missing in the estimation parameters due to the two-dimensionality of the projection images is additionally determined using a boundary condition that describes the periodicity of the motion, and is used for the animation.
The present invention is therefore based on the three-dimensional image dataset which represents a static reconstruction at a specific instant, said static reconstruction being based on all projection images, and the estimation parameter set that describes the non-periodic motion in the non-periodic motion model. Both can be obtained as described in EP 2 242 023 A1, for example, wherein other approaches are naturally also conceivable. As mentioned previously, the three-dimensional image dataset is of high quality, while the estimation parameters describe the non-periodic motion in the motion model. In order now to achieve a dynamic imaging in accordance with the invention, the static three-dimensional image dataset is determined using optimal image quality and is animated using the field of motion that is known from the reconstruction step, said field of motion being described by the estimation parameters. Therefore the excellent image quality of the static three-dimensional image dataset is used in order to obtain an easily readable and clear dynamic representation of the target region, since in fact the image quality of the static three-dimensional image dataset is continuously maintained. As a result of this analysis of the measured data, i.e. the projection images, it is therefore possible to create an extremely useful aid for planning interventions and possibly also for diagnosis.
In this case, the present invention also allows for a problem which originates from the fact that the estimation parameters in the non-periodic motion model are determined on the basis of the two-dimensional projection images. The individual projection images are recorded consecutively at specific instants and cannot necessarily capture the motion components that are perpendicular to the projection plane. This means that information relating to the motion that is perpendicular to the projection plane is ultimately missing for each projection image (or the corresponding instant). However, this information is required for the animation to be complete and correct, and therefore the inventive method for solving this problem specifically proposes that the motion information that is missing in the estimation parameters due to the two-dimensionality of the projection images should additionally be determined using a boundary condition that describes the periodicity of the motion, and used for the animation.
It is therefore proposed that the spatial components which, due to insufficient measured data, are missing in the 4D field of motion as described by the estimation parameters should be obtained by means of the boundary condition of a periodic motion. The fundamental idea here is that the acquisition of the projection images generally takes place over a plurality of cycles of the periodic motion, e.g. a plurality of heart cycles, and therefore projection information from different directions is in fact available again for a phase in the context of a periodic observation, making it possible to determine the missing spatial components. In this case, it should be emphasized here that the retrospective assumption of a periodic motion for generating the 4D animation is more advantageous than already postulating a periodic motion during the calculation of the static three-dimensional image dataset, since the image quality of the static three-dimensional image dataset is clearly better, as described above. Inconsistencies and/or errors due to non-periodic motion components therefore affect the animation only, but do not influence the static three-dimensional image on which the animated display is based, such that representation quality is not reduced at all.
The estimation parameters that are derived from the reconstruction step, i.e. the estimated field of motion, therefore contain a missing spatial component in the direction of the recording x-ray beam, said missing component being derived on the basis of the retrospective assumption that the field of motion is periodic, in particular periodic in the heartbeat. Because the time is used for the purpose of parameterization in the context of the non-periodic motion model, each instant is assigned a corresponding heart phase, wherein the periodicity in the field of motion results in the approximation that the same motion vectors were measured at different instants in different projection directions but in the same heart phase. The direction of the missing spatial components changes as a result of the different projection angles, and therefore the missing spatial components can be specified from the plurality of measurements.
In a preferred embodiment of the present invention, provision can be made in this case for motion parameters of a periodic motion model to be specified in an optimization method such that a target function is minimized, said target function describing the agreement of the motion that is described by the currently defined motion parameters with the motion that can actually be derived from the position images and is determined from the estimation parameters, wherein the definitive motion parameters that minimize the target function are used for the animation.
The calculation of the complete, now periodic four-dimensional field of motion can be formulated as an optimization problem concerning a periodic motion model. The objective is to select the parameters describing the motion in the periodic motion model in such a way that the motion which can actually be described by the projection data of the projection images is reproduced as precisely as possible. This means that a target function is formulated which ultimately describes the extent to which the actual measured spatial components agree with the corresponding components which are derived from the periodic motion model. In other words, the optimization method attempts to find a periodic four-dimensional field of motion whose projections are identical to those of the non-periodic field of motion as derived from the projection images and described by the estimation parameters.
In this case, provision can be made for the motion that can actually be derived from the projection images to be determined by projecting the motion that is determined from the estimation parameters for a specific motion phase onto a plane, in particular a detector plane, which is defined by at least one recording geometry of the at least one projection image that is assigned to the motion phase, and which is perpendicular relative to the projection direction. Provision is therefore made for determining actual or at least estimated recording geometries that define a plane on which both the motion vector that is described by the estimation parameters and the motion vector that is described by the current motion parameters are projected, in order that they can then be compared with each other. In this case, it should be emphasized here that not only actual recording instants of the projection images can be observed, but that intermediate states can also be observed, using interpolation if applicable. In the non-periodic motion model, the motion can be specified for any instant and not just for discrete instants. Depending on the model that is used, various projection images (in particular the adjacent projection images) are therefore relevant at this instant. If, as is preferred, the phase of the periodic motion is now observed continuously, e.g. as a value between 0 and 1, it is unlikely in principle that two actual recorded projection images will relate to exactly the same heart phase, and therefore an “unconnected” observation appears useful even if only several discrete heart phases are observed. If a recording geometry is to be specified for these instants which correspond to the heart phase, a continuous recording path is then determined, e.g. by means of interpolation from the existing discrete actual recording geometries, and is used for determining the plane that is perpendicular to the projection direction. Nevertheless, provision can be made for phases which correspond to actual recording instants to be selected as the phases of periodic motion that are to be observed, i.e. for taking into consideration the corresponding phase of the periodic motion at the recording instant of each projection image.
A projection can take the form of an orthogonal projection or a perspective projection. An orthogonal projection is appropriate if the images were recorded in the parallel beam geometry, while the perspective projection is preferred if the images are recorded in the fan beam geometry.
The assignment of instants in the non-periodic motion model to a motion phase in the periodic motion model can be effected with reference to an electrocardiogram that was recorded when the images were recorded and/or with reference to the periodicity information that was determined on the basis of the estimation parameters. The mapping of the instants, which effectively parameterize the non-periodic motion model, onto phases, in particular continuously defined phases, of the periodic motion can therefore be effected with reference to measurement information from a recorded electrocardiogram, for example. It is naturally also conceivable to analyze the motion that is described by the estimation parameters in the non-periodic model in respect of its periodicity, and to derive the motion information from this, such that an additional measurement from an electrocardiogram is no longer necessary in this case.
In a further embodiment of the invention, provision can be made for using a four-dimensional spline model as a motion model, preferably using cubic B-spline base functions in particular. In this way, location-dependent motions can be described locally, wherein such a description for the heart motion is already proposed in the references. Spline models describe a motion that is smooth in relation to location and time, particularly if cubic B-spline base functions are used. If such a spline model is used, control points are usually assigned to displacement vectors. In the context of the method according to the invention, these displacement vectors or their components can then form the motion parameter set that is to be optimized. However, other periodic motion models are also conceivable.
With regard to the optimization method, provision can be made for using a gradient-based optimization method, for example. Various approaches are likewise conceivable here, however, since optimization methods are generally well known in the prior art and need not be explained in further detail here.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages and details of the present invention are revealed by the exemplary embodiments described below and with reference to the drawing, in which:
FIG. 1 shows a flow diagram of the method according to the invention, and
FIG. 2 shows a drawing of the underlying principle of the present invention.
DETAILED DESCRIPTION OF INVENTION
FIG. 1 shows a flow diagram of the method according to the invention. In a step 1 , provision is made for recording projection images which, in the exemplary embodiment that is represented here, show the coronary vessels and the heart from different projection directions. The recording lasts for several heart cycles in this case. An electrocardiogram is recorded using a suitable measuring device at the same time as the projection images.
In a step 2 , the dynamic reconstruction of a static three-dimensional image dataset from the two-dimensional projection images now takes place, wherein a non-periodic motion model is used and is adapted in an optimization method to at least some of the actual recorded projection images. Specifically, provision is made for determining a current reconstruction dataset in a dynamic reconstruction method, in particular an FDK method, during each step in an optimization method. From this, projection images are then determined by means of dynamic forward projection, and compared with the actual recorded projection images until they correspond to the latter as exactly as possible. It should be noted here that provision can obviously be made for other evaluation rules in other exemplary embodiments, e.g. the comparison with a reference dataset.
Details of such a procedure can be found e.g. in the previously cited EP 2 242 023 A1, which is included in its entirety in the disclosure of the present invention with regard to the details of this determination method.
The determinations in step 2 therefore result in an optimal reconstruction dataset, subsequently referred to as a three-dimensional image dataset, and estimation parameters which describe the non-periodic motion in the non-periodic motion model. During the further course of the inventive method, a dynamic representation of the heart and the coronary vessels must now be generated, for which purpose the motion described by the estimation parameters cannot be used directly, however, due to the existence of a problem which is solved by the present invention. Concerning this, reference is made to the illustration in FIG. 2 .
This shows two projections 3 , 4 of a motion 5 , which is broken down into orthogonal components 6 , 7 and 8 here. Corresponding positions of radiation sources are denoted by 9 and 10 , the fan beam geometry being illustrated here.
If the motion 5 is recorded solely from the projection direction that is associated with the projection plane 3 , it is clear that only the components 6 and 7 are depicted. Similarly, only the components 6 and 8 of the motion 5 can be seen in the other projection direction, this being perpendicular to the first.
If a non-periodic motion is therefore estimated on the basis of two-dimensional projection images, the motion component along the direction of the x-radiation is missing at each instant, since said x-radiation cannot be identified in the corresponding projection planes 11 , 12 (e.g. the detector planes).
If the static three-dimensional image dataset determined in step 2 is now to be animated on the basis of the estimation parameters, the missing motion information must be determined. According to the invention, this is now done using a periodic motion model in step 13 ( FIG. 1 ), wherein the motion parameters of the periodic motion model are specified in such a way that they agree as exactly as possible with the motion (i.e. the corresponding motion components) that can be inferred from the two-dimensional measured data (projection images).
Equation (1) describes the parameterization of the non-periodic motion model that is used in step 2 ,
x t =x+Δx t =x+B ( t,x,s ) (1)
where x describes a three-dimensional position vector and x t describes the new position vector at the instant t in the time after the motion with the vector Δx t . B designates the motion model with the estimation parameter vector s at the position x.
As explained above with reference to FIG. 2 , however, only those motion components that are perpendicular to the x-ray beam direction, i.e. the projection direction, can be determined at a recording instant t. These components u=(u,v) T can be specified using the same projection operation P(t,x) as in the image recording.
u
=
(
u
v
)
=
P
(
t
,
x
+
Δ
x
t
)
=
P
(
t
,
x
+
B
(
t
,
x
,
s
)
)
(
2
)
P(t,x) therefore projects a vector x onto the projection plane (cf. 11 , 12 in FIG. 2 ) in which the recording is or was made at the instant t, since the concept can be applied to the continuous case, i.e. every instant t, if the recording positions are interpolated to form a recording path.
In this case, however, motions of a number N of transformed coordinates are now used as an input for the motion which the new periodic motion model is to reproduce, and are used as the measured results which the periodic motion model is to describe:
u
n
=
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P
(
t
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,
x
n
+
B
periodic
(
h
(
t
n
)
,
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n
,
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periodic
)
)
.
(
3
)
In this case, B periodic is the time-periodic motion model by means of which the coordinate x n (where n is in the range 1-N) is moved to a new position during the relative heart phase h(t n ). The heart phase here is specified as a continuous parameter between 0 and 1 in this case. The periodic motion model is described by the motion parameter s periodic and should now be in agreement with the actual measured components of the non-periodic motion.
Due to their simpler representation, the equation systems that are produced for the orthogonal projection (i.e. the parallel beam geometry) are shown below, wherein similar equation systems can also be derived for the perspective projection. The orthogonal projections result in simple projection matrices P n having dimensions of 2×3 on the projection planes at a recording time t n . As a result of this, the projections of the motion vectors are spatially invariant and compact formulas for the equation system are produced:
u
^
n
=
!
P
orthogonal
(
t
n
,
B
periodic
(
h
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t
n
)
,
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n
,
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)
)
.
(
4
)
The non-periodic field of motion is observed at M points (x n ,t n ) in space and time, wherein motion parameters s periodic should be specified such that the projections of the periodic field of motion consistently agree with the measured projections û n of the non-periodic motion model, described by the estimation parameters. In order to specify these motion parameters s periodic of the periodic motion model, the expression of the equation (1) is used in order to formulate a linear equation system of N equations for all observed space-time points, which system can be described by a matrix equation:
y = [ u ^ 1 u ^ 2 ⋮ u ^ N ] = [ P 1 P 2 ⋮ P N ] · B periodic · s periodic s periodic = argmin s periodic PB periodic · s periodic - y 2 ( 5 )
wherein the measurement vector y is composed of the vectors û n . The unknown is the vector s periodic of the motion parameters. B periodic generates the periodic field of motion for (x n ,h(t n )). P n is the projection matrix at the instant t n . The system matrix PB periodic is the product of the matrix B of the projection matrices P n and the matrix B periodic .
In this exemplary embodiment of a minimization method, provision is made for normalizing the L 2 noun of the error, said norm being the length of the difference vector between projected periodic and non-periodic motions. Cubic four-dimensional B-splines are used in the periodic motion model, such that each motion vector Δx n is influenced by just three components of s periodic for each dimension. The matrix is therefore thinly populated, since it only has 81 entries in each row. The algorithm that is used outputs a solution for s periodic , which has the fewest errors over all N observed instants.
In this case, 2×N equations are used in order to determine the 3·c s 3 ·3c h unknowns, where c s and c h represent the number of control points for the B-spline model in the spatial dimensions and during the heart phase. Since all information from all possible perspectives, i.e. projection directions, should be taken into consideration, and it should be ensured that not too few points are observed, provision is made in this exemplary embodiment for using equations from each actual recorded projection direction, i.e. for each instant at which a projection image was recorded.
In this way, the contributions of a plurality of projection images at the different heart phases can be combined, such that information is ultimately complementary as indicated in FIG. 2 . In the spatial dimensions, the same arrangement of control points is used as in the non-periodic motion model. This ultimately results in a far greater number of equations than unknowns, and therefore a corresponding solution method can be used. In this context, appropriate methods are those which are suitable for overspecified systems and at the same time take advantage of the matrix being thinly populated. It is thus possible to create a robust and computationally simple solution which requires few computing resources.
The result is therefore an optimal motion parameter set for the periodic motion model, which is used in a step 14 to animate the static three-dimensional image dataset that was determined in step 2 and hence to represent the motion of the heart and the coronary arteries during a heart phase. | A method for generating a four-dimensional representation of a periodically moving target region is proposed. A motion-compensated three-dimensional image dataset is determined from two-dimensional projection images recorded from different projection directions. Estimation parameters that describe a non-periodic motion and are derived from a motion model formulated independently of the phase of the periodic motion with respect to the recording instants of the projection images are determined from the projection images, such that the three-dimensional image dataset represents a static reconstruction based on all projection images for a specific instant. The three-dimensional image dataset is animated from the estimation parameters used in its reconstruction. The motion information that is missing in the estimation parameters due to the two-dimensionality of the projection images is additionally determined using a boundary condition that describes the periodicity of the motion, and used for the animation. | 6 |
Background
[0001] This invention relates generally to implementing wireless communication protocols.
[0002] A variety of wireless communication protocols are available currently. The Bluetooth protocol allows for relatively short-range wireless communications between devices such as desktop computer systems, peripherals, or any processor-based system, to mention a few examples. See the Specification of the Bluetooth System, Version 1.1 (Feb. 22, 2001) available from the Bluetooth Special Interest Group. The IEEE 802.11 standard is a longer range communication protocol that similarly allows processor-based devices and peripherals to communicate with one another. See Institute of Electrical and Electronics Engineers, Inc. (I.E.E.E.) Std. 802.11 1999 Edition, “Wireless LAN Medium Access Control and Physical Layer Specification” available from the I.E.E.E., Inc., New York, N.Y. 10016-5997, U.S.A.
[0003] Under the Bluetooth standard, a universal Bluetooth pointer is available that allows the user to communicate selectively with one of a plurality of wirelessly coupled devices. If there are a plurality of devices in the vicinity of the pointer, the pointer must select one of those devices to communicate with in particular. The solution to this problem under the Bluetooth standard is called limited device discovery. Communicating between the pointer and one particular device requires a manual action on both the device to be selected and the wireless pointer.
[0004] Requiring that the user manually actuate both devices may not be a desirable solution in all cases because it assumes that both devices are physically reachable by a single user. It precludes potential applications with public devices such as Bluetooth enabled Automatic Teller Machines (ATM) that may be out of the reach of users. In addition, a user who has a plurality of wirelessly coupled peripherals loses the benefit of wireless communication if the user must physically manually select each of a plurality of devices when needed.
[0005] Thus, there is a need for better ways to select from among a plurality of devices to initiate communications using a wireless communication protocol.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] [0006]FIG. 1 is a schematic depiction of a wireless network in accordance with one embodiment of the present invention;
[0007] [0007]FIG. 2 is a front elevational view of a wireless selection device in accordance with one embodiment of the present invention;
[0008] [0008]FIG. 3 is a block depiction of a wireless selection device and a processor-based system with which it communicates in accordance with one embodiment of the present invention;
[0009] [0009]FIG. 4 is a flow chart for software for finding one of a plurality of wireless devices to communicate with in accordance with one embodiment of the present invention;
[0010] [0010]FIG. 5 is a flow chart for software for contacting a plurality of wirelessly coupled devices in accordance with one embodiment of the present invention; and
[0011] [0011]FIG. 6 is a flow chart for software for operating one of a plurality of programmable buttons on a wireless selection device in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
[0012] Referring to FIG. 1, a wireless selection device 12 may communicate with a plurality of processor-based devices or peripherals 14 . While four such devices are illustrated in FIG. 1, any one of a variety of different devices may be communicated with, the number being determined by the applicable wireless communication standard. Two applicable wireless communication standards include the Bluetooth standard and the IEEE 802.11 standard.
[0013] The selection device 12 selects one of a plurality of sufficiently proximate devices 14 to communicate with at any one time. Thus, the selection device 12 allows the user to select from among a variety of proximate devices with which to communicate. Thus, the wireless selection device 12 , in one embodiment, may be a wireless pointer, which may provide pointing functions on any of a plurality of wirelessly coupled devices 14 . Alternatively, the wireless selection device 12 may be a keyboard, a joystick, or any of a variety of other devices.
[0014] Referring to FIG. 1, in one embodiment, the wireless selection device 12 includes a plurality of operators 16 , 18 , 20 and 22 . In the embodiment illustrated in FIG. 2, the selection device 12 is illustrated as a wireless pointing device including left and right mouse buttons 18 a and 18 b. On one surface of the device 12 there may be an appropriate trackball or other position determining device. Thus, movement of the device 12 , in one embodiment, can develop appropriate pointer position commands.
[0015] The wireless selection device 12 , in one embodiment, also includes a FIND button 20 , a POLL button 22 and a plurality of programmable operators 16 . The operators 20 , 22 , and 16 may be implemented by any of a variety of user selectable technologies including physically depressible buttons or touch screens, as two examples.
[0016] Each of the programmable operators 16 may be programmed to relate to or be associated with a particular device 14 with which the selection device 12 may communicate. The assignment of a device 14 to a button 16 is completely programmable, in one embodiment, as will be described in more detail hereinafter. In addition, the operator 16 may include illumination devices so that, when a operator 16 is involved, it may be illuminated.
[0017] The FIND operator 20 is useful for enabling the selection device 12 to find all of the sufficiently proximate devices 14 with which it may communicate in any given position. Thus, when the FIND operator 20 is operated, the wireless selection device 12 progressively communicates with all compatible wirelessly connected devices 14 that are sufficiently proximate pursuant to the applicable communications standards. The device 12 may obtain identifying addresses from those proximate devices 14 and store them in an appropriate fashion. Thus, the FIND operator 20 is used to set up the environment that enables selection of a specific device 14 .
[0018] The POLL operator 22 may be pressed to select a particular device 14 . By successively pressing the POLL operator 22 , successive devices 14 may be successively selected. The selected device 14 may provide an audible or visual indication in response to being selected in one embodiment. If the selected device 14 is associated with one of the operators 16 , that operator 16 may be illuminated.
[0019] Referring to FIG. 3, the communications between the wireless selection device 12 and the desktop computing device 14 c are illustrated in one embodiment. The wireless selection device 12 may include a controller 24 that is coupled to a non-volatile storage 30 and a volatile storage 34 . The volatile storage 34 may be implemented, for example, by dynamic random access memory (DRAM). The nonvolatile storage 30 may be implemented, for example, by flash memory in one embodiment. In some embodiments, the wireless selection device 12 is battery powered.
[0020] The controller 24 is also coupled to a button interface 58 that in turn communicates with the buttons 18 a and 18 b as well as operators 20 and 22 . A light driver 28 communicates between the controller 24 and the operators 16 a through 16 e to illuminate the light emitting devices associated with each operator 16 . In addition, the light driver 28 provides a button interface between the buttons 16 and the controller 24 . The non-volatile storage 30 may be used to store software 32 , 80 and 100 .
[0021] The controller 24 also communicates with a radio frequency interface 26 in accordance with one embodiment of the present invention. The radio frequency interface 26 may be in accordance with a particular wireless communications standard. The interface 26 communicates wirelessly with an interface 36 of the device 14 c.
[0022] The device 14 c may otherwise be conventional and may use any of a variety of appropriate architectures. In the illustrated embodiment, the interface 36 communicates through a serial input output (SIO) device 38 with a bus 40 that also is coupled to a basic input/output system (BIOS) storage 42 . The bus 40 in turn is coupled to a bridge 44 . The bridge 44 in one embodiment may be coupled to another bus 50 and a hard disk drive (HDD) 46 . The hard disk drive 46 may store software 48 , which implements the wireless communications standard and is responsible for enabling the device 14 c to appropriately respond with a visual or audible selection when selected by the selection device 12 .
[0023] The bus 50 may be coupled to a bridge 52 and ultimately to the processor 56 in system memory 54 in one embodiment. Again, a variety of architectures are applicable with embodiments of the present invention and the present invention is in no way limited to the architecture illustrated in FIG. 3.
[0024] Referring to FIG. 4, the FIND software 32 may be stored on the wireless selection device 12 , for example, in the non-volatile storage 30 . In other embodiments, all or part of the processing tasks illustrated in FIG. 4 may be offloaded to one of the devices 14 . In such case, the wireless selection device 12 may simply pass appropriate signals to a home base device 14 , which then executes software 32 and provides the appropriate information, in simplified format, back to the wireless selection device 12 .
[0025] The software 32 , in one embodiment, begins by determining whether the FIND operator 20 has been operated as indicated in block 60 . If so, the wireless selection device 12 enumerates the sufficiently proximate devices 14 as indicated in block 62 . The enumeration of the proximate devices may be in accordance with an applicable communications protocol. An identifying address for each of the sufficiently proximate devices 14 may be obtained as indicated in block 64 . Those addresses may be stored in a volatile storage 34 as indicated in block 66 . In one embodiment, the addresses of the sufficiently proximate devices 14 may be successively stored in a circular buffer in the volatile storage 34 .
[0026] Upon initial use, no identifying addresses are associated with any of the programmable operators 16 when the FIND operator 20 is released as determined in diamond 68 . When release is detected, the first address of a sufficiently proximate device 14 in the circular buffer of the volatile storage 34 is copied to the non-volatile storage 30 associated with a programmable button 16 . Each of the programmable buttons 16 may have an associated buffer position in the non-volatile storage 30 as indicated in block 70 . A check at diamond 72 determines whether there are more addresses and if so, the flow iterates. Otherwise, the flow ends.
[0027] Turning next to FIG. 5, the POLL software 80 is illustrated in accordance with one embodiment of the present invention. When the POLL operator 22 is operated as determined in diamond 82 , the next device 14 in the circular buffer is selected as indicated in block 84 . The selected device 14 may emit an audio and/or visual indication to inform the user that it has been selected in one embodiment. The audio or visual selection may simply be a beep or flashing symbol such as an icon or a combination of the same. Thus, the selection device 12 a commands the selected device 14 to emit a signal as indicated in block 86 .
[0028] A check at diamond 88 determines whether the selected device 14 is linked to a particular operator 16 . If so, that operator 16 may be illuminated as indicated in block 90 . By successively pressing the POLL operator 22 , the user can select any device 14 stored in the circular buffer of the volatile storage 34 . When a device 14 is selected through the POLL operator 22 , it may be controlled by the selection device 12 even if the selected device 14 is not currently associated with one of the operators 16 .
[0029] Finally, referring to FIG. 6, the operator 16 software 100 begins by determining whether a operator 16 has been pressed with what may be described as an identifying press. In one embodiment, an identifying press is a relatively short button operation, for example, when the operator 16 is pressed and released within one second. Other identifying presses may be utilized as well. In still other embodiments, multiple operators may be used.
[0030] When a shorter press is detected, as indicated in diamond 102 , the selection device 12 reads the address of a device 14 obtained from the corresponding non-volatile storage 34 and selects that device as indicated in blocks 104 and 106 . The device 14 may have been selected by operating either the POLL operator 22 or the FIND operator 20 . If no device 14 address is currently selected, then in one embodiment, the software 100 may automatically take the first address and the circular buffer and associate it with the selected programmable operator 16 .
[0031] If a longer press is detected at diamond 108 , a different operation may occur. In one embodiment, if the user presses the operator 16 , for a sufficiently long time, such as two seconds, a longer press is detected. However, any of a variety of techniques may be utilized for distinguishing the user's selection of a particular operator 16 or a plurality of buttons may be utilized.
[0032] When a longer press is detected the address of the currently selected device 14 is copied from the volatile storage 34 to a non-volatile storage 30 location corresponding to the selected programmable button 16 as indicated in blocks 110 and 112 . The current selection then remains unchanged. The selected operator 16 illuminates upon release to indicate that it has been selected as indicated in block 114 .
[0033] Thus, in one example, a typical usage model may be as follows. The user may go home and press the FIND operator 20 . When the user presses the POLL operator 22 several times, the user may discover his home desktop computer 14 c, home laptop computer 14 a, home personal digital assistant 14 b, and home cordless telephone 14 d. The user may then operate the operator 16 a and hold it down for a sufficient amount of time to program the home desktop computer 14 c to the operator 16 a. From this point onwards, the user can select the home desktop computer 14 c by simply pressing the operator 16 a. This information is not lost when the user presses the FIND operator 20 or POLL operator 22 again.
[0034] If thereafter, the user goes to his office and presses the FIND operator 20 or the POLL operator 22 again he may discover, in one embodiment, his office computer, an office printer, a cell phone and a handheld computer. The user may program the operators 16 b, 16 c and 16 d to select his office computer, cell phone and a handheld computer. Then, when the user goes home, the user may press the operator 16 a and start using the selection device 12 to control the home desktop computer 14 c. When the user presses the operator 16 b he may find that the selection device 12 still controls his home desktop computer 14 c because it could not find the office computer at home.
[0035] When the user presses the operator 16 d, the user realizes that the selection device 12 has stopped controlling the home desktop computer 14 c and started controlling his handheld computer 14 d, which he brought home with him from the office. The user may then go back to work and press the operator 16 d to still control his handheld computer 14 d, which he again brought with him. The user can press the operator 16 b at work and find that the selection device 12 controls his office computer and stops controlling the handheld computer 16 d.
[0036] While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the true spirit and scope of this present invention. | In the wireless communication system, a wireless selection device is able to select any of a plurality of sufficiently proximate wireless devices without the necessity to actually physically contact or operate any of those devices. Thus, a user may control any of a plurality of devices from a single wireless selection device. The wireless selection device may in some embodiments be a wireless pointing device or a wireless keyboard to mention two examples. | 7 |
FIELD OF INVENTION
[0001] The present inventions relates to a method of feeding cattle with feed additives to increase beef production and decrease the incidence of liver abscess.
BACKGROUND OF INVENTION
[0002] The United States is the leading beef producer of the world. In 2003, the United States produced over 26 billion pounds of beef and the United States per capita consumption averaged 64 pounds. Beef averages approximately 31 percent of the total per capita consumption of meat; however, beef's share of consumer retail spending was 40.2 percent of the total dollars spent on meat in 2000. Thus, the United States beef industry is a very diverse multi-billion dollar enterprise.
[0003] The United States feedlot industry traditionally functions to grow and finish weaned calves (˜400-600 pounds) and yearling steers and heifers (550 to 800 pounds) to slaughter weights of approximately 1,100 to 1400 pounds. Because the feedlot industry increases the size and quality of cattle, the industry is constantly driven to increase the rate and efficiency of gain of cattle. The use of growth enhancing agents by the feedlot industry can be easily visualized in that beef (meat) production has risen dramatically over the last several years, while the number of cattle has been in recent decline.
[0004] Feedlots are confinement feeding operations where cattle are fed primarily high energy finishing diets prior to harvest. Most feedlot operations feed a relatively high grain diet for 90 to 225 days (depending on starting body weight) resulting in economically efficient weight gains and improved palatability of the retail product. The very nature of a feedlot is to put as much weight on an animal in the least amount of time as possible. This process results in a number of nutritional diseases such as lactic acidosis, feedlot bloat, liver abscesses, polioencephalomalacia, and others. Of these diseases acidosis is the most important and costly nutritional disorder in United States feedlots today.
Lactic Acidosis
[0005] Acidosis is caused by a rapid production and absorption of acids, mostly lactic acid, from the rumen when cattle consume too much starch (grain) or sugar in short amount of time. As long as cattle are finished on high energy (grain) diets, lactic acidosis will remain a serious problem in the feedlot industry. Acidosis is not one disorder, rather a continuum of degrees of acidosis. The effects of this continuum of acidosis can be slight, reducing feed intake by ˜0.25 lbs/day, or severe enough to result in death. Several acidosis-related problems occur in the feedlot including, sudden death syndrome, polioencephalomalacia, founder, rumenitis, liver abscesses, malabsorption, clorstridial infestations, off-feed, and reduced feed intake.
[0006] Typical feedlot acidosis occurs when a large amount of highly fermentable feed (grain) is consumed in a short amount of time resulting in the production of more lactic acid than can be buffered by the rumen. This results in water from the circulatory system being drawn into the rumen, resulting in the rest of the body being dehydrated and pronounced changes in blood pH. Signs can be sub-acute to acute.
[0007] Liver abscesses result from a disease complex known as the acidosis-rumenitis-liver abscess complex. Fusobacterium necrophorum , a normal inhabitant of the rumen, is the primary causative bacteria. Feeding a high energy grain diet causes ruminal acidosis, as explained above, which attacks the integrity of the rumen wall, permitting opportunistic bacteria such as Fusobacterium necrophorum to colonize, enter the bloodstream, and eventually enter and infect the liver. High-concentrate diets also impact the severity and incidence of liver abscesses and acidosis. As the energy levels of the grain rations increase, problems associated with acidosis increase. This cause and effect relationship creates an interesting paradigm, considering the very nature of the feedlot is to put on rapid weight.
DETAILED DESCRIPTION OF THE INVENTION
[0000] Ionophores and Monensin
[0008] Ionophores are effective in increasing feed efficiency and improving rate of body weight gain principally by altering ruminal fermentation. Monensin is the preferred ionophore.
[0009] There are three major fermentation changes associated with feeding ionophores:
Increased production of propionate and decreased production of methane, resulting in increased efficiency of energy metabolism; decreased protein degradation and deamination of amino acids, resulting in the improvement of nitrogen metabolism in the rumen and animal; and decreased lactic acid production in the rumen, leading to a reduction of ruminal disorders.
[0011] The most consistent effect ionophores have on altering fermentation is increased molar proportion of propionic acid and a decrease in molar proportions of acetate and butyrate in the volatile fatty acids produced in the rumen. The increase in rumen propionate is accompanied by a reduction from 4 to 31% of the amount of methane produced in the rumen. Additionally, it has been reported that ionophores decrease ruminal ammonia concentrations.
[0012] Ionophores provide protection against lactic acidosis by maintaining a favorably higher rumen pH. Ionophores accomplish this by creating an environment that selects for gram-positive bacteria, the major lactic acid-producing bacteria ( Streptococcus bovis and Lactobacillius spp.) are inhibited, but gram-negative lactic acid-fermenting bacteria are unaffected. Maintaining favorable rumen fermentation also impacts the feed intake of cattle by decreasing the variance in daily feed intake, particularly during the period of adaptation to a high concentrate grain diet. The influence on feed intake variability by ionophores should potentially be an additive ruminal benefit.
[0000] Liver Abscesses and Tylosin
[0013] Dietary stresses such as starting cattle on feed or switching too quickly to high-energy concentrate diets, may spur acute rumenitis. Additionally, the reduced concentration of roughage in the high-energy concentrate diet allows the rumen microflora to produce lactic acid that leads to ulcerative lesions of the rumen mucosa. These rumen lesions allow entry of bacteria into the bloodstream where they are carried to the liver. In the liver the blood is stored and filtered, thus allowing the bacteria to build up. Colonies of bacteria, predominantly Fusobacterium necrophorum and Actinomyces pyogenes , grow and produce toxins that result in localized infections and necrosis that eventually become liver abscesses.
[0014] Generally, the incidence of liver abscesses averages from 12 to 32% in most feedlots. However, there is a range of liver abscesses severity, from none, to one or two small abscesses, to two to four well-organized abscesses under one inch in diameter, to one or more large active abscesses or multiple small abscesses. Typically, only severe abscesses are associated with negative feedlot performance. Severe liver abscesses are associated with a 3.7% decrease in feed intake, an 11.5% decrease in average daily gain, a 9.7% increase in feed to gain ratio and a 1.9% decrease in carcass yield or dressing percent. The liver accounts for approximately two percent by weight, of the carcass which can add up to a significant financial loss. Additionally, when the liver has severe abscesses the liver can become fused to the visceral cavity requiring additional carcass trimming and further trim losses. However, it is not the loss of the liver or carcass trimming that is of the greatest economic concern. A summary of 266 control cattle in five studies conducted by Eli Lilly and Company (Elanco Animal Health) revealed that cattle with abscessed livers gained 4.9% less than cattle without abscesses. Brink et al. (1990) and Farlin (1980) both showed that minor liver abscesses did not measurably affect feedlot performance while severe liver abscesses negatively impacted feedlot performance. Barlte and Preston (1991) also demonstrated that cattle with severely abscessed livers had decreased average daily gain, and USDA quality and yield grades when compared with steers without liver abscesses. These results again indicate that only the most severe liver abscesses are detrimental to feedlot performance.
[0015] In a study by Brink et al. (1985), animals with severe liver abscesses began to show reduced feed intake as early as 15 days into the feeding period which persisted through the entire 112 day feeding period. Lechtenberg and Nagaraja (1991) observed that steers developed liver abscesses as early as three day postinoculation of F. necrophorum . Theses results indicate that once the rumen wall is damaged and bacteria can escape into the blood system a minimum of three days is needed before a liver abscess can initially form.
[0016] Abscesses that exist during the feeding period affect performance, whereas, abscesses that exist at slaughter affect yield and condemnation rates.
[0017] A macrolide antibiotic is typically fed by feedlots to reduce the incidence of liver abscesses. One such macrolide antibiotic is produced by a strain of the antnomycete Streptomyces fradiae . Tylosin is this macrolide antibiotic, which has the product name of Tylan®. Tylosin inhibits bacterial protein synthesis and is effective against Antinomyces pyogenes (gram positive bacteria) and Fusobacterium necrophorum (gram negative bacteria). Cattle treated with Tylan® typically gain faster, have a reduced feed to gain ration, and have reduced carcass trim with liver abscesses being reduced 63 to 71%. While Tylan® typically has a positive effect on reducing the incidence of liver abscesses; effects on performance are not consistent. Potter et al. (1985) found Tylan® improved average daily gain but had no effect of feed intake, whereas, Laudert and Vogel (1994) reported Tylan improved gain and feed to gain ratio while there were only minor effects on feed intake and dressing percentage.
[0018] Zilpaterol is an organic compound that has been found to exhibit beta-agonist activity. Zilpaterol can be used in its hydrochloride form, as describe in U.S. Pat. No. 4,525,770, which is incorporated by reference or the crystal form described in U.S. Pat. No. 5,731,028, which is incorporated by reference.
[0019] Beta agonists are fed at the end of the finishing phase for the last 20 to 40 days on feed, while ionophores and macrolide antibiotics are fed throughout the finishing period. The inventors have found that by removing the ionophore and macrolide antibiotic during the last 20 days to 40 days of feeding and replacing them with the single compound zilpaterol, one can achieve good weight gain and unexpectedly reduced liver abscesses. This is unexpected because the removal of the macrolide antibiotic during the last 20-40 days of the finishing period could potentially increase the incidence of liver abscesses.
[0020] One embodiment of the present invention is a method of feeding cattle with additives to increase beef production by feeding with an ionophore, such as monensin, in combination with a macrolide antibiotic, such as tylosin, up to the last 20 to 40 days of the finishing period, removing the ionophore and macrolide antibiotic from the feed and adding zilpaterol or zilpaterol hydrochloride to the feed for the last 20 to 40 days.
[0021] Another embodiment is a method of reducing feed intake of cattle and maintaining beef production, comprising administering to cattle feed an effective amount of an ionophore compound in combination with a macrolide antibiotic up to the last 20 to 40 days of a finishing period, then removing the ionophore compound and the macrolide antibiotic from the feed and adding zilpaterol to the feed as the single β-agonist compound present for the last 20 to 40 days of the finishing period.
[0022] Another embodiment is a method of reducing incidences of liver abscess in cattle fed with feed additives, comprising administering to cattle feed an effective amount of an ionophore in combination with a macrolide antibiotic up to the last 20 to 40 days of a finishing period, then removing the ionophore and the macrolide antibiotic from the feed and adding zilpaterol to the feed as the single β-agonist compound present for the last 20 to 40 days of the finishing period, wherein the reduction of liver abscess is compared to ionophore and macrolide antibiotic fed cattle throughout finishing period.
[0000] Studies
[0023] In study number V-0238-0017 a total of 3,945 steers were used to test the effects of Rumensin® plus Tylan® and zilpaterol on feedlot performance, liver abscess rates, and carcass traits. The inventors discovered that Tylan® and Rumensin® could be removed from the diet for the last 30 days to feed zilpaterol without negatively affecting liver abscess rates. In fact it was discovered that zilpaterol decreased the incidence of liver abscesses.
[0024] Study Number V-0238-0017, Effects of Zilpaterol on Liver Abscesses
Study Treatments Rumensin + No Rumensin, zilpaterol + zilpaterol (No Tylan (No Tylan or Rumensin + Rumensin Zilpaterol) zilpaterol Tylan or Tylan) Live 12.35 18.40 10.40 13.29 Abscess, % P-Value of Zilpaterol Main Effect on decreasing Liver Abscesses = 0.006 P-Value of Rumensin and Tylan Main Effect on decreasing Liver Abscess <0.001 *The study consisted of a total of 3,945 steers; each of the four different treatments had 10 different pens of steers. **Steers receiving Rumensin ® and Tylan ® received these feed additives for the entire 166-day study except for the last treatment (Rumensin ® and Tylan ® were removed during the last 30 days); steers receiving zilpaterol received zilpaterol for the last 30 days on feed.
[0025] In a separate set of three studies the inventors found that supplementing steers and heifers with zilpaterol for 20 or 40 days significantly decreased liver abscesses. All of these cattle had been fed Tylan® up to the last 20 to 40 days on feed at which time Tylan® was removed and cattle were either fed a control diet without Tylan®, Rumensin® or zilpaterol or cattle were fed a treatment diet containing just zilpaterol. While the mechanism by which zilpaterol decreases liver abscess is not fully clear at this time, it seems that zilpaterol functions to decrease liver abscesses by decreasing feed intake. Because the liver abscesses discovered at slaughter are formed during the last ˜60 days or less on feed and this is the same time zilpaterol is fed, a decrease in feed intake would result in a decrease in acid production and possibly a decrease in rumen wall lesions and rumenitis.
[0026] Summary of Zilpaterol Efficacy Studies (Pooled Analysis), Study Numbers, V-0238-0019, V-0238-0020, and V-0238-0021 on Liver Abscesses and Feed Intake
Treatments Zilpate Control rol P-Value % of Livers 25.0 19.1 0.0241** Condemned for Abscesses* Average Daily Dry 19.63 18.69 0.0129 Matter Intake, lbs. *Percentages represent 957 animals. The three studies consisted of 32 pens of 10 animals. **P-Value is based on the Cochran-Mantel Haenszel test, controlling for stratification parameters of duration, sex, and site in the pooled analysis. | The present inventions relates to a method of increasing beef production in cattle with feed additives, comprising feeding cattle with feed, comprising an effective amount of an ionophore in combination with a macrolide antibiotic, and thereafter feeding cattle with feed, comprising zilpaterol and essentially no ionophore or macrolide antibiotic for the succeeding about 20 to 40 days. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to provisional application 60/802,626, filed May 23, 2006.
FIELD OF THE INVENTION
[0002] This invention relates in general to an electrical submersible pump (ESP) and in particular to a downhole capsule containing two ESP modules.
BACKGROUND OF THE INVENTION
[0003] An electrical submersible pump (“ESP”) assembly for wells typically comprises a submersible motor that drives a pump, typically a centrifugal pump. The pump assembly is usually suspended on a string of tubing within the well. The power cable to the motor is strapped alongside the tubing. Periodically, the pump assembly has to be retrieved for maintenance or repair, and this step requires pulling the tubing. Pulling the tubing requires a workover rig and is time consuming, particularly for offshore installations.
[0004] In some cases a dual tandem pump assembly is used to provide more lift. Normally two pumps are connected together and driven by a single motor. The pumps thus operate in unison with each other. Repair or replacement of either pump requires pulling the tubing and the entire assembly.
[0005] Often a pressure and temperature sensor will be mounted to the base of the motor for sensing the pressure and temperature of the dielectric liquid within the motor. The power to the motor fluid sensor and the signals are superimposed on the ESP power cable Another measuring tool comprises a reservoir sensor, which is an electrical device that senses various characteristics of the producing reservoir of the well on the exterior of the motor. These tools typically send signals up a dedicated communication line extending to the surface.
SUMMARY
[0006] In this invention a capsule having an upper end for connection to a string of production tubing lowered within casing of a well. An electrical submersible pump assembly is located within and suspended by the upper end of the capsule. A bulkhead is located within the capsule below the pump assembly. An electrically powered device suspended by and below the bulkhead. A power lead extends from the electrically powered device through the bulkhead, alongside the pump assembly within the capsule and sealingly through the upper end of the capsule. The electrically powered device may be suspended below the capsule or contained within the capsule.
[0007] The electrically powered device may be a sensor for sensing reservoir characteristics or it may be a second submersible pump assembly. In one embodiment having two ESP's, the bulkhead divides the capsule into upstream and downstream chambers, each chamber containing one of the pump assemblies. The power cables for each motor pass through the capsule alongside the outlet. The two submersible pump assemblies may operate simultaneously or one may operate while the other is shut down.
[0008] The reservoir sensor unit may be suspended below the hanger or bulkhead. The power and signals for the reservoir sensor unit may be supplied via a dedicated sensor line to the surface, or the sensor line may only extend to the motor sensor. In the latter case, the reservoir sensor and the motor sensor may be superimposed on the ESP power cable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIGS. 1A and 1B comprise a vertical sectional view of a capsule containing two ESP modules in accordance with this invention.
[0010] FIG. 2 is an enlarged sectional view of the lower hanger contained within the capsule of FIG. 1 .
[0011] FIG. 3 is an alternate embodiment of the lower hanger contained in the capsule of FIG. 1 .
[0012] FIG. 4 is a schematic view illustrating both ESP's of the capsule of FIG. 1 operating.
[0013] FIG. 5 is a schematic view illustrating the upper ESP of the capsule of FIG. 1 operating and the lower ESP not operating.
[0014] FIG. 6 is a schematic view illustrating the lower ESP of the capsule of FIG. 1 operating and the upper ESP not operating.
[0015] FIG. 7 is a vertical sectional view of an alternate embodiment of a capsule, wherein one of the ESP modules of the capsule is a downhole sensor assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Referring to FIG. 1 , a well having a casing 11 is illustrated. Casing 11 is perforated at its lower end for allowing well fluid to enter. A string of production tubing 13 is suspended within casing 11 . A capsule 15 is secured to a lower end of tubing 13 .
[0017] Capsule 15 is a cylindrical member of slightly smaller outer diameter than the inner diameter of casing 11 so that it can be lowered into casing 11 on tubing 13 . Capsule 15 has an upper or downstream end with a hanger 17 that is rigidly secured to the lower end of tubing 13 .
[0018] An optional upper or downstream sleeve valve 19 is secured into a downstream conduit 18 below upper hanger 17 . Upper sleeve valve 19 has an interior that is communication with the interior of tubing 13 for discharging well fluid upward. Upper sleeve valve 19 has an open position in which ports 21 on its sidewall are exposed to the interior of capsule 15 . Upper sleeve valve 19 has a closed position in which ports 21 are closed to the interior of capsule 15 .
[0019] An upper or downstream ESP 23 is suspended on upper sleeve valve 19 . Upper sleeve valve 19 may be a commercially available type that closes its ports 21 to the interior of capsule 15 when downstream ESP 23 is operating. When ESP 23 is not operating, upper sleeve valve 19 automatically opens its ports 21 to the interior of capsule 15 . This type of valve, known as an annulus diverter valve, is used normally in tubing above submersible pumps in applications that are prone to significant sand production. Alternately, upper sleeve valve 19 could be hydraulically actuated or stroked between the open and closed positions by pressure supplied from the surface via a hydraulic line (not shown)that extends alongside tubing 13 and sealingly through upper hanger 17 .
[0020] If upper sleeve valve 19 is not utilized, upper ESP 23 would connect directly to upper hanger 17 . Upper ESP 23 is a conventional electrical submersible pump assembly, including a centrifugal pump 25 , which is shown at the upper end of the assembly. Pump 25 has an intake 26 on its lower end and is made up of a large number of stages or impellers and diffusers. One or more seal sections 27 are connected to the lower end of pump 25 . An electrical motor 29 is connected to the lower end of the seal section or sections 27 . Motor 29 is preferably a three-phase alternating current motor. Motor 29 is filled with lubricant, and seal sections 27 equalize the interior pressure of the lubricant in motor 29 with the pressure in capsule 15 .
[0021] Motor 29 has an electrical power lead 31 that extends upward alongside seal section 27 and pump 25 within capsule 15 . Motor lead 31 extends through an upper penetrator or guide 33 in upper hanger 17 . Upper penetrator 33 seals motor lead 31 in upper hanger 17 . Above capsule 15 , motor lead 31 joins a power cable (not shown) that is strapped alongside tubing 13 and extends to the surface.
[0022] A lower extension pipe 35 extends from the lower end of motor 29 to a lower hanger or bulkhead 37 located within capsule 15 . Lower hanger 37 is sealed to the sidewall of capsule 15 , defining an upper or downstream chamber 36 above lower hanger 37 and a lower or upstream chamber 38 below lower hanger 37 . A downstream conduit or support tube 39 secured to the lower side of lower hanger 37 is illustrated in FIG. 1B . An optional sliding sleeve valve 41 is connected to the lower end of support tube 39 . Sliding sleeve valve 41 has ports 43 that lead to the interior of capsule 15 and may be of the same type of valve as upper sliding sleeve valve 19 .
[0023] A lower or upstream ESP 45 is secured to the lower end of lower sliding sleeve valve 41 , and its weight is supported by upper hanger 17 through upper ESP 23 in this embodiment. Sleeve valve 41 also may be an annulus diverter type that automatically closes ports 43 when lower ESP 45 is operating and opens ports 43 when ESP 45 is not operating. Alternately, sleeve valve 41 could open and close ports 43 in response to hydraulic fluid pressure supplied from a line extending to the surface. If desired, lower sliding sleeve valve 41 may be operated independently of upper sleeve valve 19 by a separate hydraulic line from the hydraulic line leading to upper sleeve valve 19 . Alternatively, a single hydraulic line could control both sleeve valves 19 , 41 . For example, if lower ESP 45 is a back up to be operated only after upper ESP 23 fails, sleeve valve 41 could be connected to the same hydraulic line as upper sleeve valve 19 and operated in reverse to upper sleeve valve 19 . That is, while only upper ESP 23 is operating, as illustrated in FIG. 5 , the hydraulic pressure in the hydraulic line to sleeve valves 19 , 41 keeps sleeve valve 19 closed and sleeve valve 41 open. When upper ESP 23 is shut down and lower ESP 45 started, the hydraulic pressure in the line to valves 19 , 41 would be reversed by an operator at the surface to open upper sleeve valve 19 and close lower sleeve valve 41 , as shown in FIG. 6 .
[0024] If a lower sleeve valve 41 is not utilized, lower ESP 45 will be secured directly to support tube 39 . Lower ESP 45 may be the same type as upper ESP 23 , although it may be of a different length, if desired. Lower ESP 45 includes a centrifugal pump 47 with an intake 48 . Discharge port 50 of lower ESP 45 is in extension pipe 35 in upper chamber 36 . One or more seal sections 49 connect pump 47 to electrical motor 51 . A motor lead 53 extends from the upper end of motor 51 through a lower hanger penetrator 55 in lower hanger 37 . Penetrator 55 seals motor lead 53 within lower hanger 37 . Lower ESP motor lead 53 extends alongside upper ESP 23 and through an upper penetrator 56 located within upper hanger 17 to a power cable (not shown) extending to the surface. Capsule 15 has an inlet 59 located below the lower end of lower ESP 45 . Inlet 59 communicates well fluid in casing 11 to lower chamber 38 surrounding lower ESP 45 . Optionally inlet 59 comprises a stinger that stabs into a packer (not shown). The packer isolates the well fluid below it from the fluid within casing 11 surrounding capsule 15 and production tubing 13 .
[0025] FIG. 2 illustrates a first embodiment of bulkhead or lower hanger 37 . In this embodiment, lower hanger 37 has seals 61 that seal against a polished bore 63 on the inner diameter of capsule 15 . Hanger 37 , along with seals 61 , is able to slide axially along polished bore 63 as indicated by the arrows. This axial movement of lower hanger 37 accommodates thermal growth of upper ESP 23 ( FIG. 1A ) during operation. Lower ESP 45 is able to grow thermally because its lower end is spaced above capsule inlet 59 and is free to move. The entire weight of both upper and lower ESP's 23 , 45 is supported by upper hanger 17 in the embodiment of FIG. 2 .
[0026] In the embodiment of FIG. 3 , capsule 65 differs from capsule 15 of the first embodiment in that it has a load shoulder 67 located on the inner diameter. Lower hanger 69 lands on load shoulder 67 so as to support the weight of lower ESP 45 ( FIG. 1B ). Lower hanger 69 has seals 71 that statically engage a seal surface on the inner diameter of capsule 65 above load shoulder 67 .
[0027] To accommodate thermal growth of upper ESP 23 ( FIG. 1A ) in the embodiment of FIG. 3 , a telescoping joint is utilized for connecting between lower hanger 69 and the assembly of ESP 23 ( FIG. 1A ). This telescoping joint includes an upward facing receptacle 73 in this example. Receptacle 73 is open at its upper end and slidingly receives a tubular mandrel 75 that is rigidly secured to the lower end of upper ESP 23 ( FIG. 1A ). Mandrel 75 has seals 77 that will slidingly engage a seal surface within receptacle 73 . Upper and lower stops 79 , 81 limit the travel of mandrel 75 relative to receptacle 73 during installation of ESP 23 in capsule 65 . Receptacle 73 and mandrel 75 could alternately be reversed with mandrel 75 mounted to hanger 69 and receptacle 73 mounted to the lower end of upper ESP 23 . Discharge port 82 from lower ESP 45 ( FIG. 1B ) is located in mandrel 75 .
[0028] In a third embodiment (not shown), instead of lower hanger 37 ( FIG. 2 ) or 69 ( FIG. 3 ), the bulkhead would be a packer that is conventionally actuated to expand, grip and seal to the inner surface of capsule 15 . In that embodiment, the packer would support the weight of lower ESP 45 and would not be movable either upward or downward in capsule 15 .
[0029] In operation, upper and lower ESP'S 23 , 45 are installed within capsule 15 while at the surface. The entire assembly then is lowered into the well on tubing 13 . The upper ends of motor leads 31 , 53 are connected to power cables (not shown), which are strapped alongside tubing 13 . While being lowered, capsule 15 protects motor leads 31 and 53 against damage in the areas where they pass alongside upper seal section 27 and upper pump 25 . Because both motor leads 31 and 53 pass alongside these components, the clearance within casing 11 can be quite small.
[0030] Once capsule 15 is at the desired depth, the operator has a choice of simultaneously operating both upper and lower ESP's 23 , 45 as shown in FIG. 4 , operating only the upper ESP 23 as shown in FIG. 5 , or operating only the lower ESP 45 as shown in FIG. 6 . To operate both ESP's 23 , 45 simultaneously, the operator supplies power to both motors 29 , 51 ( FIG. 1 ) and both upper and lower sleeve valves 19 , 41 are closed, either automatically or by hydraulic pressure supplied from the surface. In fact, if the operator intends to always operate both ESP's 23 , 45 simultaneously, sleeve valves 19 , 41 are not required.
[0031] In the booster mode of FIG. 4 , well fluid flows through capsule inlet 59 into lower chamber 38 and lower pump intake 48 . Lower ESP 45 increases the pressure of the well fluid and discharges it from lower pump discharge port 50 into upper chamber 36 of capsule 15 . The higher pressure in upper chamber 36 is isolated by lower hanger 37 from the intake pressure in lower chamber 38 . The higher pressure fluid enters upper pump intake 26 , which boosts the pressure and discharges the well fluid into production tubing 13 . In this mode, ESP's 23 , 45 operate in series.
[0032] As illustrated in FIG. 5 , in this mode, only upper ESP 23 operates. To avoid flowing well fluid through the stages of the non operating pump of lower ESP 45 , lower sleeve valve 41 is opened. Opening lower sleeve valve 41 could be done by hydraulic fluid pressure. Alternately, if automatic sleeve valves 19 , 41 are used, merely supplying power to upper ESP 23 while not supplying power to lower ESP 45 will cause lower sleeve valve 41 to open while upper sleeve valve 19 remains closed. In this mode, the well fluid bypasses the pump of lower ESP 45 , flows from lower chamber 38 into the ports of lower sleeve valve 41 and discharges out lower pump discharge port 50 into upper chamber 36 of capsule 15 . The pressure in upper chamber 36 is substantially the same as at capsule inlet 59 . The well fluid flows into upper pump intake 26 , which discharges it at a higher pressure into tubing 13 .
[0033] Referring to FIG. 6 , in this mode, upper ESP 23 is not operating, rather only lower ESP 45 . This mode might occur after upper ESP 23 failed, in which case lower ESP 45 is energized as a back up. Upper sliding valve 19 is opened, and lower sliding valve 41 is closed, either by hydraulic fluid pressure or by automatic valves, as discussed. The well fluid flows from lower chamber 38 into lower pump intake 48 and is discharged out lower pump discharge 50 in upper chamber 36 at a higher pressure. The well fluid flows into the open ports of upper sleeve valve 19 rather than flowing through the stages of the pump of upper ESP 23 . The well fluid is discharged into tubing 13 at substantially the same pressure that it was discharged from lower ESP discharge 50 .
[0034] In another embodiment, which isn't shown, the lower end of capsule 15 terminates at lower hanger 37 . Lower ESP 45 is not located within capsule 15 , but is suspended by lower hanger 37 . Lower ESP 45 may have a tail pipe or stinger in that instance that would sting into a packer (not shown).
[0035] Referring to FIG. 7 , an alternate embodiment is shown wherein only one ESP is utilized. In this embodiment, capsule 83 is suspended on a string of production tubing 85 within casing 87 . ESP 89 is supported by an upper hanger 88 , which in turn is connected to tubing 85 . A motor lead 91 extends sealingly through a penetrator 93 in upper hanger 88 and down to the motor of ESP 89 . ESP 89 has a pump intake 95 , which is in capsule 83 . A hanger or bulkhead 97 is located at the lower end of ESP 89 . Hanger 97 may be constructed as in either the first embodiment of FIG. 2 or the second embodiment of FIG. 3 , or it could be a packer.
[0036] In this embodiment, the lower end of capsule 83 terminates at lower hanger 97 . In this example, a downhole sensor 99 is suspended on a tubular member or stinger 100 that is mounted to lower hanger 97 . Sensor 99 is a conventional electrical device that senses various characteristics of the reservoir, such as pressure and water/oil contact, and will be referred to herein as a reservoir sensor. Tubular member 100 has a length selected to place reservoir sensor 99 close to perforations 102 of the reservoir. The well fluid flows upward through tubular member 100 into the interior of capsule 83 and into pump intake 95 . Tubular member 100 could sting into a packer, if desired.
[0037] Optionally ESP 89 also has a conventional ESP motor sensor 103 mounted at its base. ESP sensor 103 measures parameters of the well fluid inside capsule 83 , such as intake and discharge pressure, motor temperature and vibration. ESP sensor 103 is connected electrically to the motor of ESP 89 , and the signal of ESP sensor 103 may be sent via ESP motor lead 91 and power cable to the surface. At the surface, circuitry separates the signal of ESP sensor 103 from the electrical power and provides a display.
[0038] If such an ESP sensor 103 is utilized, preferably a sensor lead 101 leads from reservoir sensor 99 alongside conduit 100 and sealingly through lower hanger 97 to ESP sensor 103 . In that way, the signal from reservoir sensor 99 is also superimposed on motor lead 91 and the power cable for reception at the surface. Alternately, reservoir sensor lead 101 could extend through upper hanger 88 and alongside tubing 85 to the surface, and ESP sensor 103 could transmit its signals in a conventional manner on the power cable. If an ESP sensor 103 is not utilized, the signals for reservoir sensor 99 would preferably be communicated through reservoir sensor lead 101 to the surface.
[0039] Although not shown, a dual ESP system could be employed in which the lower ESP is not located within a capsule, but is suspended below the capsule containing the upper ESP. This system could particularly be employed when a packer is not required. In addition, the capsule could be located within a subsea flowline rather than within a well, in which case the ESP or ESP's would be oriented approximately horizontal.
[0040] The invention has significant advantages. In the dual ESP environment, the operator can use one ESP until it breaks down, then operate with the second ESP. This substitution extends the time before the tubing must be pulled. The capsule supports the weight of the lower ESP or a downhole reservoir sensor, rather than imposing a load on the upper ESP. If desired, the dedicated line normally used for a downhole reservoir sensor could be eliminated and signals superimposed on the ESP power cable.
[0041] While the invention has been shown in only a few of its forms, it should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes without departing from the scope of the invention. | Upstream and downstream pump assemblies are mounted in a capsule having a bulkhead between the upstream and downstream pump assemblies, dividing the capsule into upstream and downstream chambers sealed from each other. In a dual operation mode, well fluid flows through the inlet of the capsule into the upstream chamber, where it is pumped to a first pressure level by the upstream pump assembly and discharged into the downstream chamber. The downstream pump assembly then pumps the well fluid to a second pressure level and discharges the well fluid out the outlet of the capsule. The assembly has also an upstream pump assembly only operational mode and a downstream pump assembly only operational mode. | 4 |
The present application is a continuation-in-part of U.S. patent application Ser. No. 692,825, for TOE ADJUSTMENT APPARATUS of Craig Ralph Pettibone, filed Jan. 18, 1985, , now U.S. Pat. No. 4,616,845, which is hereby incorporated by reference for all that it contains.
BACKGROUND OF THE INVENTION
The present invention relates generally to automotive products and, more particularly, to an apparatus for adjusting the camber in the steerable front wheels of a vehicle having an independent front wheel suspension system.
In a conventional independent front wheel suspension system for an automotive vehicle, each wheel is mounted independently of the other. Each rear wheel is rotatably mounted on a wheel spindle which is fixedly bolted to an integrally formed ball joint and wheel knuckle assembly. The wheel knuckle portion of this assembly is in turn bolted to the lower end of an elongate, generally vertically extending shock strut. The upper end of the shock strut is attached to a body side panel, typically by a rubber insulated top mount assembly with attachment bolts. Due to the length and resiliency of the shock strut, the spindle and attached wheel are, to a small degree, displaceable in a direction perpendicular to the longitudinal axis of the shock strut and are also torsionally (twistably) displaceable about this axis if otherwise unrestrained. In order to restrain this movement and hold the wheel in a fixed orientation with respect to the vehicle steering assembly, a longitudinally extending restraining member, generally referred to as a tie rod, and a laterally extending restraining member, generally referred to as a control arm, is affixed at one end to the ball joint and wheel knuckle assembly and at an opposite end to the vehicle steering assembly. Due to manufacturing tolerances, etc. in the front wheel assemblies, the "camber" of a wheel in some cases needs adjustment. The "camber" of a wheel refers to the relative angle which the central plane of the wheel makes with a vertical axis extending perpendicular to the surface on which the vehicle is supported. Ordinarily the wheel knuckle in such a front wheel suspension system is fixedly bolted to a pair of laterally extending flanges affixed to a lower end of the strut assembly. In such an arrangement, camber adjustment can only be effected by using the relative "slop" provided between the bolt assembly and the associated bolt holes in the strut flanges and wheel knuckle. However, this "slop" provides very little camber adjustment. In one prior art cam adjustment assembly, a cam bolt assembly which engages factory installed bosses on a strut flange is used to provide camber adjustment. However, most vehicles having the above described type of front wheel suspension system are not provided with such a cam adjustment assembly. It would be generally desirable to provide a cam adjustment assembly which could be easily retrofit on existing vehicles. However, providing bosses on a strut flange of the appropriate strength and tolerances for use with a cam bolt assembly is a very exacting and time-consuming operation which is beyond the skill of most automotive mechanics. Thus, prior to the present invention, there existed no convenient means for retrofitting a front wheel cam adjustment assembly on a vehicle having a front wheel suspension system of the type described above.
SUMMARY OF THE INVENTION
The present invention is directed to a cam bolt and cam plate assembly and method of installation thereof which enables a vehicle to be quickly and conveniently provided with an assembly for adjusting the front wheel camber.
The invention may comprise: a camber adjustment assembly for adjusting the camber of a wheel in a vehicle suspension system of the type ordinarily including a generally vertically extending strut assembly having an upper end attached to a vehicle frame assembly and having a pair of strut flanges positioned in parallel relationship with one another and projecting laterally outwardly from a lower end portion of the strut assembly; a wheel knuckle assembly mounted on the strut assembly and having a mounting portion positioned between the two strut flanges with a first hole therein adapted to closely, axially slidingly receive a first bolt therein which also passes through a first pair of coaxially aligned holes in the strut flanges in close axially sliding relationship and with a second hole therein adapted to closely, axially slidingly receive a second bolt which also passes through a second pair of coaxially aligned holes in the strut flanges in close axially sliding relationship, the first and second holes in the wheel knuckle mounting portion being vertically spaced apart, the first and second bolt holes in the wheel knuckle mounting portion and the first and second pair of holes in the strut flanges having axes positioned in substantially perpendicular relationship with the axis of rotation of a wheel supported on the wheel knuckle assembly, the camber adjustment assembly comprising: (a) parallel laterally extending slot means provided in said pair of strut flanges by lateral extension of said first pair of holes therein; (b) cam bolt means having a central longitudinal axis for providing adjustable pivotal movement of said wheel knuckle about said axis of said second hole in said wheel knuckle mounting portion, said cam bolt means being received in said parallel slot means in said strut flanges and in said first hole in said wheel knuckle with said central longitudinal axis thereof positioned coaxially with said axis of said first hole in said wheel knuckle assembly and being adjustably laterally movable in said parallel slot means in a first relatively loosened state of said cam bolt means and being relatively fixed with respect to said parallel slot means in a second relatively tightened state of said cam bolt means; (c) cam plate means mounted on at least one of said strut flanges and adapted to coact with said strut flange and said cam bolt for causing said relative lateral displacement of said cam bolt in said strut flange parallel slot means during rotational movement of said cam bolt means about said cam bolt means central longitudinal axis in said first relatively loosened state; (d) whereby the camber of a wheel mounted on said wheel knuckle assembly is adjustable through rotation of said cam bolt means about said cam bolt means central longitudinal axis.
The invention may also comprise: a method of adjusting the camber of a wheel in a vehicle suspension system of the type ordinarily including a generally vertically extending strut assembly having an upper end attached to a vehicle frame assembly and having a pair of strut flanges positioned in parallel relationship with one another and projecting laterally outwardly from a lower end portion of the strut assembly; a wheel knuckle assembly mounted on the strut assembly and having a mounting portion positioned between the two strut flanges with a first hole therein adapted to closely, axially slidingly receive a first bolt therein which also passes through a first pair of coaxially aligned holes in the strut flanges in close axially sliding relationship and with a second hole therein adapted to closely, axially slidingly receive a second bolt which also passes through a second pair of coaxially aligned holes in the strut flanges in close axially sliding relationship, the first and second holes in the wheel knuckle mounting portion being vertically spaced apart, the first and second bolt holes in the wheel knuckle mounting portion and the first and second pair of holes in the strut flanges having axes positioned in substantially perpendicular relationship with the axis of rotation of a wheel supported on the wheel knuckle, the camber adjustment assembly comprising: (a) removing the first bolt from the first hole in the wheel knuckle and the first pair of aligned holes in the strut flanges; (b) producing oppositely positioned, parallel, laterally extending slots in said pair of strut flanges having a vertical dimension approximately equal to the diameter of one of said first pair of holes and an expanded lateral dimension by lateral extension of said first pair of holes therein; (c) providing a cam bolt assembly comprising: an elongate threaded shaft portion having a central shaft longitudinal axis, a first end and a second end and having a diameter approximately equal to said first bolt; a cylindrical cam portion having a cylindrical axis positioned in parallel offset relationship with said shaft central longitudinal axis and positioned at said first end of said shaft portion; a bolt torquing portion positioned at a terminal portion of said first end of said shaft portion; a nut threadingly mountable on said second end of said threaded shaft portion; (d) providing a cam plate comprising: parallel cam engagement surfaces extending perpendicular to the direction of extension of said parallel laterally extending slots and spaced apart by a distance slightly larger than the diameter of said cylindrical cam portion of said cam bolt; a cam plate slot extending laterally between said cam engagement surfaces and having approximately the same configuration as the slots in the strut flanges and having strut flange engaging means for maintaining the cam plate in fixed relationship with an associated strut flange; (e) placing the cam plate in engagement with an outer surface of one of the strut flanges with the cam plate slot in aligned relationship with the laterally extending slot in the flange; (f) inserting the shaft portion of the cam bolt assembly through the slots in both strut flanges and the cam plate and through the first hole in the wheel knuckle mounting portion and positioning the cylindrical cam portion of the cam bolt assembly between the parallel cam engagement surfaces of the cam plate; (g) threading the cam assembly nut onto the cam shaft portion so as to prevent substantial axial movement of the cam bolt assembly and so as to allow rotational movement of the cam assembly; (h) maintaining the second bolt passing through the strut flanges and wheel knuckle in sufficiently loose engagement therewith so as to allow pivotal movement of the wheel knuckle assembly about the second bolt; (i) adjustably laterally moving the cam bolt assembly shaft portion within the slots in the strut flanges and cam plate so as to pivotally move the wheel knuckle assembly to adjust the camber of the associated wheel by selectively rotating the cam bolt assembly about the central longitudinal axis of the cylindrical cam portion thereof.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an exploded perspective view of a prior art front wheel suspension system.
FIG. 2 is a detailed side elevation view of a strut flange and wheel knuckle portion of the front wheel suspension system of FIG. 1.
FIG. 3 is an exploded perspective view of a cam bolt and cam plate assembly.
FIG. 4 is a side elevation view illustrating the modification of the strut flange illustrated in FIG. 2.
FIG. 5 is a perspective view illustrating a pair of modified strut flanges.
FIGS. 6 and 7 are cross sectional elevation views illustrating camber adjustments using the cam plate and cam bolt assembly illustrated in FIG. 3.
FIG. 8 is an exploded perspective view illustrating a second embodiment of a cam plate and an associated strut flange.
FIG. 9 is an exploded perspective view illustrating a third embodiment of a cam plate and associated strut flange.
DETAILED DESCRIPTION OF THE INVENTION
A camber adjustment assembly shown in FIG. 2 is adapted for adjusting the camber of a wheel assembly 60 of a prior art vehicle wheel suspension system of the type illustrated in FIGS. 1 and 2. Such a suspension system in general comprises a generally vertically extending strut assembly 12 having an upper end attached to a vehicle frame and body assembly 13. The strut assembly has a pair of strut flanges 28, 29 positioned in parallel relationship with one another which project laterally outwardly from the lower end of the strut assembly. The suspension systems also comprises a ball joint assembly 30 mounted on the strut assembly by a wheel knuckle portion 36 thereof positioned between the two strut flanges 28, 28 with a first hole 42 therein adapted to closely, axially slidingly receive a first bolt 46 therein which also passes through a first pair of coaxially aligned bolt holes 21, 23 in the strut flanges and with a second hole 44 in the knuckle portion adapted to closely, axially slidingly receive a second bolt 48 therein which also passes through a second pair of coaxially aligned holes 25, 27 in the strut flanges. The first and second holes 42, 44 in the wheel knuckle mounting portion are vertically spaced apart. The first and second bolt holes in the wheel knuckle portion, and the first and second pair of holes in the strut flanges having axes BB, CC positioned in substantially perpendicular relationship with the axis of rotation AA of wheel assembly 60 supported on the ball joint assembly 30.
The camber adjustment assembly, in general, comprises parallel laterally extending slots 94, 96 provided in the pair of strut flanges 28, 29 by lateral extension of one of the pair of holes, e.g. 21, 23, FIGS. 4 and 5; a cam bolt assembly 70, FIG. 3, for providing adjustable pivotal movement of the wheel knuckle assembly 30 about the axis CC of the second bolt 48 associated with the second hole 44 in the wheel knuckle portion 36, the cam bolt assembly being received in the parallel slots 94, 96 in the strut flanges and in the first hole 42 in the wheel knuckle portion and being adjustable laterally movable in the parallel slots during a first relatively loosened state of the cam bolt assembly and being relatively fixed with respect to the parallel slots in a second relatively tightened state of the cam bolt assembly; a cam plate, e.g. 82, FIG. 3, mounted on at least one of the strut flanges and adapted to coact with the strut flange and the cam bolt assembly for causing relative lateral displacement of the cam bolt assembly in the strut flange parallel slots during rotational movement of the cam bolt assembly about a central longitudinal axis FF thereof during the first relatively loosened state; whereby the camber of a wheel mounted on the ball joint assembly 30 is adjustable through this rotation of the cam bolt assembly as shown generally in FIGS. 6 and 7.
Having thus described the invention in general, specific features of the invention and the vehicle wheel suspension system for which it is adapted will now be described in detail.
FIG. 1 illustrates a portion of a front wheel suspension system of the type which is presently in use in a number of newer vehicles. The wheel suspension system includes a strut assembly 12 which is attached at an upper end thereof to the vehicle frame and body assembly 13 as further illustrated in FIG. 6. The strut assembly may include a strut mount 14, an upper spring seat 16, a seal 18, a dust boot 20, a coil spring 22, a lower spring seat 24, a strut 26, and a pair of laterally projecting parallel strut flanges 26, 28 which are fixedly mounted on the strut. In one embodiment which is further described below, the strut flanges may comprise a peripheral outwardly projecting lip portion 31, FIG. 2, which facilitates stabilizing of a cam plate 82 of the present invention. A wheel ball joint 30, which is adapted to rotatably support a wheel assembly 60, comprises a spindle 32 having an axis AA defining the rotational axis of the wheel. The spindle is mounted on a ball joint member 34 which is integrally connected with a wheel knuckle portion 36 by arm portion 38. The wheel knuckle portion 36 has an upper horizontally extending hole 42 therein and a lower horizontally extending hole 44 therein, each having an axis BB, CC respectively, positioned perpendicular to the wheel axis AA. Horizontally extending bolt assemblies 46, 48 are adapted to attach the knuckle portion 36 to the strut flanges 28, 29, as illustrated in FIGS. 1 and 2. A steering knuckle assembly 50 associated with a lower control arm assembly 52 is adapted to be connected with a lower portion of the assembly 30. A hub portion 59 of the wheel assembly 60 which is mountable on spindle 32 is also illustrated in FIG. 1.
As illustrated in FIG. 3, in one embodiment, the cam bolt assembly 70 of the present invention may comprise a cam bolt shaft portion 72 having a central longitudinal axis EE and having a threaded portion 74; a cam bolt head 75 and a cam bolt nut 76 threadingly receivable on the cam bolt shaft threads 74. A lock washer 78 may also be provided. A cylindrical cam body 80 having a central cylindrical axis FF positioned in parallel, slightly offset relationship, e.g. 1/4 inch, with axis FF, is fixedly mounted on shaft portion 72 adjacent cam bolt head 75 as by providing a flat surface 81 on shaft 72 and a complimentary hole in the cylindrical cam body (not shown) and by welding of the cylindrical cam body 80 to the shaft portion 72, or by other conventional attachment means well-known in the art. As also illustrated by FIG. 3, a cam plate 82 of the present invention may comprise a flat, vertically extending body portion 84 having a peripheral edge portion 85 which is adapted to be engaged at portions thereof by lip portion 31 on one of the strut flanges to prevent lateral movement of the plate, FIGS. 6 and 7. The plate is also prevented from moving laterally by shoulder portion 91 of a flange produced by the curvature of strut 26. Cam plate 82 also comprises cam body engaging flange portions 86, 88 and a cam plate laterally extending slot 90 having a minor axis dimension equal to the diameter of holes 21, 23. The cam plate may also be provided with a lower open ended slot 92 adapted to receive lower bolt 48 therein for facilitating holding of the cam plate in fixed relationship with respect to an associated flange, e.g. flange 28. As illustrated in FIGS. 4 and 5, in adapting a conventional pair of strut flanges such as 28, 29 having two pair of bolt holes 21, 23, 25, 27 therein, the cam plate 82 may be used as a template which is positioned with slot 90 in circumscribing relationship with one of the upper flange holes, e.g. 23, and extending generally laterally of the flange. Thereafter, a scribing instrument such as, e.g. pencil 93, is used to trace out a slot pattern on the flange. Thereafter, an identical operation is performed for the other flange. Next, the holes 21, 23 are extended laterally to provide a pair of parallel, oppositely positioned slots 94, 96 in the two flange portions 28, 29 which are identical in configuration to the slot 90 of the cam plate as shown by FIG. 5. Next, the cam bolt assembly 70 which is designed to be of comparable length and diameter to bolt assembly 46 is, in combination with cam plate 82, used to replace bolt assembly 46. To accomplish this result, the cam plate 82 is held against one of the slotted flanges at the same position as when used for a template, as illustrated in FIG. 15. The cam bolt is then inserted through the slot 90 in the cam plate and through both slots 94, 96 in the strut flanges, and also through the associated hole 44 in the knuckle assembly which is positioned between the two flanges. The cylindrical cam body 80 which has a diameter slightly less than the diameter between the two cam engaging flanges 84, 86 of the cam plate, is positioned between these two cam engagement portions, and the nut 76 is threaded onto shaft 72 in sufficiently tight relationship to hold the cam body 80 between the two cam plate flanges 86, 88 and yet sufficiently loosely to enable rotation of the cam assembly 70 through torquing of the cam assembly head 75. The lower bolt assembly 48 is loosened somewhat to enable the wheel knuckle 36 to be relatively pivoted thereabout. Next, the cam bolt assembly is rotated by torquing end 75 so as to move the cam bolt assembly shaft portion 72 laterally within the slots 90, 94, 96. Such lateral movement of the shaft 72 produces corresponding pivotal movement of the entire ball joint assembly 30 which in turn produces displacement of the plane of symmetry XX of the wheel assembly 60 relative a vertical axis YY, i.e. an axis disposed perpendicular to a surface 99 on which the wheel is supported. Thus, the top portion of the wheel assembly 60 may be moved relatively inwardly by lateral inward movement of the cam bolt shaft, as illustrated by FIG. 6 and may also be moved relatively outwardly by lateral outward movement of the cam bolt shaft, as illustrated in FIG. 7. When a desired camber position is achieved, both the bolt assembly 48 and the cam bolt assembly 70 are tightened by torquing of the associated nuts to lock the wheel assembly 60 into the desired camber position.
FIG. 8 illustrates a somewhat different embodiment 10 of a cam plate which comprises a flat body 112, a first cam engagement flange portion 114, and a second double flange 116 having a forwardly projecting cam engagement portion 118 and a rearwardly projecting strut flange engaging portion 120. The cam plate 110 also comprises an upper rearwardly projecting strut flange engaging flange 122 and has a laterally extending slot 124 extending between cam engagement portions 114 and 118. In this embodiment, a lower hole 126 is provided for accepting lower bolt assembly 48. This cam plate 110 coacts in an identical manner with the cam bolt assembly as the previously described cam plate and is held in relatively fixed relationship with respect to an associated flange 29 by the coaction of flange portions 116, 122 thereof with peripheral portions of the associated flange 29.
In yet another embodiment of a cam plate as illustrated at 140 in FIG. 9, the cam plate assembly 140 comprises a first plate portion 142 and an identical second plate portion 144 interconnected by a flexible plate portion 145 which is adapted to extend about and engage an associated strut flange connector portion 147 which connects the two strut flanges 28, 29. Each of the first plate portions 142 and the second plate portion 144 have a double thickness comprising a first plate thickness 146 and a second plate thickness 148. A cutout portion 150 in the first plate thickness provides cam engaging surfaces 152, 154 which are operatively associated with a slot 156 in the second thickness portion 148. Flanges 158, 160 may also be provided for engaging outer peripheral portions of strut flanges 28, 29. Thus, attachment portion 145 and flange portions 158, 160 enable this cam plate assembly 140 to remain in relatively fixed relationship with respect to strut flange portions 28, 29 during adjustable movement of cam bolt assembly 70, and the cam bolt assembly 70 coacts therewith in the same manner as described above with reference to the first cam plate embodiment 82.
It is contemplated that the inventive concepts herein described may be variously otherwise embodied and it is intended that the appended claims be construed to include alternative embodiments of the invention except insofar as limited by the prior art. | A camber adjustment device including a cam bolt and cam plate assembly and method of installation thereof which enables a vehicle to be quickly and conveniently provided with an assembly for adjusting the front wheel camber. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of earlier filed U.S. provisional application no. 60/526,679, filed Dec. 3, 2003.
BACKGROUND
This invention refers to the field of data communication and is in particular directed to redundant coding for error correction and detection.
Low-density parity check codes (LDPC) are a class of linear block codes which provide a near capacity performance on a large collection of data transmission and storage channels while simultaneously admitting implementable decoders. LDPC codes were first proposed by Gallager in his 1960 doctor dissertation (R. Gallager: “Low-density parity check codes”, IRE transformation series pp 21-28, January 1962). From practical point of view, the most significant features of Gallager's work have been the introduction of iterative decoding algorithms for which he showed that, when applied to sparse parity check matrices, they are capable of achieving a significant fraction of the channel capacity with relatively low complexity. Furthermore in LDPC codes the number of computations per bit and per iteration is independent of the block length.
A parity check matrix H defines the LDPC code. To each parity check matrix H exists a corresponding bipartite Tanner graph having variable nodes (V) and check nodes (C). A check node C is connected to a variable node V when the element h ij of the parity check matrix H is 1. The parity check matrix H comprises M rows and N columns. The number of columns N corresponds to the number N of codeword bits within one encoded codeword Y transmitted via a communication channel. The codeword transmitted via the communication channel comprises K information bits and M parity check bits. The number of rows within the parity check matrix H corresponds to the number M of parity check bits in the codeword. In the corresponding Tanner graph there are M=N−K check nodes C, one check node for each check equation, and N variable nodes, one for each codebit of the codeword.
FIG. 1 shows an example for a sparse parity check matrix H and the corresponding bipartite Tanner graph.
LDPC codes have the ability to achieve a significant fraction of the channel capacity at relatively low complexity using iterative message passing decoding algorithms. These algorithms are based on the Tanner graph representation of codes, where the decoding can be understood as message passing between variable nodes V and check nodes C in the Tanner graph as shown in FIG. 1 . Since messages are sent along the edges of the Tanner graph and are processed locally at each node of the Tanner graph one tries to keep the graph as sparse as possible to facilitate the subsequent iterative processing. Sparseness means that the number of edges between the variable nodes V and check nodes C is comparatively low, i.e. the corresponding check matrix H comprises a small number of ones.
How low density parity check LDPC codes do work is best demonstrated with a simple example as shown in FIGS. 2 , 3 .
FIG. 2 shows a simple Tanner graph for an LDPC code having four variable nodes V 1 , V 2 , V 3 , V 4 and two check or constraint nodes C 1 , C 2 . Accordingly the block length of the codeword N=4 and the number of parity checkbits M=2. Consequently the number of information bits k is N−M=2.
The code rate R which is defined as the ratio between the number k of information bits and the block length N (R=k/N) is in this example ½.
The parity check matrix H corresponding to the bipartite Tanner graph is shown in FIG. 2 .
For the LDPC code there exists a generator matrix G such that:
G·H T =Ø (1)
i.e. a product of the generator matrix G and the transposed corresponding parity check matrix H T is zero.
FIG. 3 shows two transceivers which are connected via the Additive White Gaussian Noise (AWGN) Channel. LDPC codes can be applied for any possible communication channel. During data transmission the communication channel corrupts the transmitted codeword so that a one become zero or vice versa. To diminish the bit error rate BER the transmitting transceiver comprises as shown in FIG. 3 an LDCP-encoder which multiplies an information bit vector i having K=2 information bits with the generator matrix G of the LDPC code. In the example of FIG. 2 the LDPC-encoder outputs an encoded bit vector b which is modulated by a modulator within the transceiver. In the given example the modulator transforms a low logical value zero of the coded bit vector b to a transmission bit X=1 and a logically high value of the encoded bit vector b is transformed to X=−1. The transmitting transceiver transmits the modulated codeword X via the communication channel to the receiving transceiver as shown in FIG. 3 . In the given example the communication channel is a binary input AWGN channel with a single sided spectral noise density NØ=8.
The receiving transceiver receives a codeword Y from the communication channel having N values.
The codeword Y is formed by adding noise to the transmission vector X:
Y=X +Noise (2)
The received codeword Y is demodulated and log-likelihood ratios (LLR) of the received codeword bits are calculated. For a binary input AWGN channel the log-likelihood ratios LLR are calculated as following:
P
j
=
ln
(
Pr
(
y
j
/
x
j
=
1
)
Pr
(
y
j
/
x
j
=
-
1
)
)
=
4
N
0
Y
j
(
3
)
FIG. 3 shows the log-likelihood ratios for N 0 =8, where each received codeword value is divided by two. The log-likelihood ratios LLR give an a-priori estimate that a received codeword bit has a predetermined value.
The estimates are forwarded to the LDPC decoder within the transceiver which performs the LDPC decoding process.
A conventional LDPC decoder employs a standard message passing schedule for decoding the LDPC code which is called a flooding schedule as described in F. R. Kschischang and B. J. Frey “Iterative decoding of compound codes by probability propagation in graphical models”, IEEE J. Select. Areas Commun., vol. 16. Pp. 219-230, 1998.
A schedule is an updating rule which indicates the order of passing the messages between the nodes of the Tanner graph. A conventional LDPC decoder according to the state of the art employs a message passing procedure such as a belief propagation algorithm BP based on a flooding schedule.
FIG. 4 shows a flowchart of a belief propagation BP procedure employing a flooding schedule according to the state of the art.
FIG. 5 shows a belief propagation BP decoding process using the standard flooding procedure as shown in FIG. 4 with the example of FIG. 3 .
As can be seen in FIG. 4 the received codeword Y is demodulated and log-likelihood ratios LLR are calculated.
In an initialization step S 1 the messages R cv from the check nodes C to the variable nodes V are set to zero for all check nodes and for all variable nodes. Further the messages Q vc from the variable nodes to the check nodes within the Tanner graphs are initialized with the calculated a-priori estimates P v or log-likelihood ratios.
Further as shown in FIG. 4 an iteration counter iter is set to zero.
In a step S 2 the messages R cv from the check nodes to the variable nodes QVC are updated. The calculation is performed by a check node processor as shown in FIG. 7 .
The calculation performed by the check node processor can be described as follows:
S
=
∑
v
∈
N
(
c
)
φ
(
Q
vc
)
for
all
v
∈
N
(
c
)
:
R
cv
new
=
φ
-
1
(
S
-
φ
(
Q
vc
)
)
wherein
φ
(
x
)
=
(
sign
(
x
)
,
-
log
tanh
(
x
2
)
)
φ
-
1
(
x
)
=
(
-
1
)
sign
(
-
log
[
tanh
(
x
2
)
]
)
wherein
the
sign
function
is
defined
as
:
sign
(
x
)
=
{
0
x
≥
0
1
x
<
0
}
(
4
)
In a step S 3 the messages Q vc from the variable nodes V to the check nodes C are updated by a symbol node processor as shown in FIG. 8 .
The updating of the symbol to check messages Q vc can be described as follows:
Q
V
=
P
V
+
∑
C
∈
N
(
v
)
R
CV
for
all
C
∈
N
(
v
)
Q
VC
=
Q
V
-
R
CV
(
5
)
FIG. 5 shows the calculated check to symbol messages R cv and symbol to check messages Q vc after the first iteration step.
In a step S 4 an estimate vector {circumflex over (b)} is calculated from Q v according to the definition of the sign function and a syndrome vector S is calculated by multiplying the parity check matrix H with the calculated estimate vector {circumflex over (b)}:
{circumflex over (b)} =sign( Q )
s=H·{circumflex over (b)} (6)
In a step S 5 the iteration counter iter is incremented.
In a step S 6 it is checked whether the iteration counter has reached a predefined maximum iteration value, i.e. a threshold value or whether the syndrome vector S is zero. If the result of the check in step S 6 is NO the procedure continues with the next iteration.
In contrast if the result of the check in step S 6 is positive it is checked in step S 7 whether the syndrome vector S is zero or not. If the syndrome vector S is not zero the iteration has been stopped because the maximum number of iterations has been reached which is interpreted as a decoding failure. Accordingly the LDPC decoder outputs a signal indicating the decoding failure. When it is realized that the syndrome vector S is zero the coding was performed successfully, i.e. the decoding process has converged. In this case the LDPC decoder outputs the last calculated estimated vector {circumflex over (b)} as the correct decoded codeword.
For the given example of FIG. 3 the LDPC decoder of the receiving transceiver outputs the estimate vector {circumflex over (b)}=(1010) T and indicates that the decoding was performed successfully. Note that the decoded estimate vector {circumflex over (b)} corresponds to the output of the LDPC encoder within the transmitting transceiver.
FIG. 6 shows a block diagram of a conventional LDPC decoder employing the belief propagation BP decoding algorithm and using the standard flooding schedule according to the state of the art.
The LDPC decoder according to the state of the art as shown in FIG. 6 receives via an input (IN) the calculated log-likelihood ratios LLRs from the demodulator and stores them temporarily in a RAM as initialization values.
This RAM is connected to several symbol node processors as shown in FIG. 8 . The output of the symbol node processors is connected to a further RAM provided for the Q vc messages. The Q vc -random access memory is connected to a ROM in which for every check node C of the Tanner graph the corresponding edges are memorized. This ROM controls a switching unit on the output side of the Q vc -RAM. The output of the switching unit is connected to several check node processors as shown in FIG. 7 which update the check to symbol messages R cv . The updated R cv messages are stored in a further RAM as shown in FIG. 6 . At the output side the R cv -RAM is connected to a further switching unit which is controlled by a further ROM in which for every variable node V within the Tanner graph the corresponding edges are stored. The output to the switching unit is connected to the symbol node processors.
The check node processors perform the update of the check to symbol messages R cv as described in connection with step S 2 of the flowchart shown in FIG. 4 . The updated check to symbol messages R cv are stored temporarily in the R cv -RAM as shown in FIG. 6 .
The symbol node processors perform the update of the symbol to check messages Q vc as described in connection with step S 3 of the flow chart shown in FIG. 4 . The updated symbol to check messages Q vc are stored temporarily in the Q vc -RAM.
The conventional LDPC decoder as shown in FIG. 6 further comprises a RAM for the output Q v messages calculated by the symbol node processors.
A convergence testing block computes the estimate {circumflex over (b)} and calculates the syndrome vector S as described in connection with step S 4 of the flow chart of FIG. 4 . Further the convergence testing block performs the checks according to steps S 5 , S 6 , S 7 and indicates whether the decoding was successful, i.e. the decoder converged. In case that the decoding was successful the last calculated estimate is output by the LDPC decoder.
The conventional LDPC decoder employing a flooding update schedule as shown in FIG. 6 has several disadvantages.
The number of iterations necessary until the decoding process has converged is comparatively high. Accordingly the decoding time of the conventional LDPC decoder with flooding schedule is high. When the number of decoding iterations defined by the threshold value is limited the performance of the LDPC decoder according to the state of the art is degraded.
A further disadvantage of the conventional LDPC decoding method and the corresponding LDPC decoder as shown in FIG. 6 is that checking whether the decoding has converged is complicated and it is necessary to provide a separate converging testing block for processing a convergence testing. The convergence testing block of a conventional LDPC decoder as shown in FIG. 6 calculates a syndrome vector S by multiplying the parity check matrix H with the estimate vector {circumflex over (b)}.
Another disadvantage of the conventional LDPC decoding method employing a flooding schedule and the corresponding LDPC decoder as shown in FIG. 6 resides in that the necessary memory size is high. The LDPC decoder as shown in FIG. 6 comprises four random access memories (RAM), i.e. the RAM for the input P v messages, a RAM for the output Q v messages, a further RAM for the Q vc messages and finally a RAM for the R cv messages. Furthermore the LDPC decoder includes two read only memories (ROM) for storing the structure of the Tanner graph.
Accordingly it is the object of the present invention to provide a method for decoding a low density parity check codeword and a corresponding LDPC decoder overcoming the above mentioned disadvantages, in particular providing a decoding method which needs a small number of iterations for decoding a received codeword.
SUMMARY
The invention provides a method for decoding a noisy codeword (Y) received from a noisy channel, as a result of transmitting through the noisy channel a codeword (b) having a number (N) of codeword bits which belongs to a length (N) low-density parity-check code for which a (M×N) parity check matrix (H) is provided and which satisfies H*b T =0, wherein codeword (Y) has a number (N) of codeword bits which consists of K information bits and M parity check bits,
wherein the parity check matrix H represents a bipartite graph comprising N variable nodes (V) connected to M check nodes (C) via edges according to matrix elements h ij of the parity check matrix H,
wherein the method comprises the following steps:
(a) receiving the LDPC codeword (Y) via a communication channel;
(b) calculating for each codeword bit of said received LDPC codeword (Y) an a priori estimate that the codeword bit has a predetermined value from the received codeword (Y) and from predetermined parameters of said communication channel;
(c) storing the calculated estimates in a memory as initialization variable node values;
(d) calculating iteratively messages on all edges of said bipartite graph according to the following serial schedule: in each iteration, for each check node (C) of said bipartite graph, for all neighboring variable nodes (V) connected to said check node (C) input messages (Q vc ) to said check node (C) from said neighboring variable nodes (V) and output messages (R cv ) from the check node (C) to said neighboring variable nodes (V) are calculated by means of a message passing computation rule.
The main advantage of the method according to the present invention is that the decoder converges in approximately half the number of iterations. As a result the performance of a LDPC decoder employing a serial schedule is better than the performance of a LDPC decoder employing a flooding schedule when the number of decoder iterations is limited as in any practical application. Alternatively, for a given performance and decoder throughput, approximately half the processing hardware is needed for a LDPC decoder employing a serial schedule compared to a LDPC decoder employing a flooding schedule. A further advantage of the LDPC decoding method according to the present invention and the corresponding LDPC decoder is that the memory size of the LDPC decoder according to the present invention is approximately half the size compared to the necessary memory size of the corresponding LDPC decoder according to the state of the art as shown in FIG. 6 .
The decoding method according to the present invention can be applied to generalized LDPC codes, for which the left and right side nodes in the bipartite graph represent constraints by any arbitrary code. In a preferred embodiment of the decoding method according to the present invention, the codes for which the decoding is applied are LDPC codes in which the left side nodes represent constraints according to repetition codes and the right side nodes represent constraints according to parity-check codes. In this preferred embodiment the generalized check node processor is as shown in FIG. 13 .
In a preferred embodiment of the decoding method according to the present invention the message passing procedure is a belief propagation (BP) procedure which is also known as the Sum-Product procedure.
In an alternative embodiment the message passing procedure is a Min-Sum procedure.
In a preferred embodiment of the method for decoding a low density parity check codeword according to the present invention the calculated a-priory estimates are log-likelihood ratios (LLR).
In an alternative embodiment the calculated a-priori estimates are probabilities.
In a preferred embodiment of the method for decoding a low density parity check codeword a decoding failure is indicated when the number of iterations reaches an adjustable threshold value.
In the following preferred embodiments of the method for decoding a low density parity check codeword and of a corresponding LDPC decoder are described with reference to the enclosed figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example of a sparse parity check matrix H and a corresponding bipartite Tanner graph according to the state of the art;
FIG. 2 shows a simple example of a bipartite Tanner graph according to the state of the art.
FIG. 3 shows transceivers connected via a data communication channel including a LDPC encoder and a LDPC decoder for decoding the LDPC code defined by the bipartite Tanner graph as shown in FIG. 2 .
FIG. 4 shows a flow chart of a belief propagation (BP)-LDPC decoder employing a flooding schedule according to the state of the art;
FIG. 5 shows several iteration steps for a belief propagation LDPC decoder using the standard flooding schedule according to the state of the art;
FIG. 6 shows a block diagram of a conventional LDPC decoder according to the state of the art,
FIG. 7 shows a circuit diagram of a check node processor within a conventional LDPC decoder as shown in FIG. 6 ;
FIG. 8 shows a circuit diagram for a symbol node processor as provided within an LDPC decoder according to the state of the art as shown in FIG. 6 ;
FIG. 9 shows a flowchart of a belief propagation (BP)-LDPC decoder using a serial schedule according to the present invention;
FIG. 10 shows several iteration steps of the LDPC decoding method according to the present invention for the simple example of FIGS. 2 , 3 ;
FIG. 11 shows a block diagram of a LDPC decoder employing a serial schedule according to the present invention;
FIG. 12 shows a table for comparing an LDPC encoding procedure using a conventional flooding schedule and an LDPC decoding method using an efficient serial schedule according to the present invention;
FIG. 13 shows a circuit diagram of a generalized check node processor as provided within an LDPC decoder according to the present invention as shown in FIG. 11 ;
FIG. 14( a ) shows a simulation result of the average number of iterations necessary for a conventional LDPC decoder employing a flooding schedule and an LDPC decoder according to the present invention employing a serial schedule, when the decoders are limited to 10 iterations;
FIG. 14( b ) shows a simulation result of the block error rate for a LDPC decoder according to the state of the art employing a flooding schedule and of an LDPC decoder according to the present invention employing a serial schedule, when the decoders are limited to 10 iterations;
FIG. 15( a ) shows a simulation result of the average number of iterations for a conventional flooding schedule LDPC decoder and an LDPC decoder according to the present invention employing a serial schedule, when the decoders are limited to 50 iterations;
FIG. 15( b ) shows the block error rate of a conventional flooding schedule LDPC decoder in comparison to an LDPC decoder according to the present invention employing a serial schedule, when the decoders are limited to 50 iterations;
FIG. 16 shows a flowchart of a general message passing decoder using a serial schedule according to the present invention.
DESCRIPTION
As can be seen from FIG. 9 the method for decoding a low density parity check codeword according to the present invention is performed on the basis of the received channel observation, i.e. the estimate values or estimates which indicate that a received codeword bit has a predetermined value. The estimates are calculated from the received codeword Y and predetermined parameters of the communication channel. The predetermined parameters of the communication channel are known. In an alternative embodiment of the present invention, if the parameters of the communication channel are unknown, a Min-Sum message-passing computation rule can be used, for which the parameters of the communication channel are not needed. A general message passing decoding procedure covering all embodiments is shown in FIG. 16 . In a preferred embodiment the estimates are the log-likelihood ratios of the received bits (LLR).
FIG. 11 shows a block diagram of a preferred embodiment of the LDPC decoder 1 according to the present invention. The LDPC decoder 1 has an input 2 and receives the a-priori estimate values based on the channel observations from the demodulator. The a-priori estimates are in a first embodiment calculated a-priori log-likelihood ratios (LLR). In an alternative embodiment the calculated estimates are a-priori probabilities.
In an initialization step S 1 as shown in FIG. 9 the calculated log-likelihood ratios or probabilities are stored temporarily as initialization values in a random access memory (RAM) 3 within the LDPC decoder 1 . The memory 3 is connected via a switching unit 4 to a block including several generalized check node processors. The generalized check node processors are also connected to a random access memory 7 . The memory 3 and the switching unit 4 are controlled by a read only memory 6 storing the bipartite Tanner graph of the used LDPC code. The generalized check node processors 5 are provided for updating the messages between the nodes of the Tanner graph. The generalized check node processors are provided with R cv messages from memory 7 and with Q v messages from memory 3 via the switching unit 4 . The generalized check node processors compute new updated values for the R cv and Q v messages. The updated R cv messages are stored back in memory 7 and the updated Q v messages are stored back in memory 3 via the switching unit 4 .
In a preferred embodiment of the present invention the generalized check node processors 5 output for each check node of the bipartite Tanner graph a sign bit S sign which is checked by a convergence testing block 8 which checks whether the LDPC decoder 1 has converged. In an alternative embodiment of the present invention a standard convergence testing block can be used as shown in FIG. 9 step S 4 (right alternative). When the converging testing block 8 realizes that the LDPC decoding process has converged it indicates this by outputting a success indication signal via output 9 of the LDPC decoder 1 . In case that no convergence could be achieved the LDPC decoder 1 indicates such a failure via output 9 . In case of success the LDPC decoder 1 outputs the decoded codeword calculated in the last iteration step via a data output 10 .
The generalized check node processor 5 of FIG. 11 is shown in more detail in FIG. 13 , wherein each generalized check node processor 5 includes a conventional check node processor shown in FIG. 7 and further subtracting and summing means.
In the initialization step S 1 shown in FIG. 9 the check to symbol messages R cv are initialized with the value zero for all check nodes and for all variable nodes. Further an iteration counter i is set to zero. A further counter (valid) is also initialized to be zero.
In a step S 2 a check node number c is calculated depending on the iteration counter i and the number of check nodes M within the Tanner graph:
c=i·mod m (7)
In step S 3 the generalized check node processors 5 perform the updating of the messages corresponding to check node c. In a preferred embodiment of the present invention the generalized check node processor implements a BP computation rule according to the following equations:
R cv new =φ −1 ( S −φ( Q vc temp ))
Q V new =Q vc temp +R CV new (8)
for all v∈N(C), wherein N(C) is the set of neighboring nodes of check node c
and wherein
Q
VC
temp
=
Q
V
old
-
R
CV
old
S
=
∑
v
∈
N
(
c
)
φ
(
Q
vc
temp
)
with
φ
(
x
)
=
(
sign
(
x
)
,
-
log
tanh
(
x
2
)
)
φ
-
1
(
x
)
=
(
-
1
)
sign
(
-
log
(
tanh
(
x
2
)
)
)
and
with
sign
(
x
)
=
{
0
x
≥
Ø
1
x
<
Ø
}
In an alternative embodiment of the present invention the generalized check node processor implements a Min-Sum computation rule according to the following equations:
for
all
v
∈
N
(
c
)
Q
vc
temp
=
Q
v
old
-
R
cv
old
for
all
v
∈
N
(
c
)
R
cv
new
=
∏
v
′
∈
N
(
c
)
/
v
(
-
1
)
sign
(
Q
v
′
c
temp
)
min
v
′
∈
N
(
c
)
/
v
{
Q
v
′
c
temp
}
Q
v
new
=
Q
vc
temp
+
R
cv
new
For each check node c of the bipartite Tanner graph and for all neighboring nodes connected to said check node c the input messages Q vc to the check node from the neighboring variable nodes v and the output messages R cv from said check node c to said neighboring variable nodes v are calculated by means of a message-passing computation rule. Instead of calculating all messages Q vc from variable nodes V to check nodes c and then all messages R cv from check node c to variable nodes v as done in the flooding schedule LDPC decoder according to the state of the art. The decoding method according to the present invention calculates serially for each check node c all messages Q vc coming into the check node C and then all messages R cv going out from the check node c.
This serial schedule according to the present invention enables immediate propagation of the messages in contrast to the flooding schedule where a message can propagate only in the next iteration step.
The messages Q vc are not stored in a memory. Instead, they are computed on the fly from the stored R cv and Q v messages according to Q vc =Q v −R cv .
All check nodes c which have no common neighboring variable nodes can be updated in the method according to the present invention simultaneously.
After the messages have been updated by the check node processors 5 in step S 3 the iteration counter i is incremented in step S 4 .
In one preferred embodiment of the present invention, in step S 3 an indicator
S sign = Sign ( ∑ v ∈ N ( c ) φ ( Q vc temp )
is calculated by the check
node processors 5 indicating whether the check is valid. In step S 4 if S sign =1 (check is not valid) the valid counter is reset (valid=0). In contrast when the check is valid (S sign =0) the valid counter is incremented in step S 4 .
In another embodiment of the present invention a standard convergence testing mechanism is used as shown in FIG. 16 , in which in step S 4 a syndrome s=H{circumflex over (b)} is computed where {circumflex over (b)}=sign(Q).
In step S 5 it is checked whether the number of iterations (i/m) is higher than a predefined maximum iteration value, i.e. threshold value or whether the valid counter has reached the number of check nodes m. If the result of the check in step S 5 is negative the process returns to step S 2 . If the result of the check in step S 5 is positive it is checked in step S 6 whether the valid counter is equal to the number M of check nodes. If this is not true, i.e. the iteration was stopped because a maximum iteration value MaxIter has been reached the LDPC decoder 1 outputs a failure indicating signal via output 9 . In contrast when the valid counter has reached the number of check nodes M the decoding was successful and the LDPC decoder 1 outputs the last estimate {circumflex over (b)} as the decoded value of the received codeword.
{circumflex over (b)} =Sign( Q )
FIG. 10 shows a belief propagation decoding procedure performed by the LDPC decoder 1 according to the present invention using the algorithm shown in FIG. 9 for the simple examples of FIGS. 2 , 3 .
The calculated log-likelihood ratios LLRs output by the demodulator P=[−0.7 0.9 −1.65 −0.6] are stored as decoder inputs in the memory 3 of the LDPC decoder 1 . The memory 7 which stores the check to symbol messages R cv is initialized to be zero in the initialization step S 1 .
In the given example of FIG. 10 the LDPC decoder 1 performs one additional iteration step (iteration 1 ) before convergence of the decoder 1 is reached. For each check node c 1 , c 2 the symbol to check messages Q vc are computed or calculated for each variable node V which constitutes a neighboring node of said check node c. Then for each variable node which is a neighboring node of said check node c the check to symbol messages R cv and the a-posteriori messages Q v are updated using the above mentioned equations in step S 3 of the decoding method and stored in memory 7 and memory 3 respectively.
The convergence testing block 8 counts the valid checks according to the sign values S sign received from the generalized check node processor. A check is valid if S sign =0. Once M consecutive valid checks have been counted (M consecutive Ssign variables are equal to 0), it is decided that the decoding process has converged and the actual estimate value {circumflex over (b)}=Sign(Q) is output by terminal 10 of the LDPC decoder 1 .
Alternatively, the standard convergence testing block used by the state of the art flooding decoder can be used for the serial decoder as well. The standard convergence testing block computes at the end of each iteration a syndrome vector s=Hb T , where b=sign(Q). If the syndrome vector is equal to the 0 vector then the decoder converged. In the given example, the serial decoder converges after one iteration.
By comparing FIG. 10 with FIG. 5 it becomes evident, that the decoding method according to the present invention ( FIG. 10 ) needs only one iteration step whereas the conventional LDPC decoding method ( FIG. 5 ) which uses the flooding schedule needs two iteration steps before the decoder has converged.
Accordingly one of the major advantages of the LDPC decoding method according to the present invention is that average number of iterations needed by the LDPC decoder 1 according to the present invention is approximately half the number of iterations that are needed by a conventional LDPC decoder using a flooding schedule.
FIG. 14( a ), FIG. 15( a ) show a simulation result for a block length N=2400 and an irregular LDPC code over a Gaussian channel for ten and for fifty iterations. As becomes evident from FIGS. 14( a ), 15 ( a ) the necessary number of iterations for an LDPC decoder 1 according to the present invention using a serial schedule is significantly lower than the number of iterations needed by a conventional LDPC decoder using a flooding schedule.
Further the performance of the LDPC decoder 1 according to the present invention is superior to the performance of a conventional LDPC decoder using a flooding schedule. FIGS. 14( b ), 15 ( b ) show a simulation result of the block error rate BER of the LDPC decoder 1 in comparison to a conventional LDPC decoder for ten and fifty iterations. As can be seen from FIGS. 14( b ), 15 ( b ) the block error rate BLER performance of the LDPC decoder 1 according to the present invention is significantly better than the block error rate BLER performance of the conventional LDPC decoder using a flooding schedule when the number of iterations that the decoder is allowed to perform is limited.
A further advantage of the LDPC decoder 1 according to the present invention as shown in FIG. 11 is that the memory size of the memories 3 , 7 within the LDPC decoder 1 according to the present invention is significantly lower (half the memory size) than the memory size of the random access memories (RAM) provided within the state of the art LDPC decoder shown in FIG. 6 . Since in the LDPC decoder 1 a serial schedule is employed it is not necessary to provide a memory for the Q vc messages. Since the same memory which is initialized with messages P v is used also for storing the messages Q v the LDPC decoder 1 having an architecture which is based on the serial schedule requires only a memory for E+N messages (while the state of the art LDPC decoder shown in FIG. 6 requires memory for 2E+2N messages), where E is the number of edges in the code's Tanner graph (usually, for capacity approaching LDPC codes E˜=3.5N).
A further advantage of the LDPC decoder 1 employing the decoding method according to the present invention is that only one data structure containing N(C) for all check nodes c∈C is necessary. In the standard implementation of a conventional LDPC decoder using the flooding schedule two different data structures have to be provided requiring twice as much memory for storing the bipartite Tanner graph of the code. If an LDPC decoder using the conventional flooding schedule is implemented using only a single data structure an iteration has to be divided into two non overlapping calculation phases. However, this results in hardware inefficiency and increased hardware size.
It is known that LDPC codes which approach the channel capacity can be designed with concentrated right degrees, i.e. the check nodes c have constant or almost constant degrees. In such a case only the variable node degrees are different. While the conventional flooding LDPC decoder for such irregular codes needs a more complex circuitry because computation units for handling a varying number of inputs are needed a implemented LDPC decoder according to the present invention remains with the same circuit complexity even for such irregular codes. The reason for that is that the LDPC decoder 1 employing the serial schedule requires only a check node computation unit which handles a constant number of inputs.
A further advantage of the LDPC decoder 1 in comparison to a conventional LDPC decoder is that a simpler convergence testing mechanism can be used. Whereas the LDPC decoder according to the state of the art has to calculate a syndrome vector S, the indicator S sign of the LDPC decoder 1 is a by-product of the decoding process. In the convergence testing block 8 of the LDPC decoder 1 according to the present invention it is only checked whether the sign of the variable S sign is positive for M consecutive check nodes. And there is no need to perform a multiplication of the decoded word with the parity check matrix H at the end of each iteration step in order to check whether convergence has been reached.
Iterations of a LDPC decoder employing a flooding schedule can be fully parallised, i.e. all variable and check node messages are updated simultaneously. The decoding method according to the present invention is serial, however, the messages from sets of nodes can be updated in parallel. When the check nodes are divided into subsets such that no two check nodes in a subset are connected to the same symbol node V then the check nodes in each subset can be updated simultaneously.
The decoding schedule for low density parity check codes according to the invention out-performs the conventional approach in terms of complexity with no degradation in performance. With the method for decoding a low density parity check codeword according to the present invention the updating of the variable nodes is performed according to the serial schedule which propagates the information between the nodes much more rapidly. As a consequence the average number of iterations needed for successful for decoding is asymptotically half of the number needed in the conventional flooding schedule with no degradation in the performance. Another implementation advantage of the LDPC decoder 1 according to the present invention is that smaller memories are required and that the convergence testing mechanism is simplified.
FIG. 12 shows a table which shows the flooding schedule used by the conventional LDPC decoder in comparison to the efficient serial scheduling scheme as employed by the LDPC-decoding method according to the present invention. | A method for decoding a noisy codeword (y) received from a communication channel as the result of a LDPC codeword (b) having a number (N) of codeword bits is disclosed. Each codeword bit consists of k information bits and M parity check bits. The product of the LDPC codeword b and a predetermined (M×N) parity check matrix H is zero (H*bT=0) wherein the parity check matrix H represents a bipartite graph comprising N variable nodes (V) connected to M check nodes (C) via edges according to matrix elements hij of the parity check matrix H.—The method comprises receiving the noisy LDPC codeword (y) via said communication channel and calculating for each codeword bit (V) of said transmitted LDPC codeword (b) an a-priori estimate (Qv) that the codeword bit has a predetermined value. The method also comprises calculating iteratively messages on all edges of said bipartite graph according to a serial schedule and a message passing computation rule. | 7 |
This instrument, filed under 37 CFR 1.53(b) and 1.78, invoking the provisions of 35 U.S.C. 120, is a Continuation-in-Part of presently copending application Ser. No. 10/602,928 entitled “Exercise Bar and Cord Connector”, filed Jun. 23, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Exercise equipment
2. Description of the Prior Art
Occasionally a descriptive term in this application may be shortened so as to recite only a part rather than the entirety thereof as a matter of convenience and to avoid needless redundancy. In instances in which that is done, applicant intends that the same meaning be afforded each manner of expression. Thus, the term bar separation release button 31 might be used in one instance but in another, if meaning is otherwise clear from context, expression might be shortened to release button 31 or merely button 31 . Any of those forms is intended to convey the same meaning.
The term attach or fasten or any of their forms when so used means that the juncture is of a more or less permanent nature, such as might be accomplished by bolts, welds or adhesives. Thus it is stated herein that one side of the prior art resilient integral finger 348 partially cut out of the bar's body 310 from which it 348 was formed remained attached to it 310 . A connection in which one object is easily removed from another is described by the word emplace, as where it is stated herein that in preparation for the snap-fit 32 connection, the intervening section's insertion end 12 is slid into or emplaced within one portion of the exercise bar's body 310 . A connection in which two objects, though not attached, could be separated only with at least some degree of difficulty is referred to herein as one of rigid emplacement. The snap-fit means of connection 32 , once completed between the intervening section which is the subject hereof and the exercise bar's body 310 is stated herein to be such a connection. Employment merely of the words connector join or forms derived from their roots is intended to include the meaning of any of those terms in a more general way.
The word comprise may be construed in any one of three ways herein. A term used to describe a given object is said to comprise it, thereby characterizing it with what could be considered two-way equivalency in meaning for the term. Thus, it is stated that the bar separation seam 340 comprised the dividing place between the two parts of the bar's elongated extension or body 310 , meaning that the place indicated actually was that seam 340 . The term comprise may also be characterized by what might be considered one-way equivalency, as when it is stated herein that the grasshopper leg spring 347 in conjunction with a spring seat 344 within the bar's body 310 sometimes comprised the snap-fit means 342 provided in certain of the prior art exercise bar body 310 versions, meaning that in the given instance, that object is itself the type of means 342 employed. This use of the word has a generic sense to it. That is, the grasshopper leg spring 347 and spring seat 344 will always—at least potentially—be one kind of snap-fit means 342 but snap-fit means may be the grasshopper spring 347 and seat 344 in one case but something else such as a resilient integral finger 348 in another. However, the word comprise may also be used to describe a feature which is part of the structure or composition of a given object. Thus, the prior art release button 341 is indicated to have comprised as a component thereof, a protrusion molded upon it shaped to fit the button opening 343 of the bar's body 310 . The meaning in the respective cases is clear from context, however. Accordingly, modifying words to clarify which of the three uses is the intended one seem unnecessary.
The word proximate with reference to two objects herein need not entail true nearness but may express a relative relationship between them. Thus, the release button 31 is said to be disposed proximate the receptor end 11 of the subject matter hereof while the button opening 33 is indicated to proximate the insertion end 12 thereof. The proximity in both cases is, nevertheless, such as to allow substantial clearance at those sites, however.
Terms relating to physical orientation such as top or bottom, upper or lower, refer to the positioning of the assembly in the manner it would be observed during a commonly practiced mode of operation. This convention has been adopted as a matter of convenience in discussing orientation and as shown in the drawings. Thus, the release button 31 is stated to be preferably disposed upon the bar body's uppermost surface 310 where it is most accessible to the operator; and that the cord stretching recess 49 , when present, is described as being disposed longitudinally along the underside of the intervening section. The use of the terms in this manner must, of course, be interpreted so as to be equally understood regardless of what attitude the assembly is positioned—such as, for example, when it is inverted in switching from one mode of exercise to another. In such instances, it is appropriate to specifically qualify what is meant by such recitations as on top of or beneath.
The word longitudinal and derivations thereof refer merely to the longest dimension of a given object, provided it has one. Thus, it is stated herein that the cord stretching recess 49 along the intervening section's underside is longitudinal in disposition. This merely means that the recess 49 is oriented along the length of the structure.
In recent decades, popularity of exercise bar assemblies 300 has increased dramatically. The currently available models 300 , while useful for many, could best be lengthened to suit the exercise needs of some who use them 300 . Following that line, one might devise a short bar for youths, one of medium length for women and yet an elongated one for men. Better still would be an exercise bar capable of having its body itself 310 easily extended in length.
It readily occurs to one that an exercise bar's body 310 which can be taken apart for packing, storage or other convenience, might accept an intermediate piece to provide the desired length. Two part separable models, herein considered to be part of the prior art, have, in fact, already been provided by the applicant hereof.
Some of the prior art take-apart assemblies 300 additionally comprised a button opening 343 and snap-fit means of connection 342 . Such means 342 usually comprised either a grasshopper leg spring 347 connected both to a separation release button 341 and a separation spring seat 344 ; or the more preferred plastic memory resilient integral finger 348 . Upon depressing the button 341 , it 341 was cleared from an otherwise obstructing site, permitting opposing portions of the exercise bar's elongated body 310 to separate from one another 310 . Upon rejoining the portions 310 and releasing the button 341 , causing it 341 to co-engage a button opening 343 , the snap-fit connection means 342 returned the button 341 to its obstructing disposition thereby preventing unintended separation of the portions 310 .
The bar separation seam 340 comprised the dividing place between the two parts of the bar's elongated extension or body 310 . When the two pieces were interconnected, the release button 341 was disposed to emerge through the button opening 343 —merely an orifice in the body of the longitudinal extension 310 . The two pieces were usually shaped to slide together in telescope-like fashion as shown in FIGS. 16 and 17 . The separated members of the exercise bar's body 310 may be considered to comprise a bar's receptor end 311 and a bar's insertion end 312 . The bar body's receptor end 311 is that at which its button opening 313 is disposed. The body's insertion end 312 is that at which its separation release button 311 is disposed. These respective sites 311 , 312 become important in connection with the subject matter hereof, ante.
The grasshopper leg spring 347 —so named because of its strength and resilience when bent and seated as shown there—together with a spring seat within the bar's body 310 sometimes comprised the snap-fit means 342 provided in certain of the prior art exercise bar body 310 versions. It 347 was connected to the release button 341 in any known manner; often by impingement within a hollow disposed within the button 341 . The mid-portion of the spring 347 could be bent to accomplish this fitted connection. The ends of the spring 347 were then preferably bent as shown and fitted along portions within the body 310 to provide a firm tensioning seat. When the button 341 was depressed, it 341 cleared the opening 343 and the two body 310 pieces could be pulled apart at the separation seam 340 . When the pieces were slid back together, by reason of the tension provided by the grasshopper leg spring 347 , the button 341 popped through the opening 343 the instant the two 341 , 343 became aligned.
The resilient integral finger 348 comprised merely a somewhat elongated partial cut-out in the bar's body 310 , permitting it 348 to be pushed downward so that its 348 inherent plastic memory provided it 348 a springboard-like character. Thus, when released, it 348 popped back into its 348 previous position. The release button 341 comprised a protrusion molded upon it shaped to fit the button opening 343 so that the mechanism produced the same result as that of the grasshopper leg spring 347 . The cut-out, had the shape of three sides of a rounded rectangle. One of the finger's 348 short sides—uncut—of course, remained attached to the body 310 from which it 348 was formed. This version of snap-fit means 342 was understandably preferred in large part because of its 348 lower production cost.
One may conceive of various other snap-fit means 342 , of course. Over the years, a number of longitudinal pole or pipe extension schemes have emerged which would provide an acceptable connection. Although great effort is not required to snap-fit the body's 310 pieces together or pull them apart once the release button 341 is depressed, because of the body's 310 structural integrity, the connection could properly have been considered one of rigid emplacement.
Certain modes of exercise were also made possible in the prior art exercise bar assembly 30 by the usual addition of an underlying cord stretching recess 371 in the bar's body 310 , a feature which permitted the stretchable exercise cord 200 to seat within it 371 against the bar's body 310 with the ends of the cord 200 anchored elsewhere.
U.S. Pat. No. 1,456,304 issued to Fritschka represented in part a fairly early version of prior art snap-fit means 342 in which a spring supported button 341 was urged through a button opening 343 to lock together two parts of a combination walking stick and outdoor stool. U.S. Pat. No. 2,937,653 issued to Danciart, et al provided similar means 342 for the take-apart center-post of the familiar beach umbrella. These useful constructions did not immediately translate over into any of the exercise bar assemblies 300 . U.S. Pat. No. 4,316,610 issued to Hinds, the inventor herein, provided an exercise bar assembly 300 featuring snap-fit means 342 entirely within the bar's body 310 , so that there was no exterior projecting button 341 to depress. The two portions of the bar's body 310 were merely pushed together or pulled apart to forcibly compress or expand the supporting spring. Because the put-together and take-apart works was ensconced entirely inside the bar's body 310 , repair or replacement of a failed spring would provide difficulty. Looking beyond the differences between the snap-fit means 342 therein from that 342 provided by the subject matter hereof, however, that patent may be properly recognized as prophetic in expressing the possibility of incorporating within the length of the bar's body 310 one or more sections to be added to the two already present.
As merit-worthy as the exercise bar assemblies 300 of prior art were, such additional section accommodation would be highly beneficial where increased bar body 310 length is sought after. The more recent prior art assemblies 300 offer considerable benefit to exercise enthusiasts in meeting the needs and objectives relevant. Some still remain to be addressed, however.
SUMMARY OF THE INVENTION
In its most important aspect, the invention is a construction which may be emplaced for connection within the mid-portion of a separable exercise bar's body 310 . Emplacement is effected at the bar's separation seam 340 by disconnecting respective parts of the body 310 and snap-fitting the structure into it, thereby increasing the bar's overall length. The separation and rejoining means already in place within the body 310 is duplicated and used within this intermediate structure. Thus, duplications of the exercise bar's separation release button 341 and button opening 343 are made to appear at opposing ends of the intervening section. Thus, the section's insertion end 12 may be slid into the bar's body 310 and the bar's separation release button 341 caused to pop in snap-fit fashion into the section's button opening 33 ; and the bar body 310 may be slid into the section's receptor opening 11 and the section's separation release button 31 caused to similarly connect with the bar body's 310 button opening 343 .
The button 341 is connected to known prior art snap-fit structures preferably comprising either a grasshopper leg spring 47 and spring seat 44 or a resilient integral finger 48 molded within the structure itself.
By thus snap-fitting the intermediate section into place, the exercise bar's body 310 is effectually lengthened.
An orientation assuring track 45 and orientation juncture groove 46 are also present to aid in the section's emplacement and retention.
BRIEF DESCRIPTION OF THE DRAWINGS
Solid lines in the drawings represent the invention. Dashed lines represent either non-inventive material, that not incorporated into an inventive combination hereof and which may be the subject of another invention, or that which although so incorporated, lies beyond the focus of attention.
FIG. 1 represents a cut-away view of an exercise bar assembly 300 wherein the intervening section therefor is connected by snap-fit means at each of its ends to the bar's elongated body 310 .
FIGS. 2-12 are perspective depictions of exercise bar assemblies 300 capable of accommodating the subject matter of this application as respective improvements thereto. All were previously invented by the applicant hereof and most are the subject matter of pending applications. The assembly disclosed by FIG. 9 comprises that of an expired patent. Although certain portions of all are carried over in one case or another as a novel part of the combination which is the subject hereof, for the sake of discussion the entirety or wholeness of each of those assemblies is herein designated prior art.
FIGS. 13 and 14 illustrate embodiments of the invention positioned for connection by separation snap-fit means 32 to the elongated body 10 portions of respective exercise bars. The means 32 is shown in FIG. 13 to comprise a grasshopper leg spring 347 and in FIG. 14 , a resilient integral finger 34 .
FIGS. 15 and 16 address prior art versions of embodiments in which snap-fit means 32 were employed to join opposing parts of the exercise bar's elongated body 10 .
FIG. 17 features a resilient integral finger 34 as prior art snap-fit means 32 .
FIG. 18 comprises an orientation securing track 345 and orientation juncture groove 346 as convenient prior art means of aligning the pieces of the exercise bar's elongated body 10 when snap-fitted 32 together.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The subject of this application is an intervening section for an exercise bar body 310 , the section is in the main comprised of a separation release button 34 , a button opening 33 and separation snap-fit means 32 . This combination permits the section to be snap-fitted into the mid-portion of a prior art exercise bar body 310 , itself 310 already comprising snap-fit means 342 of its 310 own by which it 310 was already capable of being separated for storage, portability or other convenient handling. By reason of its emplacement, the snapped-in section effectually lengthens the bar's body 310 .
The intervening section is configured slightly elongated, thereby comprising an insertion end 11 and a receptor end 12 . Its interior is preferably configured to match the interior of the particular exercise bar body 310 it is designed to be joined to. Thus, if the bar's body 310 has a hollow aspect, the intervening section is also preferably hollowed. It should be recognized, of course, that an exercise bar body 310 —and for that matter, the subject matter hereof—may be generally of solid configuration comprising merely a hollowed sector allowing space to accommodate the snap-fit means referred to supra. Completely hollow construction, however, is less expensive to manufacture, provides the more sought-after lightweight characteristic and is generally simpler to produce in the molding process.
The intervening section's release button 31 is disposed proximate the section's insertion end 11 and the section's button opening 33 proximate its receptor end 12 . Each 31 , 33 should be set back sufficiently to assure some degree of security upon the joining of the respective parts.
The intervening section's separation release button 31 is disposed to work in conjunction with the button opening 343 of the bar's body 310 , disposed upon the section—preferably upon its uppermost surface where it is readily accessible to the operator—and configured to operate in the same manner as the bar body's release button 341 , so that when the intermediate section's insertion end 11 is joined to the body's separation receptor end 311 , the section's release button 31 will snap through the body's button opening 343 in the same manner the body's release button 341 would have if the intervening section were not in place.
Conversely, an intermediate section's button opening 33 is disposed to work in conjunction with the separation release button 341 of the bar's body 310 . The button opening 33 is disposed upon the intervening section and configured to operate in the same manner as the bar body's button opening 343 , so that when the section's receptor end 12 is joined to the bar body's insertion end 312 , the body's release button 341 will snap through the intervening section's button opening 33 in the same manner it 341 would have with the body's button opening 343 if the intervening section were not in place.
Preferably, the fit between the intervening section's ends 11 , 12 and that of the bar body's separation ends 311 , 312 are both snug and the respective members joined are, therefore, properly stated to be mated in configuration and size to the cross-sectional configuration and size of the exercise bar's body 310 . Moreover, the relationship of any separation release button 31 , 341 to its respective button opening 33 , 343 is such that upon proper alignment, the button 31 , 341 is urged through a respective button opening 33 , 343 by snap-fit means, thereby retaining the joined members.
Just as the separation seam 340 comprised merely the dividing place between the two parts of the prior art bar's elongated body 310 , snap-fitting the intermediate section in place transforms that singular seam 340 into two sectional separation seams 38 , 39 —one at each of the section's ends 11 , 12 , respectively. That nearest the insertion end 11 is herein designated the section's insertion separation seam 38 ; that nearest its receptor end 12 , its receptor separation seam 39 .
As was the case with the prior art exercise bar's snap-fit means of connection 342 , that 32 of the intervening section preferably comprises a release button 31 and either a grasshopper leg spring 47 connected both to it 31 and a separation spring seat 44 ; or the more preferred resilient integral finger 48 . Upon depressing the button 31 , it 31 is cleared from an otherwise obstructing site, permitting the intervening section at its receptor end 11 to separate from the exercise bar's elongated body 310 . A similar effort is required—depression of the exercise bar's button 341 to clear it 341 from the otherwise obstructing site comprising the intervening section's button opening 33 —to permit separation of the intervening section at its insertion end 12 from the bar's body 310 . Upon sliding the pieces back together the portions— 31 , 310 and 33 , 310 —become rejoined. This is accomplished by two simple operations, identical but at different sites. The section's depressed button 31 is released, causing it 31 to co-engage or pop through the bar body's opening 343 the instant the two 31 , 343 become aligned. This snap-fit connection means 32 returns the button 31 to its obstructing disposition thereby preventing unintended separation of the intervening section's receptor end 11 from the bar's body 310 . Similarly, releasing the bar body's depressed button 341 and causing it 341 to co-engage the intervening section's button opening 33 , by reason of the tension provided by either the grasshopper leg spring 47 or the resilient integral finger 48 reconnects the section's insertion end 12 to the body 310 .
The grasshopper leg spring 47 and separation spring seat 44 when employed herein, comprise the same configuration, function and relative disposition as their counterparts 347 within any of the prior art exercise bar assemblies 300 . Similarly, the resilient integral finger 48 , when employed herein, comprises the same configuration, function and relative disposition as their counterparts 348 for those models. It should be readily apparent, of course, the same is true of the section's separation release button 31 and button openings 33 vis-a-vis their counterparts 341 , 343 , respectively, in the prior art constructions.
As in prior art, the grasshopper leg spring 47 —so named because of its strength and resilience when bent and seated as shown there—is connected to the release button 31 in any known manner; preferably by impingement within a hollow disposed within the button 31 . The mid-portion of the spring 47 may be bent to accomplish this fitted connection. The ends of the spring 47 are then preferably bent as shown and fitted along portions within the body 310 to provide firm tension at the separation seat 44 within the section, supra.
The resilient integral finger 48 , similarly as in prior art, comprises merely a somewhat elongated partial cut-out in the intervening section, permitting it 48 to be pushed downward so that its 48 inherent plastic memory provides it 48 a springboard-like character. Thus, when released, it 48 pops back into its previous position. The release button 31 comprises a protrusion molded upon it shaped to fit the bar body's button opening 343 so that the mechanism produces the same result as that of the grasshopper leg spring 47 . The cut-out, has the shape of three sides of a rounded rectangle. One of its 48 short sides—uncut—of course, remains attached to the intervening section from which it 48 is formed. This version of snap-fit means 32 is preferred in large part because of its 48 lower production costs.
One may conceive of various other snap-fit means 32 , of course. Although great effort is not required to snap-fit the pieces together or pull them apart once the release buttons 31 , 341 are depressed, because of the structural integrity of the bar body 310 and the intervening section which is the subject hereof, the connection may properly be considered one of rigid emplacement as it has been at prior art.
If the exercise bar body 310 comprises a cord stretching recess 371 , a similarly configured sectional cord stretching recess 49 is disposed longitudinally upon the intermediate section's underside so that the surfaces match when the section is snap-fitted into place. This is consistent with the preference herein that the intervening section's configuration be consistent with that of the exercise bar's body 310 .
An orientation assuring track 45 and orientation juncture groove 46 are also present to aid in the section's emplacement and retention. | An intermediate section is inserted into the mid-portion of an exercise bar's body to increase its effectual length. The section is locked in place at each end thereof by the protrusion of a separation release button in one of the connecting members through a button opening in the member it is joined to. The button is retained in place either by a grasshopper leg spring supported upon a spring seat or a plastic memory resilient integral finger as snap-fit connection means. | 0 |
FIELD OF THE INVENTION
The invention is concerned with a controller for a linear accelerator, particularly but not exclusively for use in an ion implanter.
BACKGROUND OF THE INVENTION
A linear accelerator structure accelerates charged particles of a specific mass/charge ratio which are injected into the accelerator at a specific injection energy. Radio frequency (rf) linear accelerators have been known for many years from the field of nuclear physics where they have been employed to accelerate heavy ions. More recently, rf accelerators have been used in semiconductor wafer processing. Typically, a beam of ions of a required species (such as boron, phosphorous, arsenic or antimony) is produced and directed at a wafer so that the ions become implanted under the surface of that wafer. Although electrostatic acceleration systems are suitable for producing beams of singly charged ions of 200 keV or more, it has been recognised that the desirable characteristics (for certain applications) of relatively high beam current and relatively high beam energy can be achieved by including an rf accelerator in the ion implanter device.
The use of rf linear accelerators for implantation of ions into semiconductor wafers has been suggested at least since 1976 in “Upgrading of Single Stage Accelerators” by K. Bethge et al, pages 461-468, Proceedings of the Fourth Conference on the Scientific & Industrial Applications of Small Accelerators, North Texas State University, Oct. 27-29, 1976; and in “Heavy Ion Post-acceleration on the Heidelberg MP Tandem Accelerator”, edited by J. P. Wurm, Max Planck Institute for Nuclear Physics, Heidelberg, May 1976. U.S. Pat. No. 4,667,111 discloses an ion implanter incorporating a radio frequency linear accelerator to provide ultimate beam energies as high as 2 MeV or more.
As discussed by Glavish et al in “Production of high energy ion implanters using radio frequency acceleration”, Nuclear Instruments and Methods in Physics Research B21 (1987), at pages 264 to 269, it is necessary that each resonator in the rf accelerator be kept in precise tune and matched to its amplifier, for example by feedback control of a movable plate capacitor. The resonators tend to be sensitive to thermal and mechanical disturbances as they are part of highly tuned systems, with Q values between 1000 and 2000. It is also important that the amplitude and phase of the rf voltage at the acceleration electrode be controlled. In one arrangement, a signal from the inductive or capacitative probes associated with each cavity is compared with the desired phase and amplitude derived from a master oscillator via a precision phase shifter. Using a microprocessor, a “parameter set” for a given ion beam energy and species may be developed. Phase may be held to about 1° and amplitude to within 1%.
U.S. Pat. No. 5,801,488 also describes the control of an rf accelerating device. Here, a control unit determines the respective value is of phase and rf power, based upon a predetermined programmed algorithm, to obtain a target energy which is set by an operator. The controller adjusts the phase and amplitude under feedback control. In “The Development of a Beam Line using an RFQ and 3-Gap RF Accelerators for High Energy Ion Implanters”, presented by Fujisawa et al at IIT in Kyoto, Japan, Jun. 24, 1998, a personal computer is employed to control phase and amplitude to an RFQ and 3-gap rf beam line. Again, phase is controlled to around 1° and amplitude to around 0.5%.
It will thus be appreciated by those skilled in the art that the precision and stability of the system relies upon the ability to generate a signal, for each resonator, which has a precise phase and amplitude. It is also important that the relative phase shift between resonators is accurately maintained.
SUMMARY OF THE INVENTION
One object of the present invention is accordingly to stabilize and set the phase shift between signals as it fluctuates due to mechanical or thermal drift, for example. It is a further object to provide a technique for introducing an accurate chosen phase shift into a sinusoidal signal. Still a further object is to accurately determine and control the amplitude of such a signal.
In a first aspect of the invention, there is provided a controller for controlling a phase shift between a reference signal and a measured signal in an rf resonator having an rf power supply, the controller comprising an oscillator for providing a reference sinusoidal signal having a reference phase; a detector for generating a transduced signal from the rf resonator, the transduced signal having a detected phase; a phase shifter apparatus including a quadrature signal generator arranged to shift the phase of the reference sinusoidal signal by 90° relative to the reference phase so as to generate a reference cosinusoidal signal; a phase demand signal generator arranged to generate a first phase demand signal representing the sine of a desired angle of phase shift of the said reference sinusoidal signal plus a further 90° phase shift, and to generate a second phase demand signal representing the cosine of the said desired angle of phase shift plus a further 90° phase shift; a first multiplier arranged to multiply the said cosinusoidal reference signal with the first phase demand signal representing the sine of the desired angle of phase shift plus 90° to generate a first composite signal, and a second multiplier to multiply the said sinusoidal reference signal with the second phase demand signal representing the cosine of the desired angle of phase shift plus 90° to generate a second composite signal; and a summer arranged to sum the first and second composite signals to generate a phase shifter output signal which is a second sinusoidal signal that is shifted in phase relative to the reference phase of the reference sinusoidal signal by the said desired angle of phase shift plus 90°, the second sinusoidal signal being equivalent to a second cosinusoidal signal that is shifted in phase relative to the reference phase of the reference cosinusoidal signal by the said desired angle of phase shift; a second multiplier arranged to multiply the transduced signal with the second cosinusoidal signal and to generate a phase error signal having a dc component from the resultant product; and a processor arranged to generate a control signal on the basis of the dc component of the phase error signal, to control the output of the said power supply so as to minimize the dc phase error signal.
The controller of the present invention relies upon the trigonometrical identity
sin(ωt+b)=sin(ωt)cos(b)+cos(ωt)sin(b)
where the phase shift in the sinusoidal signal is represented by “b”.
Sin(b) and cos(b) are dc values which may be accurately generated. Thus, precise linear adjustment of the phase shift relative to a master oscillator may be provided. The phase angle “b”, may be continuously adjusted over a full 360° and with no discontinuity. The linearity and stability of the apparatus is also improved relative to the prior art.
It is desirable to ensure that the phase of the second sinusoidal signal (having a “demand phase” accurately determined using the trigonometrical function outlined above) is identical with the phase of the rf signal in the rf resonator which is obtained by the detector. When this is the case, the product of the second sinusoidal signal, shifted by exactly 90°, (so that it becomes the second cosinusoidal signal) and the transduced signal, should be zero. This principle can be used to provide a phase controller which uses the accurately determined phase shift as a reference to which the phase of the rf signal in the resonator cavity is locked via closed loop feedback. With this technique, phase can be controlled to about 0.5°. It will be appreciated that, instead of shifting the desired phase angle by 90° so as to produce, in effect, the second cosinusoidal signal, a quadrature signal of the transduced signal may instead be multiplied by a sinusoidal signal shifted by the chosen phase shift only (that is, not by an additional 90°) to create a phase error signal having a dc component. Alternatively, this sinusoidal signal (phase shifted by the desired angle of phase shift only) can be generated and then passed through a second quadrature signal generator which converts it, in effect, into the second cosinusoidal signal.
The quadrature signal generator may, for example, be an accurate single delay cable. Although this is adequate for a fixed frequency apparatus, a stripline structure is preferred for variable frequency devices. For example, the stripline structure, provided with taps and jumpers, can be embedded into a circuit board. This potentially allows sub-nanosecond adjustment of the time delay provided by the stripline structure, such that a precise 90° phase shift can be made to the first sinusoidal signal for a range of signal frequencies.
The multiplier is in preference a fast analogue multiplier, such as the high precision AD834 or AD835 multiplier manufactured by Analog Devices. In that case, the d.c. values of sin(b+90) and cos(+90) may be generated by a digital to analog converter (DAC). In preference, a pair of 16 bit DAC's are employed, operating under microprocessor control.
The controller of the invention is particularly suitable for application to a resonator which is part of an rf accelerator. Specifically, it may be desirable to apply a signal of a first known relative phase to a first resonator, and to apply a signal of a second known relative phase to a second resonator which is, for example, downstream of the first resonator. This may be done using a single apparatus controller arranged to generate two separate phase shifts relative to a common signal having a reference phase, or by using two separate apparatuses (again preferably relying upon a common signal having a reference phase). It may desirable that the first and the second relative phases are equal, that is, there is no phase difference between the signal applied to the first and the signal applied to the second resonator.
The controller may further comprise scaling means for attenuating the amplitude of the reference sinusoidal signal by a predetermined fraction to generate a scaled reference sinusoidal signal having a predetermined amplitude. Likewise, the scaling means may be further arranged to attenuate the amplitude of the reference cosinusoidal signal by the predetermined fraction to generate scaled reference cosinusoidal signal having the said predetermined amplitude.
The scaling means may be further arranged to attenuate the amplitude of the transduced signal by the said predetermined fraction.
In one embodiment, the scaling means may be arranged to attenuate the demand signal generated by the processor to a predetermined fixed amplitude.
The controller may further comprise signal processor means arranged to control the amplitude of the rf signal in the rf resonator, the signal processor means being configured to receive the said transduced signal from the detector, and to calculate an amplitude error signal by comparing the amplitude of the said transduced signal with a reference signal having a reference amplitude; the controller being further arranged to adjust the amplitude of the control signal generated by the processor in dependence upon the said amplitude error signal so as to minimize the amplitude error signal.
The analog multipliers of preferred embodiments have a maximum input voltage of 1.25 V peak and scaling the signals is therefore desirable. Furthermore, scaling the signals to a reference voltage eliminates the effects of non-linearities which arise in amplitude detection circuitry.
In a further aspect of the invention, there is provided a controller for controlling a phase shift between a reference signal and a measured signal in an rf resonator having an rf power supply, the controller comprising an oscillator for providing a reference sinusoidal signal having a reference phase; a detector for generating a transduced signal from the rf resonator, the transduced signal having a detected phase; a phase shifter apparatus including a quadrature signal generator arranged to shift the phase of the reference sinusoidal signal by 90° relative to the reference phase so as to generate a reference cosinusoidal signal; a phase demand signal generator arranged to generate a first phase demand signal representing the sine of a desired angle of phase shift of the said reference sinusoidal signal, and to generate a second phase demand signal representing the cosine of the said desired angle of phase shift; a first multiplier arranged to multiply the said cosinusoidal reference signal with the second phase demand signal representing the cosine of the desired angle of phase shift to generate a first composite signal, and to multiply the said sinusoidal reference signal with the first phase demand signal representing the sine of the desired angle of phase shift to generate a second composite signal; a summer arranged to generate a phase shifter output signal by determining the difference between the said first and said second composite signals, the phase shifter output signal being a second cosinusoidal signal which is shifted in phase relative to the reference phase of the reference cosinusoidal signal by the said desired angle of phase shift; and a second multiplier arranged to multiply the transduced signal with the second cosinusoidal signal and to generate a phase error signal having a dc component from the resultant product; and a processor arranged to generate a demand signal on the basis of the dc component of the phase error signal, to control the output of the said rf power supply so as to minimize the phase error signal.
Here, the trigonometrical relationship
cos(ωt+b)=sin(ωt)sin(b)−cos(ωt)cos(b)
is employed, so that the resultant phase shifted signal is cosinusoidal.
In further aspects of the invention, methods of controlling a phase shift between a reference signal and a measured signal are provided.
In still a further aspect of the present invention, there is provided an apparatus for measuring the amplitude of an rf signal in an rf resonator having an rf power supply, comprising a signal processor means configured to receive as a first input, a transduced signal representative of the amplitude of the rf signal, and to receive, as a second input, a command scaling signal having a predetermined amplitude, the signal processor means being arranged to generate a scaled transduced signal having an amplitude scaled by an amount directly proportional to the predetermined command scaling signal amplitude; means for generating a reference signal having a reference amplitude; a comparator arranged to compare the amplitude of the scaled transducer signal with the reference amplitude of the reference signal and to generate an amplitude error signal representative of the difference between the scaled transducer signal amplitude and the reference signal amplitude; the signal processor means being further arranged to adjust the output of the rf power supply in dependence upon the amplitude error signal so as to minimize the subsequent difference between the scaled transducer signal amplitude and the reference signal amplitude.
By scaling the transduced signal rather than trying to measure the amplitude directly, the inaccuracy arising from the non-linearities present in peak measurement devices is eliminated.
A fast analog multiplier may be used to carry out scaling. One of the multiplicands is the transduced signal to be scaled, and the other is a variable analog signal generated, for example, by a DAC. Suitably, pre-scaling by a fixed fraction is also carried out, for example by using a network of resistors.
The invention also extends to a phase shifter apparatus for generating a phase shift in a sinusoidal signal, comprising: an oscillator for generating a first sinusoidal signal having a reference phase; a quadrature signal generator arranged to shift the phase of the said sinusoidal signal by 90° relative to the said reference phase so as to generate a first cosinusoidal signal; a desired phase shift signal generator arranged to generate a first phase signal representing the sine of a desired angle of phase shift of the said first sinusoidal signal, and a second phase signal representing the cosine of the said desired angle of phase shift; a first multiplier arranged to multiply the said cosinusoidal signal with the first phase signal representing the sine of the said desired angle of phase shift, to generate a first composite signal, and a second multiplier to multiply the said sinusoidal signal with the second phase signal representative of the cosine of the said desired angle of phase shift, to generate a second composite signal; and a summer arranged to sum the first and second composite signals to generate a phase shifter output signal which is a second sinusoidal signal that is shifted in phase relative to the reference phase of the first sinusoidal signal by the said desired angle of phase shift.
In still a further aspect of the present invention there is provided a phase shifter apparatus for generating a phase shift in a cosinusoidal signal comprising: an oscillator for generating a first sinusoidal signal having a reference phase; a quadrature signal generator arranged to shift the phase of the said sinusoidal signal by 90° relative to the said reference phase so as to generate a first cosinusoidal signal; a desired phase shift signal generator arranged to generate a first phase signal representing the sine of a desired angle of phase shift of the said first sinusoidal signal, and a second phase signal representing the cosine of the said desired angle of phase shift; a first multiplier arranged to multiply the said first cosinusoidal signal with the second phase signal representing the cosine of the said desired angle of phase shift to generate a first composite signal, and a second multiplier to multiply the said first sinusoidal signal with the said first phase signal representing the sine of the said desired angle of phase shift to generate a second composite signal; and a summer arranged to generate an output representative of the difference between the said first and second composite signals, which output is a second cosinusoidal signal that is shifted in phase by the said desired angle of phase shift relative to the phase of the first cosinusoidal signal.
Methods of generating a phase shift in a sinusoidal signal and in a cosinusoidal signal are also provided by the invention.
The invention also extends to an rf accelerator including a controller incorporating the invention as defined in the claims, and to an ion implanter for implanting ions into a substrate employing such an rf accelerator.
There follows by way of example only a description of a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic view of an rf accelerator assembly including a controller embodying certain aspects of the present invention;
FIG. 2 shows a schematic close-up view of the controller of FIG. 1;
FIG. 3 shows, in further detail, a phase feedback loop constituting a part of the controller of FIG. 2;
FIG. 4 shows a schematic diagram of a phase shift circuit suitable for use in the phase feedback loop of FIG. 3;
FIG. 5 shows a detailed circuit diagram of the phase shift circuit of FIG. 4;
FIG. 6 shows a detailed circuit diagram of part of the phase feedback loop of FIG. 3;
FIG. 7 shows a schematic diagram of an amplitude detection and control circuit embodying a further aspect of the invention;
FIGS. 8 a and 8 b show detailed circuit diagrams of the amplitude detection and control circuit of FIG. 7;
FIG. 9 shows a detailed circuit diagram of the overall phase and amplitude control of the output command supplied to the resonator amplifier of FIG. 1; and
FIG. 10 shows a schematic view of an ion implanter including the rf accelerator assembly and controller of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a schematic diagram of an rf accelerator assembly is shown. The illustrated assembly comprises first and second rf accelerator cavities or stages 250 and 251 respectively arranged in tandem for changing the energy of a beam 252 of ions. The beam 252 is injected into the first rf accelerator cavity 250 at energy E (keV).
Each cavity 250 , 251 is preferably a three gap cavity having grounded entrance and exit electrodes 253 , 254 and 255 , 256 respectively and a pair of intermediate rf electrodes 257 , 258 and 259 , 260 respectively. The electrodes of the first cavity 250 define a first gap 261 , between entrance electrode 253 and first rf electrode 257 , a second gap 262 between the two rf electrodes 257 and 258 , and a third gap 263 between the second rf electrode 258 and the exit electrode 254 . The cavity 251 has similar gaps 264 , 265 and 266 .
The rf electrodes 257 and 258 of the first cavity 250 are connected to coils 268 and 269 , and the rf electrodes 259 and 260 of the second cavity 251 are connected to coils 270 and 271 . Each cavity 250 , 251 incorporating the respective electrodes and coils, provides a resonant tank designed to have a resonant frequency at or around a predetermined value f which is the intended operating frequency of the rf accelerator. The arrangement shown schematically in FIG. 1 is described in more detail in commonly assigned patent application Ser. No. 09/321,731, filed May 28, 1999 and entitled “Ion implanter and a method of implanting ions”, the contents of which are incorporated by reference in their entirety.
The resonance of the cavities 250 and 251 can be fine tuned to match the desired operating frequency f by means of adjustable tuning capacitors 272 and 273 , as will be detailed further below. Rf energy is coupled to the respective cavities 250 , 251 via coupling loops 274 and 275 . Pick up loops 276 and 277 in the respective cavities provide an output on lines 278 and 279 providing a feedback signal representing the amplitude and phase of the rf voltage in the respective cavity. This feature will be described in more detail particularly in connection with FIGS. 2, 3 and 7 below.
A pair of magnetic quadrupole lenses 280 and 281 are located in sequence between the cavities 250 and 251 .
An rf amplifier or power supply 282 amplifies an rf drive signal on a line 283 from an rf generator in controller 100 and supplies the amplified rf signal to energise the coupling loop 274 in the first rf cavity 250 . Similarly a second rf amplifier 285 amplifies an rf drive signal on a line 286 from a second rf generator in the controller 100 to supply an amplified rf signal to the coupling loop 275 of the second rf cavity 251 .
It is an important feature of all rf linear accelerators that the phase of the rf fields in each of the cavities not drift. Phase drift can result in bunches of charged particles passing through the accelerator not receiving the prescribed and preset acceleration. Furthermore, it should be appreciated that the resonant tank circuits 250 and 251 are provided to ensure that the required rf potential is applied to the rf electrodes in the respective cavity with minimum ohmic losses. The resonant circuits tend to have a high Q value (1000 to 2000) and this means that any small thermal or mechanical disturbance will move the circuits rapidly off resonance. Accordingly, it is very important that the resonance of the tank circuits is accurately maintained at the fixed frequency f of the rf drive. Deviation of the tank circuit resonance from the drive frequency f requires the amplitude of the rf drive to be increased for the same rf voltage applied to the electrodes of the cavity. Also, if the resonance of the cavity drifts away from the frequency f, in the absence of feedback control, there would be a change in the phase of the rf voltage on the electrodes.
The controller 100 of FIG. 1 thus employs both fast electronic feedback for small deviations in the resonance of the cavity, and slower, mechanical feedback to ensure that the resonance of the cavities remains at the drive frequency f when, for example, thermal expansion occurs. The principles of the fast feedback control are described in connection with FIGS. 2 to 6 (for phase control) and 7 - 8 (for amplitude control). Slow mechanical feedback control is preferably carried out by tuning the variable capacitance 272 and 273 of the respective cavities, by applying control signals on lines 297 and 298 respectively to dc or stepper motors. Typically, the tuner can adjust the frequency over a range of approximately 40 kHz. The phase difference between the control or command phase and the transduced phase will be either positive or negative and this in turn can provide an indication of the required direction of movement of the plates of the variable capacitor.
Because the variable capacitor 272 is a mechanical device, the response time of the variable capacitor 272 is relatively slow. Thus, fast electronic feedback control of the rf drive signal (as set out below) is required to maintain accurate amplitude and fixed phase within the cavity in response to any fast changes in the feedback signal, such as can arise due to mechanical vibration of the cavity. On the other hand, the capacitance 272 is adjusted to compensate for slow changes in the resonance of the cavity, e.g. resulting from thermal expansion. The slower mechanical feedback technique does not form a part of the present invention and in any event is disclosed in the above referenced U.S. patent application Ser. No. 09/321,731.
FIG. 2 shows a simplified block diagram of the controller 100 of FIG. 1, together with a highly schematic representation of some of the features of an rf resonator. For simplicity of explanation, only one resonator is shown in FIG. 2 although it will be understood that the controller can control two rf resonators (as is shown schematically in FIG. 1) or more. Features common to FIGS. 1 and 2 have been labelled with like reference numerals.
The controller 100 includes a communication processor 10 which provides two-way communication with a host computer 108 , for example using an RS-232 interface. The host computer 108 enables user-defined parameters to be sent to the controller 100 by a system operator.
It is a known requirement in the construction of multiple cavity linear accelerators to ensure that bunches of ions accelerated by a first cavity arrive at the first gap of the second cavity, when the rf voltage across this first gap is at an appropriate value to provide the required acceleration to the bunch of ions. A different set-up of any linear accelerator is required for use with ions of different mass-to-charge ratio, because the speed of the ions emerging, even with the same energy, from the first cavity will be different depending upon that mass-to-charge ratio. Although various parameters may be changed, it is preferable to maintain the distance between the two cavities 250 and 251 , and to maintain the phases of the rf voltages in the two cavities 250 and 251 , but to set up the accelerator for the desired ion mass-to-charge ratio by adjusting the speed of the ions from the first cavity to the second. This is achieved, in the illustrated example, by adjusting the amplitude of the signal supply to the resonator coil 268 . Thus, the host computer 108 allows different demand amplitudes to be loaded into the controller 100 , depending upon the mass-to-charge ratio of the ions in the ion beam E.
In addition to the communication processor 105 , the controller 100 also includes a control processor 110 , a signal detector 120 and a master oscillator 130 . The master oscillator 130 is common to each of the channels, although only one channel (labelled channel 1 ) is shown in FIG. 2 . The detector 120 receives a pick-up signal on line 278 from pick-up loop 276 adjacent resonator coil 268 . The control processor 110 and the signal detector 120 between them determine the amplitude and phase of the signal detected by the pick-up loop 276 . Once these values have been determined, they may be compared with a desired amplitude and phase to ascertain amplitude and phase error signals respectively.
The control processor 110 provides command phase and command amplitude signals to a phase shifter 400 and a variable gain amplifier 410 respectively. These are supplied on line 283 to the amplifier 282 which drives the coils 268 , 269 . The command phase and command amplitude values are chosen so as to adjust the amplitude and phase of the signal supplied to the coils 268 and 269 from the amplifier 282 , so that the difference between the desired and measured phase/amplitude in the resonator is minimised.
FIG. 3 shows, in further detail, a phase feedback loop constituting a part of the controller 100 of FIG. 2 . As will be appreciated, in order for ion acceleration to occur, each rf resonator must have a precisely defined phase relationship to a master oscillator 130 .
FIG. 3 shows a schematic diagram of the feedback loop used to establish and maintain the phase shifts.
A master oscillator 130 generates a sinusoidal wave having a reference phase. It will of course be appreciated that phase is a relative quantity. However, other signals within the phase feedback loop may have a phase relative to the phase of the sinusoidal wave generated by the master oscillator 130 and the phase angle of the sinusoidal wave generated by the master oscillator 130 is therefore considered to be 0° to facilitate explanation. The sinusoidal wave generated by the master oscillator 130 is hereinafter termed a “reference sine wave”.
The reference sine wave from the master oscillator 130 is sent as a first input to a reference phase shifter 500 . The host computer 108 (FIG. 2) also supplies a target phase angle of b° to the reference phase shifter 500 . The reference phase shifter 500 shifts the phase of the reference sine wave by b°. In other words, if the reference sine wave is represented as sin(ωt), then the reference phase shifter 500 operates to generate a phase-shifted sine wave which may be mathematically represented as sin(ωt+b).
The phase-shifted sine wave is further phase-shifted through exactly 90° to generate a sine wave of the form sin(ωt+b+90). This is, of course, a cosinusoidal wave, cos(ωt+b).
The principles of operation of the reference phase shifter 500 will be described in further detail in connection with FIGS. 4 and 5. However, it should be appreciated that although the additional 90° phase shift imparted by the phase-shifter is most preferably carried out by employing a target phase angle of (b+90), a similar result could be obtained by using a target phase angle b and then using, for example, an accurate delay line to shift the phase-shifted sine wave sin(ωt+b) by a further 90 °.
The resultant phase-shifted cosinusoidal wave, cos(ωt+b), is used as a first input to a multiplier 510 . The multiplier also receives an input on line 278 from the pick-up loop 276 adjacent the resonator (FIG. 2 ). The signal received from the pick-up loop 276 is a sine wave which should, in principle, be phase-shifted relative to the reference sine wave of the master oscillator 130 via the target phase angle b. In other words, the signal from the pick-up loop 276 should be of the form sin(ωt+b).
The input to the multiplier 510 from the reference phase shifter 500 is (as previously explained) an accurately generated signal of the form cos(ωt+b), having the same frequency as the signal from the pick-up loop 276 . If the signal from the pick-up loop 276 is exactly sin(ωt+b), then the product of this and cos(ωt+b) will have a DC component having zero amplitude. This condition is independent of the relative amplitudes of the two signals input to the multiplier 510 .
Using this principle, a feedback loop can be generated. When the signal from the pick-up loop 276 is not exactly sin(ωt+b), but instead has a slightly different phase relative to the reference sine wave such as sin(ωt+b+Δb), the multiplier will yield an output having a non-zero dc component.
The DC signal generated by the multiplier 510 is received by a processor 520 , such as a digital signal processor. The processor calculates a phase demand signal which is passed along line 525 to a control phase shifter 530 . The control phase shifter 530 receives the reference sine wave from the master oscillator 130 together with the phase demand signal from the processor 520 . Again using the technique described in FIG. 4, the control phase shifter 530 generates an output command wave form on line 540 which is a sine wave having the same frequency as the reference sine wave but which is phase-shifted by an angle x°. The phase angle x is typically similar to the target phase angle b, but is calculated so as to drive the actual phase of the signal in the resonator (measured by pick-up loop 276 ) to have a phase angle as close to b as possible; that is, to drive Δb to zero. This is achieved by applying the output command wave form to the power amplifier 282 which in turn drives the resonator.
Turning now to FIG. 4, a schematic diagram of a phase shift circuit suitable for use in the phase feedback loop of FIG. 3 is shown. Although FIG. 4 shows in particular the reference phase shifter 500 , the principles employed to create a phase shift are similar to those used in the control phase shifter of 530 of FIG. 3 .
The reference phase shifter 500 and the control phase shifter 530 both employ fast analog multipliers to effect the trigonometrical identity
sin(a+b)=sin(a)cos(b)+sin(b)cos(a).
By letting “a” be time-variable, the identity becomes
sin(ωt+b)=sin(ωt)cos(b)+cos(ωt)sin(b).
The master oscillator 130 (FIGS. 2 and 3) generates a reference sine wave sin(ωt). This is first passed through a buffer 600 . The output of the buffer 600 is passed directly to a first fast analog multiplier 610 . The output of the buffer 600 is also sent to a second fast analog multiplier 620 , via a phase delay 630 . In one embodiment, this may simply be an accurately measured length of cable to introduce a time delay between the buffer 600 and the second fast analog multiplier 6 such that a phase delay of 90° is introduced. Although this may be acceptable for certain applications, often the frequency of the reference sine wave may be adjustable. In that case, it is preferable to employ a stripline structure embedded into a circuit board to provide the 90° phase delay. This stripline structure may be provided with taps and jumpers to allow sub-nanosecond adjustment of the time delay, by reducing or increasing the aeffective length presented to the signal in between the buffer 600 and the second fast analog multiplier 620 so that the time delay and hence phase delay is altered.
By introducing a 90° phase delay, the input to the second fast analog multiplier 620 is sin(ωt+90°)=cos(ωt). In order to complete the right-hand side of the trigonometrical identity above, DC values representing the sine and cosine of the desired phase angle b must be generated. Preferably, this is carried out by the control processor 110 (FIG. 2) in combination with one or more digital-to-analog converters (DACs) (not shown in FIG. 4 ). In presently preferred embodiments, the desired phase shift (the phase angle b relative to the phase of the reference sine wave) is factory pre-set and cannot be adjusted by an operator of the described controller. However, it is clearly possible, if necessary or desirable, that the host computer 108 (FIG. 2) could allow any phase angle b between 0 and 360° to be selected. The control processor 110 may, for example, then employ a look-up table to convert a desired phase angle b into the sine and cosine thereof for generation by the DACs.
The first and second fast analog multipliers 610 , 620 are preferably high precision multipliers such as the AD834 or AD835 multipliers manufactured by Analog Devices. The former has a maximum frequency of 250 MHz, whereas the latter has a maximum frequency of 500 MHz.
The first fast analog multiplier 610 multiplies the reference sine wave sin(ωt) with the DAC generated DC value representing cos(b). Similarly, the second fast analog multiplier 620 multiplies the reference cosine wave cos(ωt) with the DAC generated DC value representing sin(b). The outputs of each of the two multipliers 610 , 620 are added together by summer 640 . The output of the summer 640 is thus sin(ωt)cos(b)+cos(ωt)sin(b), which is sin(ωt+b). In other words, the output of the reference phase shifter 500 is a sine wave having a phase shift relative to the phase of the reference sine wave of b°. Again, by setting the desired phase shift b as b+90, the output of the summer becomes sin(ωt+b+90)=cos(ωt+b).
The control phase shifter 530 operates in a similar manner; the reference sine wave is used to generate sin(ωt) and cos(ωt), and the control processor 110 (FIG. 2) controls the DACs so as to produce DC values equivalent to the sine and cosine of the output command phase angle x.
Referring again to FIG. 1, it will be noticed that there are, in fact, two rf accelerator cavities or stages 250 , 251 . The controller 100 is configured to control the phase of each cavity by using separate phase feedback loops such as are shown in FIG. 3, all tied to a single master oscillator 130 but using separate phase measurements from the pick-up loops 276 , 277 in the two rf accelerator cavities 250 , 251 respectively. It may, in certain circumstances, be desirable that there is a known, controlled phase shift between the two cavities. Using the principles described above in connection with FIG. 4, it is preferable that the first rf accelerator cavity 250 uses a signal at a phase angle b 1 relative to the phase of the reference sine wave generated by the master oscillator 130 , and the second rf accelerator cavity 251 uses a signal controlled to a second phase angle b 2 relative to the phase angle of the reference sine wave generated by the same master oscillator 130 . Thus, rather than adjusting the phase of one rf accelerator relative to the other, known phase angles are generated and controlled separately for each rf accelerator cavity. The relative phase shift between the two rf accelerator cavities (in this case, (b 1 -b 2 )) may be non-zero, or this value is either 0 or 180°. Even in this latter case, it is important to appreciate that the relative phase difference is not controlled so as to be zero, but rather the phase shift of each rf accelerator cavity is controlled to be the same relative to the phase of the reference sine wave generated by the master oscillator 130 .
Likewise, it will be understood that although, in FIG. 1, a single controller is shown for controlling both of the rf accelerator cavities 250 , 251 , separate controllers can be used for each, although a single master oscillator would still be necessary.
FIG. 5 shows a detailed circuit diagram of the phase shift circuit of FIG. 4 . The signals labelled REFSINE and REFCOS are generated upon a communications board (not shown) and are available to each RF processor 100 , should more than one processor be present. As will be explained in further detail in connection with FIGS. 7, 8 a and 8 b , REFSINE and REFCOS are scaled using separate circuitry to an approximately equal amplitude of 1.0 V peak-to-peak. There are two main reasons for this. Firstly, using a signal with constant amplitude, errors arising from circuit non-linearities are eliminated. Secondly, the fast analog multipliers 610 , 620 each have a maximum input voltage of only 1.25 V peak-to-peak.
The signal REFSINE represents the amplitudescaled reference sine wave generated by the master eoscillator 130 , considered to have a notional phase angle of zero and mathematical representation sin(ωt). Likewise, the REFCOS signal is derived from the reference sine wave generated by the master oscillator 130 and phase-shifted by exactly 90° relative thereto to generate an amplitude-scaled signal represented by cos(ωt). Sin(b) and cos(b) are generated using digital-to-analog converters DAC 0 and DAC 1 respectively. In the preferred embodiment, the output of DAC 1 is in fact a DC signal representative of cos(90+b), and the output of DAC 0 is a DC signal representative of sin(90+b). This is to ensure that the ultimate output of the reference phase shifter 500 is sin(ωt+b+90), i.e. cos(ωt+b). The fast analog multiplier 610 and 620 multiply the output of DAC 1 with the signal REFSINE and the output of DAC 0 with the signal REFCOS respectively. Both multipliers are given an offset trim adjustment using resistors R 66 and R 76 respectively. These can be used to remove any DC offsets by monitoring the outputs of the fast analog multipliers 610 , 620 at tap points TP 1 and TP 2 respectively.
Summing is carried out by the summer 640 . Both inputs have equal gain. The output of the summer 640 is a cosine wave, cos(ωt+b). In other words, the signal SHIFTREF is effectively a sine wave whose phase angle is shifted by 90°+b relative to the reference sine wave generated by the master oscillator 130 .
FIG. 6 shows a detailed circuit diagram of another part of the phase feedback loop shown schematically in FIG. 3 . Specifically, FIG. 6 shows, in more detail, the multiplier 510 .
The signal SHIFTREF, representing cos(ωt+b) is used as an input to a first buffered multiplexer 650 . The first buffered multiplexer 650 tracks and compensates for any phase delay drifts that might occur at a matching multiplexer in the pick-up loop amplifier circuitry described below.
The signal from the pick-up loop 276 is available from line 278 (FIG. 1) as PUSINOUT. This signal has been scaled to a nominal voltage of 1 V peak-to-peak using amplitude detection circuitry (FIGS. 7, 8 a and 8 b ).
The scaled pick-up loop signal PUSINOUT is multiplied with the signal SHIFTREF (which is also scaled, as previously explained) at third fast analog multiplier 660 . The multiplier 660 is configured as a current-output multiplier. If the signals PUSINOUT and SHIFTREF differ by exactly 90°, the DC component of the output of the third analog multiplier 660 will be zero. Otherwise, the differential output of third fast analog multiplier 660 is converted to a voltage using resistors R 103 and R 104 . The voltages are filtered using the low pass filter arrangement indicated generally at 665 , before passing into a differential amplifier 670 . The final phase error is provided as an output signal from the differential amplifier 670 which is labelled PHAS_ERR in FIG. 6 . This signal PHAS_ERR is used to generate suitable values for sin(x) and cos(x) for use as inputs to the control phase shifter 530 (FIG. 3 ).
FIG. 7 shows, again schematically, a circuit for amplitude detection and control. The signal from the pick-up loop 276 is attenuated by one of a range of fixed fractions in order that it is less than 1.25 V. The attenuated signal is used as a first input to a fourth fast analog multiplier 700 , which is why attenuation by a fixed fraction is necessary.
The other input to the fourth fast analog multiplier 700 is derived from a third digital-to-analog converter 710 . The DAC 710 provides a variable amplitude DC output such that the product of the fourth fast analog multiplier 700 is a sinusoidal signal having a phase angle relative to the master oscillator 130 which should be approximately b°, assuming phase control of the resonator signal. This amplitude scaled signal is used in the phase feedback loop of FIG. 3 and is labelled PUSINOUT in FIG. 6 . The use of a variable gain amplifier in the form of a fast analog multiplier to scale a signal of arbitrary amplitude to a fixed reference amplitude is also employed to generate the signals REFSINE and REFCOS in FIGS. 4 and 6. It will of course be understood that scaling the amplitude of the signals using this technique should not affect the phase of the signals which is why the amplitude and phase feedback loops can notionally be shown separately. However, scaling the amplitude of the signals eliminates the problem of non-linearities present in peak detection devices.
The amplitude scaled signal from the pick-up loop 276 is then squared by a fifth fast analog multiplier 720 . This is achieved by supplying the output of the fourth fast analog multiplier 700 to both inputs of the fifth fast analog multiplier 720 .
The output of the fifth fast analog multiplier 720 is filtered using a low pass filter 730 , to generate a DC signal. This is compared in comparator 740 with a fixed DC voltage and the output of the comparator 740 is thus an amplitude error representing the difference between the scaled amplitude of the pick-up loop relative to the fixed DC voltage.
The amplitude error is supplied to a microprocessor 745 for use in a feedback algorithm. The microprocessor determines the output amplitude and phase. This is fed to an amplitude shifter 750 which adjusts the amplitude of the output command wave form to the power amplifier 282 . This in turn adjusts the amplitude of the signal supplied to the resonator in order to drive the amplitude error signal towards zero.
FIG. 8 a shows, in greater detail, a part of the schematic circuit of FIG. 7 . The raw signal from the pick-up loop 276 is passed through a high precision resistive attenuator 800 (R 5 -R 11 ). Each of four taps on the attenuator 800 represents a factor of 2.5, so that the pick-up loop signal can be reduced in amplitude by factors of 1.0, 2.5, 6.25, and 15.625. Resistors R 3 and R 4 are used to apply an overall attenuation of 0.75. The selection of any of the four taps associated with the resistive attenuator 800 is carried out by selection of one of the four channels of a second buffered multiplexer 810 . Inputs A 0 and A 1 are used for this purpose.
The second buffered multiplexer 810 also includes a fixed gain stage with a gain of 2.0, determined by the resistors R 16 and R 17 . The signal on output line 820 thus has an amplitude of between 0.4 and 0.8 V peak-to-peak. It should be appreciated, however, that the signal on line 820 is still a fixed fraction of the raw pick-up loop signal PICKUPIN.
A sixth fast analog multiplier 830 receives as one of its inputs the attenuated signal on line 820 . The other input is determined by the value of DAC 2 , which is the DAC 710 shown schematically in FIG. 7 . The raw output of DAC 2 is 10.0 V full-scale. Thus, this signal is attenuated by resistors R 19 and R 20 , so that the input to the multiplier supplied by DAC 2 ranges from 0 to 1.25 V , the latter being the maximum input voltage to the multiplier 830 . Assuming the desired input amplitude, the combination of the resistive attenuator 800 and the sixth fast analog multiplier 830 produces a signal at tap point TP 4 of 0.3 V peak-to-peak.
Amplifier 840 multiplies the sinusoidal signal received from the sixth fast analog multiplier 8 by a factor of 3.3. Thus, the output of the amplifier 840 , labelled PUSINOUT, may be a sinusoidal signal having a amplitude of 1.0 V peak-to-peak. As previously explained, this signal PUSINOUT is used in the phase comparator shown in FIG. 6 .
Turning now to FIG. 8 b , the signal PUSINOUT is reduced by a factor of 0.7 and then supplied to both inputs of a seventh fast analog multiplier 850 . The output of the seventh fast analog multiplier 850 is then the square of the input, i.e. a positive wave form with an RMS value of 0.5 V. This signal is available at tap point TP 3 .
A low pass filter arrangement 860 receives the output of the seventh fast analog multiplier 850 and the output of the low pass filter arrangement 860 is in turn a DC signal of +0.5 V.
A reference voltage of −0.5 V is generated by a voltage source and resistor arrangement 865 . This is added to the notional +0.5 V signal which is the output of the low pass filter arrangement 860 . The voltage at circuit node X in FIG. 8 b is thus notionally zero. A summing junction 870 has a gain of 20x and amplifies the difference between the non-inverting input, held at ground potential, and the inverting input which is notionally at 0.0 V. The output of the summing junction 870 is an amplitude error, labelled AMPL_ERR in FIG. 8 b , which will be either positive or negative depending upon whether the original raw pick-up signal amplitude is larger than it should be (i.e. the output of the low pass filter arrangement 860 is larger than the reference voltage), or smaller than it should be. A 10 mV output from the summing junction 870 represents a 0.1% signal amplitude error.
Trim potentiometer R 123 is used to null out any offsets in the circuit; in practice a known signal is injected into the lefthand side of FIG. 8 a in lieu of the PICKUPIN signal from the pick-up loop 277 . The gains and attenuators in FIGS. 8 a and 8 b are set to a theoretical value, and trim potentiometer R 123 is adjusted to produce 0.0 V at the output of the summing junction 870 .
Table 1 below summarises the signal amplitudes between PICKUPIN and AMPL_ERR:
TABLE 1
Output of
Output of
Second
PICKUPIN
Attenuator
BUFF · MUX (810)
Output of DAC2
(VP-P)
800 (V p—p)
(V p—p)
(V p—p)
Voltage 1
0.2-0.5
1
0.3-0.75
1.0-0.4
Voltage 2
0.5-1.2
2.5
0.3-0.75
1.0-0.4
Voltage 3
1.2-3.0
6.3
0.3-0.75
1.0-0.4
Voltage 4
3.0-7.5
16
0.3-0.75
1.0-0.4
Output of
Input to
Output of
Multiplier
PUSINOUT
Multiplier 850
Multiplier 850
830 (V p—p)
(V p—p)
(V p—p)
(V RMS)
Voltage 1
0.3
1.0
0.7
0.5
Voltage 2
0.3
1.0
0.7
0.5
Voltage 3
0.3
1.0
0.7
0.5
Voltage 4
0.3
1.0
0.7
0.5
Output of
LPF (dc V)
AMPL_ERR
Voltage 1
0.5
20 × 0.0
Voltage 2
0.5
20 × 0.0
Voltage 3
0.5
20 × 0.0
Voltage 4
0.5
20 × 0.0
FIG. 9 shows a detailed circuit diagram of the overall phase and amplitude control of the output command supplied to the resonator amplifier of FIG. 1 . The signals PHAS_ERR shown in FIG. 6 and AMPL_ERR shown in FIG. 8 b are supplied to the control processor 110 (see FIG. 2 ). The control processor 101 implements a proportional integral differential (PID) algorithm to calculate suitable command values to drive the amplitude and phase errors to zero. Both PHAS_ERR and AMPL_ERR are read by fast, 16-bit analog-to-digital converters (not shown). The algorithms for calculating the command DC sine and cosine signals (referred to in FIG. 3 as sin(x) and cos(x)) and likewise the amplitude command voltage are preferably implemented using firmware and do not form a part of the present invention.
The output command phase shifts cos(x) and sin(x) are generated by digital-to-analog converters under the control of the control processor processor 110 . Cos(x) is generated by digital-to-analog converter DSP-DAC 1 and sin(x) is generated by DSP-DAC 2 . As seen in FIG. 9, these are multiplied with the reference sine wave sin(ωt) and the reference cosine wave cos(ωt) using eighth and ninth fast analog multipliers 900 , 910 respectively. The reference sine and cosine waves are generated from the master oscillator 130 . The products, cos(ωt)sin(x) and sin(ωt)cos(x), are summed to produce a first input to a tenth fast analog multiplier 920 . The other input to the tenth fast analog multiplier 920 is an amplitude scaling factor to scale the command wave for having the command phase shift x. The jumper labelled JPR 2 permits selection between two modes of operation of amplitude control. In a first, “variable output” mode, the control processor 110 calculates a scaling factor in dependence upon the amplitude error AMPL_ERR and provides an output from digital-to-analog converter DSP-DAC 3 . The output of DSP-DAC 3 is used as an amplitude control for amplifier 930 . In other words, the phase control signal (the first input to the tenth multiplier 920 ) is amplitude-modulated with a variable amplitude control signal.
The raw output from DSP-DAC 3 is first attenuated by a factor of eight through the divider provided by resistors R 139 and R 131 . The resulting level is the amplitude of the command RF signal. The output of the tenth fast analog multiplier 920 is buffered through buffer 940 to generate a scaled, phase-shifted control wave form at the circuit output. This variable output mode is selected by shorting pins 2 and 3 of the jumper JPR 2 .
In a second, “fixed output” mode, the amplitude control signal is a DC signal reflecting the value of the output from DSP-DAC 3 , again as buffered by amplifier 930 . The signal has a range of 0-10 V DC. In the fixed output mode, the rf output amplitude signal at the tenth analog multiplier 920 (pin 8 ) is determined by the voltage divider represented by resistors R 166 and R 135 . The fixed output mode is selected by shorting pins 1 and 2 of jumper JPR 2 .
RF linear accelerators find application in a number of areas of technology. However, they are of particular use in the acceleration of ions in an ion implanter. Such implanters allow the doping of silicon wafers and the like with dopant ions such as boron or phosphorous.
FIG. 10 illustrates schematically a single wafer implanter incorporating a radio frequency linear accelerator assembly 10 . The rf accelerator assembly is shown in highly schematic form and reprsents a single three-gap rf booster having two central electrodes. It is also to be understood that the implanter of FIG. 10 is illustrated simply to put the controller described above into context and is not intended of itself to represent a part of the present invention.
In the simplified arrangement of FIG. 1, the implanter comprises an ion source 11 directing a beam of ions at a predetermined energy E into an analyser magnet 12 , which passes ions according to their mass to charge ratio (m/e) into a buncher 23 , supplied with rf power from an rf source 24 . Only ions of the required velocity times mass/charge (m/e) ratio pass through a mass selection (resolving) slit 13 at the exit of the buncher 23 , and enter as a beam 14 , still at energy E, into the radio frequency accelerator assembly 10 . The beam exiting the rf accelerator assembly then enters an energy analyser 25 , after which it enters a beam scanning device 15 which is arranged to scan the ion beam to and fro in a direction 16 transverse to the beam direction. The scanning device 15 may be either electrostatic or electromagnetic. Electromagnetic scanning systems are preferred in applications especially for high current beams. A suitable electromagnetic scanning system is disclosed in U.S. Pat. No. 5,393,984. The scanned beam then enters a process chamber 17 in which a semiconductor substrate 18 is held on a holder 19 . The holder 19 is mounted on a mechanical scanning mechanism shown generally at which can be actuated to reciprocate the wafer in a direction normal to the plane of the paper in FIG. 1 and across the plane of the scanned beam. The combination of scanning of the beam and mechanical scanning of the wafer holder 19 allows the beam to scan over all parts of the wafer during an implant process. Processed wafers are removed from the holder 19 and passed out of the process chamber 17 , and fresh wafers for processing are brought into the chamber 17 and mounted on the holder 19 one at a time, via a load lock 21 , and using robot handling mechanisms which are not shown in this drawing for simplicity.
Further details of single wafer implanters can be determined from U.S. Pat. Nos. 5,003,183 and 5,229,615, and of a preferred form of process chamber from International Patent Application WO 99/13488. The specific details of the ion source, the mass selection magnet and the scanning and processing mechanisms of the implanter are not crucial to aspects of the present invention, which concern solely the arrangement of an rf accelerator assembly which may be used to increase the energy of ions in implanters such as disclosed in the above prior art documents.
It should be understood that rf accelerators are equally suitable for use in batch implanters, which typically rely solely on mechanical scanning to process a batch of semiconductor wafers simultaneously. The wafers are usually mounted around the periphery of a rotating wheel, which rotates to bring the wafers one by one across the line of the ion beam. Meanwhile, the axis of rotation of the wheel is reciprocated to and fro to complete the scanning in the orthogonal direction.
The accelerator assembly shown in FIGS. 1 and 10 is intended to handle and accelerate primarily the ions B ++ (m/e=5.5), B + (m/e =11), P ++ (m/e=15.5), and P +++ (m/e=10.3). The structure parameters of the accelerator assembly are designed to be near optimum for the B + ions. However, for ion implantation applications, useful energy gains from at least the first booster stage can be obtained for ions with an m/e range up to about 40. | A method and apparatus for generating an accurate, table phase shift (b) in a sinusoidal signal employs fast analog multiplication to implement the trigonometric relationship sin(ωt+b)=sin(ωt)cos(b)+cos(ωt)sin(b). Cos (ωt) is generated by accurately shifting a signal sin(ωt) through 90° using a delay line, for example. Sin(b) and cos(b) are dc signals generated by digital to analogue conversion, using a demanded phase shift (b) whose sine and cosine are obtained from look-up tables. A controller for controlling a phase shift in an rf cavity is also disclosed and operates on the basis of the same trigonometrical principle. The amplitude of the signals in the rf cavity is also controllable; fast analogue multipliers are again employed to scale the signal amplitude to a nominal fixed value such as 1 volt. | 7 |
[0001] This application claims the priority benefit of Taiwan patent application number 100110737 filed on Mar. 29, 2011.
FIELD OF THE INVENTION
[0002] The present invention relates to a centrifugal heat dissipation device, and more particularly to a centrifugal heat dissipation device that rotates and utilizes a produced centrifugal force to enable enhanced vapor-liquid circulation of a working fluid filled therein. The present invention also relates to a motor that uses the above-described centrifugal heat dissipation device and therefore has largely upgraded heat dissipation performance.
BACKGROUND OF THE INVENTION
[0003] All the currently available motors, power generators, and various kinds of electric engines include a rotor and a stator. When a motor is excited due to the effect of stator-rotor mutual induction, the motor works or generates power. Heat will be generated when the silicon steel sheets provided on the rotor and the winding coils wound on the silicon steel sheets are supplied with an electric current. The hysteresis loss (iron loss) and copper loss of the rotor would generate thermal power, which causes increased temperature and lowered efficiency of the motor rotor, and thereby limits the maximum power of the rotary motor.
[0004] A motor usually has an efficiency of 85%. The 15% loss of the motor would cause heat transfer among the motor windings, the motor stator and/or the motor housing. When operating under atmospheric pressure, the heat generated by the motor rotor is transferred to the motor housing mainly via convection. That is, the heat generated by the motor rotor is transferred to the motor housing with the air inside the motor as the heat transfer medium. By providing the motor rotor with radiating fins to cool the motor, the effect of heat transfer via convection can be maximized.
[0005] It is also possible to transfer part of the thermal loss power of the motor or the power generator to an external environment through heat conduction and radiation via the rotary shaft and bearings of the motor or the power generator. However, this type of heat transfer mechanism can only provide relatively small cooling effect. When a high-speed shaft and a thermal rotor operate in a high-temperature condition, the rotor must be cooled. Otherwise, the rotor rotating at high load is subject to burnout due to the thermal power generated by the hysteresis loss (iron loss) and copper loss.
[0006] The currently cooling systems available for motors and power generators are mainly designed to carry heat away from the stator. As to the rotor, it could not be effectively cooled since there has not been any effective heat dissipation means for rotor up to date.
[0007] In brief, the prior art motors or power generators have the following disadvantages: (1) the hysteresis loss and copper loss of the rotor thereof generates thermal power to result in increased rotor temperature and limited motor power; (2) heat tends to accumulate in the rotor; and (3) the rotor has low cooling performance.
SUMMARY OF THE INVENTION
[0008] A primary object of the present invention is to provide a centrifugal heat dissipation device that utilizes a centrifugal force to enable enhanced vapor-liquid circulation of a working fluid filled therein, so as to provide increased heat dissipation effect.
[0009] Another object of the present invention is to provide a motor with centrifugal heat dissipation device.
[0010] To achieve the above and other objects, the centrifugal heat dissipation device according to the present invention includes a main body having a shaft hole, a heat-absorption zone, and a heat-transfer zone. The heat-transfer zone has a radially inner side connected to the shaft hole and a radially outer side connected to the heat-absorption zone; and the shaft hole axially extends through the main body.
[0011] To achieve the above and other objects, the motor with centrifugal heat dissipation device according to an embodiment of the present invention includes at least one shaft, a centrifugal heat dissipation device, a plurality of silicon steel sheets, and a housing. The shaft internally defines a hollow space, and has a first end and an opposite second end communicating with the hollow space. The centrifugal heat dissipation device includes a main body having a shaft hole, a heat-absorption zone, and a heat-transfer zone. The heat-transfer zone has a radially inner side connected to the shaft hole and a radially outer side connected to the heat-absorption zone; and the shaft hole axially extends through the main body for receiving the shaft therein. The silicon steel sheets are externally fitted around the main body of the centrifugal heat dissipation device. The housing is internally provided with a magnetic member, which is located corresponding to but spaced from the silicon steel sheets when the centrifugal heat dissipation device and the shaft are mounted in the housing. The housing has at least one end being an open end, to which a cap is connected to close the housing.
[0012] To achieve the above and other objects, the motor with centrifugal heat dissipation device according to another embodiment of the present invention includes at least one shaft, a centrifugal heat dissipation device, at least one magnetic member, and a housing. The shaft internally defines a hollow space, and has a first end and an opposite second end communicating with the hollow space. The centrifugal heat dissipation device includes a main body having a shaft hole, a heat-absorption zone, and a heat-transfer zone. The heat-transfer zone has a radially inner side connected to the shaft hole and a radially outer side connected to the heat-absorption zone; and the shaft hole axially extends through the main body for receiving the shaft therein. The magnetic member is externally fitted around the main body of the centrifugal heat dissipation device. The housing is internally provided with a plurality of silicon steel sheets, which are located corresponding to but spaced from the magnetic member when the centrifugal heat dissipation device and the shaft are mounted in the housing. The housing has at least one end being an open end, to which a cap is connected to close the housing.
[0013] When the centrifugal heat dissipation device rotates along with the shaft of the motor, a centrifugal force is produced. The centrifugal force enables enhanced vapor-liquid circulation of a working fluid filled in the heat-absorption zone of the main body of the centrifugal heat dissipation device, so that heat generated by the operating motor is absorbed by the centrifugal heat dissipation device and transferred to the shaft for guiding out of the motor, allowing the motor to have largely upgraded heat dissipation performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The structure and the technical means adopted by the present invention to achieve the above and other objects can be best understood by referring to the following detailed description of the preferred embodiments and the accompanying drawings, wherein
[0015] FIG. 1 is a perspective view of a first embodiment of a centrifugal heat dissipation device according to the present invention;
[0016] FIG. 2 is a cross sectional view of FIG. 1 ;
[0017] FIG. 3 a is a cross sectional view of a second embodiment of the centrifugal heat dissipation device according to the present invention;
[0018] FIG. 3 b is a cross sectional view of a variant of the second embodiment of the centrifugal heat dissipation device according to the present invention;
[0019] FIG. 4 is a cross sectional view of a third embodiment of the centrifugal heat dissipation device according to the present invention;
[0020] FIG. 5 is a perspective view of a fourth embodiment of the centrifugal heat dissipation device according to the present invention;
[0021] FIG. 6 is an exploded perspective view of a first embodiment of a motor with centrifugal heat dissipation device according to the present invention;
[0022] FIG. 7 is an assembled view of FIG. 6 ;
[0023] FIG. 8 is an assembled longitudinal sectional view of the motor of FIG. 6 ;
[0024] FIG. 9 is an exploded perspective view of a second embodiment of the motor with centrifugal heat dissipation device according to the present invention without showing the housing thereof;
[0025] FIG. 10 is an assembled perspective view of a third embodiment of the motor with centrifugal heat dissipation device according to the present invention without showing the housing thereof;
[0026] FIG. 11 is an assembled longitudinal sectional view of a fourth embodiment of the motor with centrifugal heat dissipation device according to the present invention;
[0027] FIG. 12 is an assembled longitudinal sectional view of a fifth embodiment of the motor with centrifugal heat dissipation device according to the present invention;
[0028] FIG. 13 is an assembled longitudinal sectional view of a sixth embodiment of the motor with centrifugal heat dissipation device according to the present invention;
[0029] FIG. 14 is an exploded perspective view of a seventh embodiment of the motor with centrifugal heat dissipation device according to the present invention;
[0030] FIG. 15 is an assembled view of FIG. 14 ;
[0031] FIG. 16 is an assembled longitudinal sectional view of the seventh embodiment of the motor with centrifugal heat dissipation device according to the present invention;
[0032] FIG. 17 is an assembled perspective view of an eighth embodiment of the motor with centrifugal heat dissipation device according to the present invention without showing the housing thereof;
[0033] FIG. 18 is an assembled perspective view of a ninth embodiment of the motor with centrifugal heat dissipation device according to the present invention without showing the housing thereof;
[0034] FIG. 19 is an assembled longitudinal sectional view of a tenth embodiment of the motor with centrifugal heat dissipation device according to the present invention;
[0035] FIG. 20 is an assembled longitudinal sectional view of an eleventh embodiment of the motor with centrifugal heat dissipation device according to the present invention; and
[0036] FIG. 21 is an assembled longitudinal sectional view of a twelfth embodiment of the motor with centrifugal heat dissipation device according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] The present invention will now be described with some preferred embodiments thereof and with reference to the accompanying drawings. For the purpose of easy to understand, elements that are the same in the preferred embodiments are denoted by the same reference numerals.
[0038] Please refer to FIGS. 1 and 2 that are assembled perspective view and cross sectional view, respectively, of a first embodiment of a centrifugal heat dissipation device la according to the present invention. As shown, the centrifugal heat dissipation device la in the first embodiment includes a cylindrical main body 1 having a shaft hole 11 , a heat-absorption zone 12 , and a heat-transfer zone 13 . The heat-transfer zone 13 has a radially outer side connected to the heat-absorption zone 12 and a radially inner side connected to the shaft hole 11 . The shaft hole 11 axially extends through the main body 1 .
[0039] The heat-absorption zone 12 is internally provided with a working fluid 2 .
[0040] Please refer to FIG. 3 a that is a cross sectional view of a second embodiment of the centrifugal heat dissipation device la according to the present invention, and to FIG. 3 b that is a cross sectional view of a variant of the second embodiment of the centrifugal heat dissipation device 1 a . As can be seen from FIGS. 3 a and 3 b , the centrifugal heat dissipation device 1 a in the second embodiment and the variant thereof are generally structurally similar to the first embodiment, except for a wick structure 125 that is further provided in the heat-absorption zone 12 . The wick structure 125 may be a sintered powder structure as shown in FIG. 3 a , or a net-like structure as shown in FIG. 3 b , or include a plurality of continuous or discontinuous grooves (not shown), or be any combination of the previous structures.
[0041] FIG. 4 is a cross sectional view of a third embodiment of the centrifugal heat dissipation device according to the present invention. As shown, the third embodiment is generally structurally similar to the first embodiment, except for a plurality of recesses 126 formed in the heat-absorption zone 12 .
[0042] FIG. 5 is a perspective view of a fourth embodiment of the centrifugal heat dissipation device according to the present invention. The fourth embodiment is generally structurally similar to the first embodiment, except that the heat-absorption zone 12 is radially outward extended from only a partial axial length of the heat-transfer zone 13 and has a first transverse surface 12 a and an opposite second transverse surface 12 b.
[0043] The present invention also relates to a motor 9 with centrifugal heat dissipation device. Please refer to FIGS. 6 , 7 and 8 , in which a first embodiment of the motor 9 with centrifugal heat dissipation device according to the present invention is shown. As shown, the motor 9 in the first embodiment thereof includes at least one shaft 3 , a centrifugal heat dissipation device 1 a , a plurality of silicon steel sheets 4 , and a housing 5 .
[0044] The shaft 3 internally defines a hollow space 31 and has a first end 32 and an opposite second end 33 . The first and the second end 32 , 33 are communicable with the hollow space 31 .
[0045] The centrifugal heat dissipation device la includes a cylindrical main body 1 , which includes a shaft hole 11 , a heat-absorption zone 12 , and a heat-transfer zone 13 . The heat-transfer zone 13 has a radially inner side connected to the shaft hole 11 and a radially outer side connected to the heat-absorption zone 12 . The shaft hole 11 axially extends through the main body 1 , and the shaft 3 is fitted in the shaft hole 11 .
[0046] The silicon steel sheets 4 are externally fitted around the main body 1 of the centrifugal heat dissipation device 1 a.
[0047] The housing 5 is internally provided with a magnetic member 51 , which is located corresponding to but spaced from the silicon steel sheets 4 when the centrifugal heat dissipation device la and the shaft 3 are mounted in the housing 5 . The housing 5 has at least one end being an open end, to which a cap 52 is connected to close the housing 5 . In a preferred embodiment, the magnetic member 51 is a magnet.
[0048] A cooling fluid 6 is filled in the hollow space 31 of the shaft 3 . The cooling fluid 6 may be air, oil, or water.
[0049] The silicon steel sheets 4 have a plurality of winding coils 41 externally wound thereon.
[0050] Please refer to FIG. 9 that is an exploded perspective view of a second embodiment of the motor according to the present invention without showing the housing thereof. As shown, the motor in the second embodiment is generally structurally similar to the first embodiment, except that the centrifugal heat dissipation device for the second embodiment has a heat-absorption zone 12 that is radially outward extended from only a partial axial length of the heat-transfer zone 13 and has a first transverse surface 12 a and an opposite second transverse surface 12 b , and the silicon steel sheets 4 are in contact with the first or the second transverse surface 12 a , 12 b of the heat-absorption zone 12 of the centrifugal heat dissipation device.
[0051] FIG. 10 is an assembled perspective view of a third embodiment of the motor according to the present invention without showing the housing thereof. As shown, the motor in the third embodiment is generally structurally similar to the second embodiment, except for a first rotary oil seal 71 and a second rotary oil seal 72 that are further mounted around the first and the second end 32 , 33 of the shaft 3 , respectively.
[0052] Please refer to FIG. 11 that is an assembled longitudinal sectional view of a fourth embodiment of the motor according to the present invention. As shown, the motor in the fourth embodiment is generally structurally similar to the third embodiment, except for a pressure device 10 that is further connected to the shaft 3 . The pressure device 10 is a pump formed of a pressure unit 101 , a first pipe 102 , and a second pipe 103 . The pressure unit 101 has an outlet 1011 and an inlet 1012 , which are connected to the two ends of the shaft 3 via the first pipe 102 and the second pipe 103 , respectively.
[0053] Please refer to FIG. 12 that is an assembled longitudinal sectional view of a fifth embodiment of the motor according to the present invention. As shown, the motor in the fifth embodiment is generally structurally similar to the third embodiment, except for a pressure device 10 that is further mounted to the hollow space 31 of the shaft 3 . The pressure device 10 is a turbine blade assembly being able to guide a cooling fluid 6 (i.e. ambient air) into the hollow space 31 when the shaft 3 is rotating, so as to remove heat from the rotating shaft 3 to achieve the purpose of cooling the motor.
[0054] FIG. 13 is an assembled longitudinal sectional view of a sixth embodiment of the motor according to the present invention. As shown, the motor in the sixth embodiment is generally structurally similar to the second embodiment, except for a pressure device 10 that is further connected to one end of the shaft 3 . The pressure device 10 is a fan being able to guide a cooling fluid 6 (i.e. ambient air) into the hollow space 31 of the shaft 3 when the shaft 3 is rotating, so as to remove heat from the rotating shaft 3 to achieve the purpose of cooling the motor.
[0055] Please refer to FIGS. 14 , 15 and 16 , which are respectively an exploded perspective view, an assembled perspective views, and an assembled longitudinal sectional view of a seventh embodiment of the motor 9 with centrifugal heat dissipation device according to the present invention. As shown, the motor 9 with centrifugal heat dissipation device in the seventh embodiment thereof includes at least one shaft 3 , a centrifugal heat dissipation device 1 a , at least one magnetic member 51 , and a housing 5 .
[0056] The shaft 3 internally defines a hollow space 31 , and has a first end 32 and a second end 33 . The first and second ends 32 , 33 are communicable with the hollow space 31 .
[0057] The centrifugal heat dissipation device 1 a includes a main body 1 , which has a shaft hole 11 , a heat-absorption zone 12 , and a heat-transfer zone 13 as that shown in FIG. 1 . The heat-transfer zone 13 has a radially inner side connected to the shaft hole 11 and a radially outer side connected to the heat-absorption zone 12 . The shaft hole 11 axially extends through the main body 1 , and the shaft 3 is fitted in the shaft hole 11 .
[0058] The magnetic member 51 is externally fitted around the main body 1 of the centrifugal heat dissipation device 1 a.
[0059] The housing 5 is internally provided with a plurality of silicon steel sheets 4 , which are located corresponding to but spaced from the magnetic member 51 when the centrifugal heat dissipation device 1 a and the shaft 3 are mounted in the housing 5 . The housing 5 has at least one end being an open end, to which a cap 52 is connected to close the housing 5 . In a preferred embodiment, the magnetic member 51 is a magnet.
[0060] A cooling fluid 6 is filled in the hollow space 31 of the shaft 3 . The cooling fluid 6 may be air, oil, or water.
[0061] The silicon steel sheets 4 have a plurality of winding coils 41 externally wound thereon.
[0062] FIG. 17 is an assembled perspective view of an eighth embodiment of the motor according to the present invention without showing the housing thereof. As shown, the motor in the eighth embodiment is generally structurally similar to the seventh embodiment, except that the centrifugal heat dissipation device for the eighth embodiment has a heat-absorption zone 12 that is radially outward extended from only a partial axial length of the heat-transfer zone 13 and has a first transverse surface 12 a and an opposite second transverse surface 12 b , and the magnetic member 51 is in contact with the first or the second transverse surface 12 a , 12 b of the heat-absorption zone 12 .
[0063] FIG. 18 is an assembled perspective view of a ninth embodiment of the motor according to the present invention without showing the housing thereof. As shown, the motor in the ninth embodiment is generally structurally similar to the eighth embodiment, except for a first rotary oil seal 71 and a second rotary oil seal 72 that are further mounted around the first and the second end 32 , 33 of the shaft 3 , respectively.
[0064] Please refer to FIG. 19 that is an assembled longitudinal sectional view of a tenth embodiment of the motor according to the present invention. As shown, the motor in the tenth embodiment is generally structurally similar to the ninth embodiment, except for a pressure device 10 that is further connected to the shaft 3 . The pressure device 10 is a pump formed of a pressure unit 101 , a first pipe 102 , and a second pipe 103 . The pressure unit 101 has an outlet 1011 and an inlet 1012 , which are connected to the two ends of the shaft 3 via the first pipe 102 and the second pipe 103 , respectively.
[0065] Please refer to FIG. 20 that is an assembled longitudinal sectional view of an eleventh embodiment of the motor according to the present invention. As shown, the motor in the eleventh embodiment is generally structurally similar to the seventh embodiment, except for a pressure device 10 that is further mounted to the hollow space 31 of the shaft 3 . The pressure device 10 is a turbine blade assembly being able to guide a cooling fluid 6 (i.e. ambient air) into the hollow space 31 when the shaft 3 is rotating, so as to remove heat from the rotating shaft 3 to achieve the purpose of cooling the motor.
[0066] FIG. 21 is an assembled longitudinal sectional view of a twelfth embodiment of the motor according to the present invention. As shown, the motor in the twelfth embodiment is generally structurally similar to the ninth embodiment, except for a pressure device 10 that is further connected to one end of the shaft 3 . The pressure device 10 is a fan being able to forcedly guide a cooling fluid 6 (i.e. ambient air) into the hollow space 31 of the shaft 3 when the shaft 3 is rotating, so as to remove heat from the rotating shaft 3 to achieve the purpose of cooling the motor.
[0067] In the previous eighth to twelfth embodiments, the cooling fluid 6 filled in the hollow space 31 of the shaft 3 may also be air, oil, a refrigerant, or water.
[0068] Please refer to FIGS. 1 to 21 . According to the embodiments of the present invention, the centrifugal heat dissipation device 1 a is a thermosiphon plate. The centrifugal heat dissipation device 1 a is internally in a vacuum low-pressure state and filled with a working fluid 2 . The working fluid 2 absorbs the heat transferred to the centrifugal heat dissipation device 1 a , so that the working fluid 2 in the centrifugal heat dissipation device 1 a is vaporized or boiled. In other words, the working fluid 2 absorbs sufficient latent heat of evaporation and is transformed into a vapor-phase working fluid 21 . The vapor-phase working fluid 21 is subject to a lower radially outward centrifugal force compared to a liquid-phase working fluid 22 . The centrifugal force would guide the vapor-phase working fluid 21 toward a rotating center, i.e. toward a center of the shaft 3 , while guiding the liquid-phase working fluid 22 toward the radially outer side of the heat-absorption zone 12 to thereby achieve a vapor-liquid separating function. Therefore, the centrifugal heat dissipation device 1 a provides better heat transfer efficiency than conventional heat pipes and vapor chambers that guide the working fluid only via the force of gravity.
[0069] The present invention has been described with some preferred embodiments thereof and it is understood that many changes and modifications in the described embodiments can be carried out without departing from the scope and the spirit of the invention that is intended to be limited only by the appended claims. | A centrifugal heat dissipation device and a motor using same are disclosed. The centrifugal heat dissipation device includes a main body having a shaft hole, a heat-absorption zone and a heat-transfer zone. The heat-transfer zone has a radially outer side connected to the heat-absorption zone and a radially inner side connected to the shaft hole. The shaft hole axially extends through the main body for receiving a shaft of a motor therein. A centrifugal force generated by the rotating shaft and accordingly, the heat dissipation device enables enhanced vapor-liquid circulation of a working fluid in the heat dissipation device, so that heat generated by the operating motor is absorbed by the centrifugal heat dissipation device and transferred to the shaft for guiding out of the motor, allowing the motor to have largely upgraded heat dissipation performance. | 5 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a soft stainless steel sheet, which can be formed to an objective shape with high dimensional accuracy without occurrence of cracking even by severe or multi-stage deep drawing or cold-forging.
[0002] Application of a stainless steel excellent in corrosion resistance has been extended to various fields as deterioration of the environment. For instance, a member of a hydraulic pump, which is usually exposed to a humid atmosphere, is manufactured by shearing a stainless steel sheet 1 to a predetermined size, drawing and punching the sheared sheet 1 , piercing the punched sheet 1 , stretch flanging forming the pierced sheet 1 so as to expand a pierced part 2 to an expanded edge 3 , as shown in FIG. 1.
[0003] Austenitic stainless steel such as SUS304 is material much superior in workability to ferritic stainless steel. But, when the austenitic stainless steel is plastically deformed to an objective shape by severe working as shown in FIG. 1, fine cracks often occur especially at the expanded edge 3 .
[0004] Although the inventors investigated and researched for working conditions which enables formation of an austenitic stainless steel sheet to an objective shape without fine cracks, cracking was not completely suppressed by mere control of working conditions. Then, the inventors investigated effects of materials on occurrence of fine cracks, and reached the conclusion that cracking is assumed to be caused by the following mechanism:
[0005] When a product manufactured by working an austenitic stainless steel sheet is observed, strain-induced martensite is often detected. Generation of strain-induced martensite is distinct at a heavily deformed part such as an expanded edge 3 . Such the strain-induced martensite makes a stainless steel sheet 1 harder.
[0006] When such a heavily deformed part is further worked (expanded), a work stress concentrates at boundaries of the strain-induced martensite due to difference in deformation resistance between austenite grains and the strain-induced martensite. Concentration of a work stress causes occurrence of microcracks. Microcracks are developed by distortion introduced during working and observed as fine cracks.
[0007] Fine cracks significantly degrades a commercial value of a product, but also causes troubles on the succeeding steps. It is also difficult to install such a defective member in a hydraulic pump. Furthermore, fine cracks acts as starting points of corrosion, so that a life time of a hydraulic pump is shortened.
[0008] Fine cracks are also detected in a product which is manufactured by cold-forging a stainless steel sheet to an objective shape. Moreover, demands for improvement on properties of stainless steel including longevity of forging dies is getting stronger and stronger in correspondence with adoption of severe forging conditions.
SUMMARY OF THE INVENTION
[0009] The present invention aims at provision of a soft austenitic stainless steel sheet, which is formed to an objective shape without any cracking even by severe or multi-stage deep drawing, cold-forgiability and also superior of corrosion resistance.
[0010] A soft austenitic stainless steel sheet newly proposed by the present invention has an austenite-stability index Md 30 , which is defined by the formula (1), adjusted in a range of −120 to −10, a stacking fault formability index SFI, which is defined by the formula (2), adjusted at a value not less than 30 (preferably 35) and Cu concentration of precipitates not more than 1.0 mass % so as to maintain Cu content dissolved in a matrix at 1.0-4.0 mass %.
Md 30 (° C. )=551−462(C+N)−9.2Si−8.1Mn−29(Ni+Cu)−13.7Cr−18.5Mo (1)
SFI ( mJ/m 2 )=2.2Ni+6Cu−1.1Cr−13Si−1.2Mn+32 (2)
[0011] Not less than 70 mass % of nonmetallic inclusions dispersed in a matrix are preferably composed of MnO—SiO 2 —Al 2 O 3 containing not less than 15 mass % of SiO 2 and not more than 40 mass % of Al 2 O 3 , in order to improve workability. Furthermore, a work-hardening exponent n defined by an inclination of a true stress-true strain curve detected by a tensile test and elongation El detected by a uniaxial tensile test are preferably adjusted to 0.40-0.55 and not less than 50%, respectively, in order to manufacture a product without occurrence of any cracking even by multi-stage deep drawing.
[0012] For use as a cold-forged product, the steel sheet is improved in cold-forgiability by adjusting a true stress not more than 1200 MPa at a true strain of 1.0 in a true stress-true strain curve obtained by a compression test at a strain speed of 0.01/second.
[0013] The newly proposed austenitic stainless steel sheet preferably consists of up to 0.06 mass % (C+N), up to 2.0 mass % Si, up to 5 mass % Mn, 15-20 mass % Cr, 5-9 mass % Ni, 1-5 mass % Cu, up to 0.003 mass % Al and the balance being essentially Fe except inevitable impurities. The austenitic stainless steel sheet may further contain at least one of up to 0.5 mass % Ti, up to 0.5 mass % Nb, up to 0.5 mass % Zr, up to 0.5 mass % V, up to 3.0 mass % Mo, up to 0.03 mass % B, up to 0.02 mass % REM (rare earth metals) and up to 0.03 mass % Ca.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a schematic view explaining a process for manufacturing a pump member.
[0015] [0015]FIG. 2 is a graph showing an effect of each element on yield strength of 17Cr-12Ni-0.8Mn stainless steel.
[0016] [0016]FIG. 3 is a graph showing an effect of each element on tensile strength of 17Cr-12Ni-0.8Mn stainless steel.
[0017] [0017]FIG. 4 is a flow chart from drawing to expansion of a pierced part.
[0018] [0018]FIG. 5 is a graph showing an effect of an austenite-stability index Md 30 on maximum hardness of a pierced edge.
[0019] [0019]FIG. 6 is a graph showing an effect of a stacking fault formability index SFI on maximum hardness of a pierced edge.
[0020] [0020]FIG. 7 is a graph showing an effect of an austenite-stability index Md 30 on a expanding ratio of a pierced edge.
[0021] [0021]FIG. 8 is a graph showing an effect of a stacking fault formability index SFI on a expanding ratio of a pierced edge.
[0022] [0022]FIG. 9 is a sectional view illustrating a cold-forged product obtained in Example 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] The inventors assumed that occurrence of cracking during forming an austenitic stainless steel sheet was caused by generation of strain-induced martensite as well as difference in deformation resistance between austenite grains and the strain-induced martensite. On the basis of such the assumption, the inventors have investigated and examined effects of mechanical properties on generation of strain-induced martensite.
[0024] Transformation of an austenitic phase to strain-induced martensite is promoted by deformation of crystal lattice of the austenitic phase due to stress introduced during working and concentration of stress in various precipitates dispersed in the austenitic phase.
[0025] Generation of the strain-induced martensite is suppressed by such an alloying design as to maintain an austenite-stability index Md 30 , which is defined by the formula (1), in a range of −120 to −10, preferably −90 to −20. However, neither cracking during working nor hardening is completely inhibited by mere stabilization of an austenitic phase, especially in a process for manufacturing a product with heavy deformation. That is, a remaining austenitic phase is also hardened by introduction of strain during working. The work hardening behavior in this case is influenced by increase of dislocations in the austenitic phase of f.c.c. structure, and a degree of work hardening is determined by occurrence of stacking faults.
[0026] Possibility to generate stacking faults can be indicated by a stacking fault formability index SFI defined by above-mentioned formula (2). When the stacking fault formability index SFI is small, occurrence of stacking faults is accelerated even by a little energy, and propagation of dislocations is suppressed by the stacking faults. As a result, dislocations are accumulated in the matrix, and an austenitic stainless steel sheet is work-hardened. The stacking fault formability index SFI is remarkably raised by solution of Cu in the matrix. In this regard, an alloying element Cu is not only an alternative additive replacing Ni to save a steel cost, but also an effective element for improvement of formability and decrease of work-hardening during severe or multi-stage deep drawing or cold-forging.
[0027] The austenite-stability index Md 30 and the stacking fault formability index SFI are properly adjusted by an alloying design of an austenitic stainless steel. Most important matter is to maintain a ratio of Cu dissolved in a matrix at 1.0-4.0 mass %. Dissolution of Cu at such the ratio remarkably reduces 0.2%-yield strength and tensile strength, as noted in FIGS. 2 and 3, which show effects of each element on yield strength and tensile strength of 17Cr-12Ni-0.8Mn stainless steel, as reported in ISIJ International, Vol. 34 (1994), No.9, p.764-772.
[0028] An effect of Cu on softening is bigger than Ni. According to researches of the inventors on the effect of Cu, dissolved Cu exerts a big influence on softening of the stainless steel, but Cu precipitates such as ε-Cu rather degrades workability of the stainless steel. Concentration of Cu in the matrix or the precipitates is detected by EDX-analysis of a sample observed by a transmission electron microscopy (TEM).
[0029] Dissolved Cu can be adjusted to a proper ratio by controlling conditions of rolling and heat-treatment during manufacturing a stainless steel strip or sheet. For instance, a proper ratio of dissolved Cu is assured by annealing a hot- or cold-rolled strip at a temperature of 1000° C. or higher. There is not any restriction of a heating time, as far as the strip is heated at 1000° C. or higher.
[0030] Generation of strain-induced martensite is suppressed by maintenance of the austenite-stability index Md 30 in a range of −120 to −10, and occurrence of stacking faults is suppressed by maintenance of the stacking fault formability index SFI at a value not less than 30. Furthermore, hardening caused by generation of the strain-induced martensite and also hardening of an austenitic phase caused by accumulation of dislocations are suppressed by maintenance of dissolved Cu at a ratio of 1.0-4.0 mass %. Consequently, an austenitic stainless steel sheet can be plastically deformed to an objective shape without degradation of workability and softness.
[0031] The austenite-stability index Md 30 not more than −20 assures formation of the austenitic stainless steel to an objective shape under stable working conditions, since the transformation behavior toward strain-induced martensite is hardly influenced by falling of an ambient temperature or rise of a working speed. On the other hand, adjustment of the austenite-stability index Md 30 not less than −90 favorably saves a steel cost, since austenite formers such as expensive Ni are not necessarily added too much.
[0032] The work-hardening exponent n in a range of 0.40-0.55 and elongation El not less than 50% also facilitate a severe or multi-stage deep drawing process for manufacturing a product without cracks. The work-hardening exponent n and the elongation El can be adjusted to proper levels by controlling conditions of rolling and heat-treatment during manufacturing a stainless steel strip.
[0033] The work-hardening exponent n is calculated as inclination of a true stress-true strain curve obtained from data of a tensile test using a sample, which is cut off a stainless steel sheet along a transverse direction crossing a rolling direction and shaped to a 13B specimen regulated under JIS Z2201. The elongation El is detected by the same tensile test, wherein a sample is pulled until broken, and the broken pieces are butted together to measure elongation of a distance between marked points.
[0034] Furthermore, a stainless steel sheet is plastically deformed with ease during press-working by adjustment of a true stress to a level not more than 1200 MPa at a true strain of 1.0 in a true stress-true strain curve obtained by a compression test at a strain speed of 0.01/second. Such the adjustment is also effective for longevity of metal dies. Consequently, a cold-forged product can be manufactured at an economical cost.
[0035] A soft stainless steel sheet, which has a work-hardening exponent n in a range of 0.40-0.55 and elongation El not less than 50%, absorbs a strain introduced during working as plastic deformation (i.e., metal flow). Moreover, softness of austenitic stainless steel itself is maintained during secondary operation due to the alloying design resistant to generation of strain-induced martensite and occurrence of stacking faults. Therefore, the stainless steel sheet can be applied to a member of a hydraulic pump as shown in FIG. 1, but also casing of a motor or sensor manufactured by severe multi-stage deep drawing, and a canopy of a lamp or the like manufactured by ironing.
[0036] Workability of the austenitic stainless steel sheet is further improved by conversion of nonmetallic inclusions precipitated in a matrix to soft MnO—SiO 2 —Al 2 O 3 . The effect of nonmetallic inclusions on workability is apparently noted by converting not less than 70 mass % of the nonmetallic inclusions to MnO—SiO 2 —Al 2 O 3 containing not less than 15 mass % of SiO 2 and not more than 40 mass % of Al 2 O 3 .
[0037] MnO—SiO 2 —Al 2 O 3 inclusion is generated by deoxidizing molten steel with a Si alloy containing less than 1 mass % of Al in present of basic slag in a vacuum or non-oxidizing atmosphere. The MnO—SiO 2 —Al 2 O 3 inclusion, different from hard galaxite (MnO—Al 2 O 3 ) containing more than 40 mass % of Al 2 O 3 generated in an ordinary refining process, is elongated in response to plastic deformation of an austenitic stainless steel during working so that it does not act as a point for initiation of cracking.
[0038] The newly proposed austenitic stainless steel sheet preferably contains up to 0.06 mass %(C+N), up to 2.0 mass % Si, up to 5 mass % Mn, 15-20 mass % Cr, 5-9 mass % Ni, 1.0-4.0 mass % Cu, up to 0.003 mass % Al and up to 0.005 mass % S. The austenitic stainless steel sheet may further contain at least one or more of up to 0.5 mass % Ti, up to 0.5 mass % Nb, up to 0.5 mass % Zr, up to 0.5 mass % V, up to 3.0 mass % Mo, up to 0.03 mass % B, up to 0.02 mass % REM (rare earth metals) and up to 0.03 mass % Ca.
[0039] Although the above-mentioned composition itself is already proposed by the applicant in JP 9-263905 A1, a new austenitic stainless steel sheet good of formability is provided by properly conditioning the austenite-stability index Md 30 and the stacking fault formability index SFI. The new austenitic stainless steel sheet can be formed to an objective shape without any cracks caused by generation of strain-induced martensite or hardening of an austenite phase, so as to enable of manufacturing a product good of corrosion resistance and dimensional accuracy.
[0040] Effects of these alloying elements will be apparent from the following explanation.
[0041] (C+N) up to 0.06 Mass %
[0042] As increase of C and N contents, an austenitic stainless steel sheet raises its 0.2%-yield strength and hardness due to solution-hardening. C and N unfavorably harden strain-induced martensite, and put harmful influences on deep drawability, stretch flanging formability, secondary operation formability and compression deformability. Excessive addition of C also causes occurrence of fracture (so-called “season-cracking”) at a part heavily strained during stretch flanging forming. Defects caused by C and N is inhibited by controlling a total ratio of C and N to 0.06 mass % or less.
[0043] Si up to 2.0 Mass %
[0044] Si is an alloying element derived from a deoxidizing agent added to molten steel during steel-making. Excessive addition of Si more than 2.0 mass % hardens an austenitic stainless steel sheet, accelerates work-hardening, and degrades secondary operation formability. Si content is preferably controlled not more than 1.2 mass % (more preferably not more than 0.8 mass %), in order to increase a stacking fault formability index SFI to a value of 35 or more effective for suppression of work-hardening.
[0045] In the region where Si content exceeds 1.2 mass %, an austenitic stainless steel sheet is improved in stress corrosion cracking-resistance although its workability is somewhat degraded. An alloying design to maintain a stack fault difficulty index SFI at a value not less than 30 is also effective even in such the case, in order to well balance stress corrosion cracking-resistance with secondary operation formability.
[0046] Mn up to 5 Mass %
[0047] As increase of Mn content, strain-induced martensite is hardly generated, and 0.2%-yield strength, a degree of work-hardening and resistance to compression deformation are reduced. However, excessive addition of Mn more than 5 mass % accelerates damage of refractory during steel-making and generation of Mn-containing inclusions which will act as points for initiation of cracking during working.
[0048] 15-20 Mass % Cr
[0049] Cr is an essential element for improvement of corrosion resistance, and its effect on corrosion resistance is apparently noted at Cr content not less than 15 mass %. Co-presence of Ni intensifies the effect of Cr on corrosion resistance. But, an austenitic stainless steel sheet is made harder, and its secondary operation formability, deep-drawability, stretch flanging formability and compression deformability are unfavorably degraded as increase of Cr content. In this regard, an upper limit of Cr content is determined at 20 mass %.
[0050] 5-9 Mass % Ni
[0051] Ni is an alloying element effective for improvement of corrosion resistance such as pitting resistance in co-presence of Cr. The effect of Ni on corrosion resistance is apparently noted at 5 mass % or more. As increase of Ni content, an austenitic stainless steel is softened and improved in secondary operation formability, deep-drawability, stretch flanging formability or compression deformability due to suppression of work-hardening caused by generation of strain-induced martensite. However, since excessive addition of expensive Ni raises a steel cost, an upper limit of Ni content is determined at 9 mass % accounting the effect on workability in relation with a steel cost.
[0052] 1.0-4.0 Mass % Cu
[0053] Cu is an alloying element, which suppresses work-hardening caused by generation of strain-induced martensite, softens an austenitic stainless steel sheet and improves secondary operation formability, deep-drawability, stretch flanging formability and compression deformability. These effects are typically noted at Cu content not less than 1.0 mass %. Dissolution of Cu in a steel matrix is preferable for realizing such the effects, but workability is rather degraded as increase of Cu-containing precipitates. A ratio of Cu-containing precipitates can be properly suppressed by controlling conditions of rolling and heat-treatment. Since Cu is an austenite former, Ni content can be selected within a broader range as increase of Cu content. For instance, addition of Cu at a ratio of 2.0 mass % or more allows reduction of a lower limit of Ni content near 5 mass %. However, excessive addition of Cu more than 4.0 mass % puts harmful influences on hot-workability of an austenitic stainless steel sheet.
[0054] Al up to 0.003 Mass %
[0055] Al content shall be controlled to a value not more than 0.003 mass %, in order to convert nonmetallic inclusions, which are precipitated in a steel matrix, to soft and elongatable MnO—SiO 2 —Al 2 O 3 . If Al content exceeds 0.003 mass %, hard Al 2 O 3 clusters, which will act as points for initiation of cracking during working, are easily generated.
[0056] S up to 0.005 Mass %
[0057] Hot-workability of an austenitic stainless steel sheet in a hot-rolling step is degraded, if S content exceeds 0.005 mass %. S also puts harmful influences on secondary operation formability, deep-drawability, stretch flanging formability and compression deformability. Corrosion resistance is also degraded, since dispersion of MnS inclusion in a steel matrix is accelerated as increase of S content. S content is preferably controlled at a value not more than 0.03 mass %, in order to reduce type-A inclusions, especially MnS, which act as points for initiation of fracture in a working step to expand a pierced part.
[0058] 0-0.5 Mass % Each of Ti, Nb, Zr and V
[0059] Ti, Nb, Zr and V are optional elements, which suppress hardening of an austenitic stainless steel sheet by fixing solution-hardening elements such as C and N, resulting in improvement of secondary operation formability, deep-drawability, stretch flanging formability and compression deformability. The effect of these elements is saturated at 0.5 mass %. A lower limit of each element is preferably determined at 0.01 mass %, in order to convert nonmetallic inclusions to soft MnO—SiO 2 —Al 2 O 3 .
[0060] 0-3.0 Mass % Mo
[0061] Mo is also an optional alloying element for improvement of corrosion resistance. But, excessive addition of Mo causes increase of hardness and resistance to compression deformation, so that an upper limit of Mo content shall be determined at 3 mass %.
[0062] B is also an optional alloying element for improvement of hot-workability to inhibit cracking during hot-rolling. But, excessive addition of B rather degrades hot-workability, so that an upper limit of B content shall be determined at 0.03 mass %.
[0063] 0-0.2 Mass % REM (Rare Earth Metals)
[0064] REM is also an optional alloying element effective for improvement of hot-workability as the same as B. The effect of REM is saturated at 0.02 mass %, but excessive addition of REM more than 0.02 mass % causes hardening and poor workability of an austenitic stainless steel sheet. An upper limit of REM is preferably 0.005 mass %, in order to convert nonmetallic inclusions to soft MnO—SiO 2 —Al 2 O 3 .
[0065] 0-0.03 Mass % Ca
[0066] Ca is also an optional alloying element effective for improvement of hot-workability. The effect of Ca on hot-workability is saturated at 0.03 mass %, and excessive addition of Ca more than 0.03 mass % causes poor cleanliness of an austenitic stainless steel. An upper limit of Ca is preferably 0.005 mass %, in order to convert nonmetallic inclusions to soft MnO—SiO 2 —Al 2 O 3 .
EXAMPLE 1
[0067] Each stainless steel having composition shown in Table 1 was refined, continuously cast to a slab, and hot-rolled to thickness of 3 mm at an extracting temperature of 1230° C. The hot-rolled steel strip was annealed 1 minute at 1150° C., pickled with an acid, and then cold-rolled to thickness of 0.4 mm. Thereafter, the cold-rolled steel strip was annealed 1 minute at 1050° C., and pickled again.
[0068] Each cold-rolled steel strip manufactured in this way had mechanical properties as shown in Table 2.
TABLE 1 COMPOSITIONS OF AUSTENITIC STAINLESS STEELS USED IN EXAMPLE 1 Steel Alloying Elements (mass %) dissolved Cu Kind C Si Mn Ni Cr S Cu Mo N Md 30 SFI (mass %) NOTE A 0.014 0.37 1.69 7.91 16.90 0.001 3.20 0.10 0.021 −37.8 43.2 2.9 Inventive Example B 0.014 0.33 1.47 12.02 17.03 0.003 1.93 0.07 0.012 −114.7 45.2 1.8 Inventive Example C 0.047 0.46 0.90 8.70 18.20 0.015 0.20 0.78 0.029 −17.5 25.3 0.2 SUS304 D 0.005 0.22 1.15 9.53 18.84 0.013 0.05 — 0.013 −4.6 28.3 0.1 Comparative Example E 0.020 1.44 2.03 6.99 15.90 0.004 1.95 — 0.028 −22.0 20.4 1.7 Comparative Example
[0069] [0069] TABLE 2 MECHANICAL PROPERTIES OF STAINLESS STEEL SHEETS Steel 0.2%-yield tensile strength Vickers hardness elongation* Kind strength (MPa) (MPa) (HV) (%) A 220 511 111 55 B 222 502 109 52 C 274 637 160 57 D 339 631 154 46 E 288 626 130 55
[0070] A blank of 74 mm in diameter was sheared from each stainless steel sheet, and drawn to height of 7 mm with a blank-holding pressure of 1 ton, using a cylindrical punch of 33 mm in diameter having a punch radius of 3 mm and a die of 35 mm in diameter having a die radius of 3 mm. An opening of 10 mm in diameter was then formed in the drawn blank at its center, and then the opened edge 2 was expanded in presence of a lubricating oil having viscosity of 60 mm 2 /s (at 40° C.), as shown in FIG. 4, using a cylindrical punch of 33 mm in diameter having a punch radius of 3 mm and a beaded die of 35 mm in diameter having a die radius of 3 mm.
[0071] Thereafter, hardness of the pierced edge 2 was measured, and hardening of the blank caused by piercing was evaluated by the maximum value of the measured hardness.
[0072] In order to quantitatively evaluate stretch flanging formability, the pierced edge 2 was expanded by pushing a punch therein until occurrence of cracking, a diameter of the opening on occurrence of cracking was measured, and a critical expanding ratio ER cri. (%) was calculated according to the formula of: ER cri. =(R 1 −R 0 )/R 0 ×100, wherein R 0 is an initial diameter of the opening and R 1 is a diameter of the opening on occurrence of cracking.
[0073] Results are shown in Table 3. It is understood that the maximum hardness of the expanded edge 2 was merely 310 HV as for the steel A or 308 HV as for the steel B (Inventive Examples), while the maximum hardness was significantly raised to a value of 360 HV or more as for the steels C to E (Comparative Examples). Cracks were not detected at the expanded edge 2 , until an expanding ratio of the edge 2 exceeded 70% as for the steel A or 69% as for the steel B. On the contrary, cracks occurred at the expanded edge 2 , even when any of the steels C to E was worked at a fairly low expanding ratio.
TABLE 3 MAXIMUM HARDNESS OF PIERCED EDGES AND CRITICAL EXPANDING RATIOS IN RESPONSE TO STEEL KIND Steel maximum hardness of A critical expanding ratio Kind a pierced edge (HV) (%) A 310 70 B 308 69 C 362 52 D 381 47 E 390 43
[0074] Results shown in Table 3 prove that the critical expanding ratio is more reduced as a steel sheet was made harder by deep-drawing and piercing. Decrease of the critical expanding ratio means limitation of an opening defined by the expanded edge to small diameter.
[0075] Then, the inventors researched and examined an effect of an austenite-stability index Md 30 on work-hardening as well as an effect of a stacking fault formability index SFI on elongation. For the researches and examinations, various stainless steel sheets were prepared, whose austenite-stability index Md 30 and stacking fault formability index SFI were varied by increase or decrease of each alloying component on the basis of the composition of the steel A.
[0076] A blank sheared from each stainless steel sheet was deeply drawn, pierced and expanded under the same conditions as above-mentioned. Maximum hardness of the expanded edge 2 and a critical expanding ratio were investigated in relation with the austenite-stability index Md 30 and the stacking fault formability index SFI.
[0077] Results are shown in FIGS. 5 to 8 . It is understood that a bigger expanding ratio above 60% was gained while suppressing increase of maximum hardness of the expanded edge 2 at a level not more than 350 HV, when the austenite-stability index Md 30 was controlled in a range of −120 to −10, and the stacking fault formability index SFI was controlled not less than 30.
[0078] Accounting these results, a stainless steel sheet (which belongs to the steel A in Table 1) having an austenite-stability index Md 30 of −37.8 and a stacking fault formability index SFI of 43.2 was drawn to height of 7 mm, pierced with a diameter of 26 mm and burred to expand a pierced edge 2 to diameter of 33 mm under the same conditions as above-mentioned.
[0079] 1000 pieces of blanks were worked in this way, without occurrence of cracking at the expanded edges 3 . Therefore, the blanks were well used as members installed in hydraulic pumps. On the other hand, when blanks sheared from stainless steel sheets having either one or both of an austenite-stability index Md 30 more than −10 and a stacking fault formability index SFI less than 30 were worked under the same conditions, cracking inevitably occurred at the expanded edge 3 .
TABLE 4 EFFECTS OF VALUES Md 30 AND SFI ON OCCURRENCE OF CRACKING after piercing after expanding a number of maximum hardness (HV) maximum hardness (HV) presence defective goods Md 30 SFI of a pieced edge of an expanded edge of cracks (pieces/1000) −38 43 310 357 no 0 −28 21 361 441 yes 113 −18 20 381 446 yes 204 −2 32 392 453 yes 831 −5 38 390 452 yes 797 −88 42 302 351 no 0 −93 29 294 350 yes 76 −42 41 315 363 no 0 −37 29 357 438 yes 37
EXAMPLE 2
[0080] Each stainless steel having the composition shown in Table 5 was refined, continuously cast to a slab, hot-rolled to thickness of 3 mm at an extracting temperature of 1230° C. After the hot-rolled steel strip was annealed 1 minute at 1150° C., it was pickled and cold-rolled to thickness of 0.4 mm. Thereafter, the cold-rolled steel strip was finish-annealed 1 minute at 1050° C. and then pickled again.
[0081] A blank sheared from each steel strip was observed by a microscope, and SiO 2 and Al 2 O 3 concentrations of nonmetallic inclusions precipitated in a steel matrix were measured by EPMA analysis. Results are shown in Table 6, together with an austenite-stability index Md 30 and a stacking fault formability index SFI. Cu concentration of precipitates, which was measured by EDX analysis in a visual field of TEM, is also shown in Table 6. On the other hand, Table 7 shows mechanical properties of each stainless steel sheet.
TABLE 5 COMPOSITIONS OF STAINLESS STEELS USED IN EXAMPLE 2 Steel Alloying Elements (mass %) No. C Si Mn Ni Cr S Cu N Al others 1 0.010 0.32 1.58 7.96 17.01 0.001 3.19 0.010 0.0013 — 2 0.020 0.60 0.56 8.91 18.21 0.003 2.12 0.020 0.0016 — 3 0.030 0.45 1.44 8.20 18.45 0.002 2.86 0.028 0.0026 — 4 0.040 0.44 1.44 8.31 17.81 0.001 1.95 0.022 0.0024 — 5 0.052 0.29 1.21 7.31 18.46 0.001 2.03 0.040 0.0022 — 6 0.012 0.95 3.12 8.20 14.60 0.002 2.85 0.010 0.0010 — 7 0.020 0.50 0.51 9.12 21.51 0.002 2.21 0.020 0.0013 — 8 0.010 0.41 1.31 8.19 18.43 0.006 2.01 0.010 0.0011 — 9 0.020 0.55 1.12 8.74 18.31 0.008 1.99 0.011 0.0019 — 10 0.020 0.44 0.65 7.42 18.33 0.001 2.23 0.020 0.0014 Mo: 2.55 11 0.013 0.59 0.55 7.91 16.41 0.003 1.95 0.022 0.0008 Mo: 3.02 12 0.010 0.50 0.70 7.21 17.63 0.002 4.21 0.010 0.0012 B: 0.008 13 0.035 0.61 4.02 8.61 18.25 0.001 2.85 0.012 0.0010 — 14 0.008 0.42 2.01 7.93 17.98 0.002 3.05 0.002 0.0018 Ti: 0.002 15 0.011 0.83 1.12 6.32 18.93 0.001 4.33 0.008 0.0015 Nb: 0.22 16 0.020 0.48 0.89 8.96 18.12 0.002 1.78 0.015 0.0017 Zr: 0.003 17 0.010 0.22 4.21 6.78 17.12 0.003 2.96 0.020 0.0025 V: 0.004 18 0.021 0.35 2.12 8.81 19.12 0.001 2.33 0.018 0.0026 Ca: 0.001 19 0.018 0.65 1.58 6.92 19.52 0.001 3.35 0.011 0.0012 REM: 0.001
[0082] [0082] TABLE 6 Md 30 , SFI AND INCLUSIONS OF EACH STAINLESS STEEL nonmetallic inclusions SiO 2 Al 2 O 3 Cu concentration Steel concentration concentration of precipitates No. Md 30 SFI (mass %) (mass %) (mass %) 1 −30.4 43.9 93 5 0.1 2 −46.9 35.8 77 8 0.3 3 −65.1 39.3 65 21 0.1 4 −34.9 34.9 31 32 0.2 5 −27.7 34.7 45 29 0.5 6 −13.6 35.0 60 5 0.1 7 −99.5 34.6 52 18 0.1 8 −20.9 34.9 17 5 0.3 9 −39.5 34.5 33 21 0.1 10 −54.9 35.0 25 13 0.1 11 −41.7 34.7 85 5 0.1 12 −41.2 46.4 96 2 0.8 13 −91.3 35.2 98 1 0.3 14 −38.5 40.1 61 12 0.4 15 −42.7 38.9 74 13 0.7 16 −36.5 35.2 82 14 0.2 17 −16.0 37.9 65 31 0.2 18 −72.4 37.2 42 28 0.1 19 −46.4 35.5 33 11 0.2
[0083] [0083] TABLE 7 MECHANICAL PROPERTIES OF EACH STAINLESS STEEL 0.2% yield tensile Vickers a work Steel strength strength Hardness elongation El* hardening No. (MPa) (MPa) (HV) (%) exponent n 1 195 489 112 64 0.40 2 203 512 123 63 0.48 3 225 530 108 65 0.44 4 264 652 151 61 0.52 5 288 671 158 59 0.51 6 210 514 131 63 0.41 7 291 675 165 61 0.43 8 203 531 118 58 0.41 9 201 525 121 53 0.49 10 281 551 158 56 0.51 11 295 581 171 61 0.42 12 216 498 131 65 0.43 13 222 501 125 66 0.40 14 198 533 121 65 0.41 15 234 541 126 61 0.46 16 241 581 131 68 0.44 17 218 602 138 62 0.42 18 205 591 118 59 0.40 19 198 570 113 58 0.41
[0084] A blank of 74 mm in diameter was sheared from each stainless steel sheet, and drawn to height of 7 mm with a wrinkle-suppressing pressure of 1 ton, using a cylindrical punch of 33 mm in diameter having a punch radius of 3 mm and a die of 35 mm in diameter having a die radius of 3 mm. The drawn blank was pierced with an opening of 26 mm in diameter at its center bottom, and then burred to expand the pierced part 2 in presence of a lubricating oil having viscosity of 60 mm 2 /s (at 40° C.) using a cylindrical punch of 33 mm in diameter with a punch radius of 3 mm and a die of 35 mm in diameter with a die radius of 3 mm, as shown in FIG. 1.
[0085] Each blank was observed to research its workability according to occurrence of cracking at the expanded edge 3 .
[0086] Furthermore, after a 5%-NaCl solution of 35° C. was continuously sprayed 1000 hours to each blank, a surface of each blank was observed by an optical microscope to measure depth of pitting corrosion at 30 points. Pitting resistance was evaluated according to maximum depth of pitting corrosion among the measured values.
[0087] Results are shown in Table 8. It is understood that the steels Nos. 1 to 3 are materials suitable for a pump member, which shall be manufactured by a severe multi-stage deep drawing process, since the steels Nos. 1 to 3 were formed to an objective shape without occurrence of cracking and maximum depth of pitting corrosion was suppressed less than 0.1 mm.
[0088] On the other hand, a pump member made of the steel No. 4 containing more than 0.06 mass % of (C+N) had the defect that necking occurred at the expanded edge 3 , although its pitting resistance was sufficient. A pump member made of the steel No. 5 containing much more of (C+N) involved numerous cracks at the expanded edge 3 , and season cracking also occurred at 20 hours after the expansion. The steel No. 5 was poor of pitting resistance, as noted by maximum depth of pitting corrosion above 0.1 mm.
[0089] A pump member made of the steel No. 6 containing less than 16 mass % of Cr was good of stretch flanging formability, but poor of pitting resistance as noted by maximum depth of pitting corrosion above 0.1 mm. When the steel No. 7 containing more than 20 mass % of Cr was formed to a pump member, numerous cracks occurred at an edge 3 expanded by stretch flanging forming.
[0090] The steel No. 8 containing more than 0.005 mass % of S was good of pitting resistance, but could not be formed to a pump member since necking occurred at an edge 3 expanded by stretch flanging forming. The steel No. 9 could not be formed to a pump member either due to the same defective shaping as the steel No. 8, and its pitting resistance was inferior as noted by maximum depth of pitting corrosion above 0.1 mm.
[0091] Any of the other steels Nos. 10 and 12 to 19 containing one or more of Mo V, Al, Ti, Nb, Zr, V, Ca and REM at a ratio defined by the present invention was superior both of stretch flanging formability and pitting resistance, so that it was formed to a pump member without any cracks at the expanded edge 3 . However, when a steel No. 11 containing more than 3 mass % of Mo was formed to a pump member, occurrence of cracking was detected at an edge 3 expanded by stretch flanging forming.
TABLE 8 WORKABILITY AND PITTING RESISTANCE OF EACH STEEL condition of an maximum depth (mm) integrated Steel No. expanded edge of pitting corrosion evaluation 1 good 0.02 ◯ 2 good 0.03 ◯ 3 good 0.02 ◯ 4 necking 0.07 X 5 season cracking 0.12 X 6 good 0.22 X 7 cracking 0.03 X 8 necking 0.06 X 9 necking 0.15 X 10 good 0.03 ◯ 11 cracking 0.04 X 12 good 0.02 ◯ 13 good 0.05 ◯ 14 good 0.01 ◯ 15 good 0.01 ◯ 16 good 0.02 ◯ 17 good 0.04 ◯ 18 good 0.06 ◯ 19 Good 0.06 ◯
EXAMPLE 3
[0092] Each stainless steel having the composition shown in Table 9 was refined, continuously cast to a slab, hot-rolled to thickness of 5 mm at an extracting temperature of 1230° C. After the hot-rolled steel strip was annealed 1 minute at 1100° C., it was pickled.
TABLE 9 COMPOSITIONS OF AUSTENITIC STAINLESS STEELS USED IN EXAMPLE 3 Steel Alloying Elements (mass %) dissolved Cu Kind C Si Mn Ni Cr S Cu Mo N Md 30 SFI (mass %) A 0.014 0.37 1.69 7.93 16.90 0.001 3.2 0.1 0.021 −38.4 43.2 2.9 B 0.020 1.01 1.32 7.52 17.10 0.003 2.6 0.2 0.033 −24.9 30.6 1.9 C 0.042 0.52 0.90 8.10 18.20 0.004 0.2 0.1 0.032 12.8 23.2 0.2 D 0.005 0.61 1.82 9.12 19.11 0.008 0.1 0.2 0.013 −10.6 21.5 0.1 E 0.018 0.52 1.44 9.21 18.21 0.004 2.9 0.2 0.028 −91.1 41.1 1.8 F 0.014 0.33 1.47 8.98 18.50 0.002 4.8 0.2 0.018 −135.3 54.1 3.9
[0093] A columnar test piece of 3.0 mm in outer diameter and 4 mm in height was sampled from each stainless steel sheet. The test piece was compressed at a strain speed of 0.01/second along an axial direction of the column, in order to investigate relationship of a true strain with a true stress during compression deformation.
[0094] Table 10 shows a value of a true stress with a true strain of 1.0 at the time period when height of each test piece was reduced 60% compared with original height. It is understood that the inventive steels A and B exhibited deformation resistance(represented by the true stress) less than 1200 MPa, while deformation resistance of each comparative steels C to E was fairly bigger than 1200 MPa. A test piece of the comparative steel F was cracked at its side before the true strain reached 1.0, and its deformability was worsened.
TABLE 10 COMPRESSION DEFORMABILITY OF STAINLESS STEEL Steel a true stress evaluation of Kind (MPa) compression deformability NOTE A 1045 good Inventive B 1035 good Examples C 1456 bad Comparative D 1376 bad Examples E 1429 bad F (undetectable) bad (cracked before completion of compression)
EXAMPLE 4
[0095] Each stainless steel having composition shown in Table 9 was refined, continuously cast to a slab, and hot-rolled to thickness of 5 mm at an extracting temperature of 1230° C. Each hot-rolled steel strip was annealed at 1100° C. for 1 minute, pickled and then cold-rolled to thickness of 2 mm. The cold-rolled steel strip was annealed at 1050° C. for 1 minute and then pickled.
[0096] Many test pieces of 1 m in width and 2 m in length were sampled from each annealed cold-rolled steel strip, and continuously pressed to a shape of cross-section with ruggedness, as shown in FIG. 9. Height of a convex part of the test piece was measured for evaluation of deformability, after the pressing was repeated to 1000 test pieces. Test results are shown in Table 11, together with an austenite-stability index Md 30 , a stacking fault formability index SFI and a ratio of Cu dissolved in a matrix of each stainless steel.
[0097] It is understood from Table 11 that a cold-forged product manufactured from the inventive steels A and B, which had austenite-stability indices Md 30 in a range of −120 to 10, stacking fault formability indices SFI not less than 30 and ratios of dissolved Cu not less than 1.0 mass %, were of 1 mm height or higher at the convex parts, even after the pressing was repeated 1000 times. Such the height was a value of 80% or more compared with predetermined height.
[0098] On the other hand, any of cold-forged products made from a comparative steel C having an austenite-stability index above −10 and the stacking fault formability index below 30, the comparative steel D having a stacking fault formability index below 30 and the comparative steel E having the structure that precipitates containing Cu at a ratio above 1.0 mass %, was lower than 1 mm at the convex part after 1000 times pressing. Such lower height was a value less than 80% compared with predetermined height. Decrease of height means significant abrasion of metal dies, and proves short longevity of metal dies. When test pieces sampled from the comparative steel F were pressed, they were not pressed to the objective shape due to occurrence of cracks at the convex part from the beginning of press-working.
TABLE 11 EFFECTS OF MD 30 , SFI AND DISSOLVED CU ON SHAPE OF COLD-FORGED PRODUCTS Austenite Stacking Fault Shape of cold-forged product after 1000 times pressing Steel Stability Index Formability Index dissolved Cu height (mm) a ratio (%) to a Kind Md 30 SFI (mass %) at a convex part predetermined height judgement A −38 43 2.9 1.24 99 ◯ B −25 31 1.9 1.22 98 ◯ C 13 23 0.2 0.76 61 X D −11 22 0.1 0.83 66 X E −91 41 1.8 0.82 66 X F −135 54 3.9 cracked from the beginning of press-working X
[0099] The soft stainless steel sheet newly proposed by the present invention is plastically deformed even at a heavy working ratio without either local accumulation of deformation strains or increase of hardness caused by generation of strain-induced martensite and hardening of an austenitic phase, due to an alloying design to suppress generation of strain-induced martensite and hardening of an austenitic phase, as above-mentioned. As a result, the stainless steel sheet can be formed to an objective shape with sufficient elongation, and defects such as cracks are suppressed even during severe or multi-stage deep drawing. The stainless steel sheet can be also cold-forged to an objective shape with less damage of metal dies, due to decrease of resistance to compression deformation. | A new soft stainless steel sheet has an austenite-stability index Md 30 controlled in a range of −120 to −10 and a stacking fault formability index SFI controlled not less than 30, and involves precipitates whose Cu concentration is controlled not more than 1.0%, so as to maintain concentration of dissolved Cu at 1-5%. The stainless steel sheet preferably contains up to 0.06%(C+N), up to 2.0% Si, up to 5% Mn, 15-20% Cr, 5-9% Ni, 1.0-4.0% Cu, up to 0.003% Al, up to 0.005% S, and optionally one or more of up to 0.5% Y, up to 0.5% Nb, up to 0.5% Zr, up to 0.5% V, up to 3.0% Mo, up to 0.03% B, up to 0.02% REM (rare earth metals) and up to 0.03% Ca. The stainless steel sheet can be plastically deformed to an objective shape without any cracks even at a part heavily-worked part by multi-stage deep drawing or compression deforming.
Md 30 (° C. )=551−462(C+N)−9.2Si−8.1Mn−29(Ni+Cu)−13.7Cr−18.5Mo
SFI ( mJ/m 2 )=2.2Ni+6Cu−1.1Cr−13Si−1.2Mn+32 | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to cabinets generally and, more particularly, but not by way of limitation, to novel cabinet and sliding drawer with improved roller construction, improved manufacturability, and a drawer that remains essentially horizontal when fully extended from the cabinet.
2. Background Art
Cabinets with one or more drawers are universally used for the storage and ready accessibility of a wide variety of materials, small parts and business papers being common examples of such materials.
Some such cabinets and drawers are constructed with telescoping two- or three-piece drawer slides, with one of the slides being attached to the drawer and another of the slides being attached to the inside of the cabinet, such a drawer slide assembly being employed on either side of the drawer. In may cases, the slides have one or more wheels, or rollers, disposed between adjacent ones of the slides, the roller(s) being mounted inside the smaller of the slides. This greatly reduces the sliding friction between the slides, but the diameter of the roller is necessarily limited and, therefore, the reduction in sliding friction is limited to the capabilities of a roller having a given diameter. The width of the slides in which the rollers are mounted is somewhat narrow, leading to instability and the tendency for the roller and its corresponding slide to become disengaged.
Cabinet drawer slides are typically horizontally attached to the drawer and to the inside of the cabinet. This arrangement results in the outer end of the drawer dropping somewhat downwardly when the drawer is fully or nearly fully withdrawn from the cabinet, due to the weight of the drawer and because the slides have a certain amount of "play" therebetween as a result of wear or intentional design clearances, the latter being required so that the slides move freely.
Cabinets are typically constructed of metal, with an outer housing having side, rear, top, and bottom walls formed or permanently attached together, sometimes with front rails or a front wall extending between the side walls, separate members being welded together. Slides are usually spot welded to the inside surfaces of the side walls. If an error or defect in one of the members is discovered during manufacture or at final inspection, the entire work to that point must usually be discarded.
Accordingly, it is a principal object of the present invention to provide an improved drawer slide for a cabinet in which the slide has at least one roller having a diameter which can be greater than the internal height of the smaller slide and a width which can be greater than the width of the slide in which it would conventionally be mounted.
It is a further object of the invention to provide an improved cabinet and drawer with which the drawer is substantially horizontal when fully or nearly fully withdrawn from the cabinet.
It is an additional object of the invention to provide an improved cabinet and drawer slide construction that reduces the amount of material that must be discarded due to defects.
It is another object of the invention to provide an improved cabinet in which the foregoing features are economically manufactured.
Other objects of the present invention, as well as particular features, elements, and advantages thereof, will be elucidated in, or be apparent from, the following description and the accompanying drawing figures.
SUMMARY OF THE INVENTION
The present invention achieves the above objects, among others, by providing, in one preferred embodiment, a cabinet with a sliding drawer, comprising: a housing; two opposing outer slides attached to inner surfaces of opposite sides of said housing; two inner slides attached to said sliding drawer and disposed in and telescopingly engaging said outer slides; and two first rollers contacting said inner slides and having their axes attached to said sides of said housing, with said axes of said first rollers spaced below a lower edge of said outer slide. In a further aspect of the invention, there is provided a cabinet with a sliding drawer, comprising: a housing having opposite side panels and front and rear ends; two opposing slide mechanisms attached to inner surfaces of said side panels and to sides of said sliding drawer; and said slide mechanisms being downwardly sloped from said front end of said housing toward said rear of said housing a degree sufficient to compensate for sagging from horizontal said sliding drawer may experience when extended from said housing. In yet another aspect of the invention, there is provided a cabinet, comprising: a generally hollow, rectilinear housing having opposite sides and top, back, and bottom walls; said side panels having rearwardly facing U-shaped channels formed along front edges thereof; inner side panels attachable to said side panels by insertion of front edges thereof into said U-shaped channels and rotating said inner panels about said U-shaped channels to parallel proximity with inner surfaces of said side panels and being removably secured in such position.
BRIEF DESCRIPTION OF THE DRAWING
Understanding of the present invention and the various aspects thereof will be facilitated by reference to the accompanying drawing figures, submitted for purposes of illustration only and not intended to define the scope of the invention, on which:
FIG. 1 is a fragmentary, side elevational view, partially cutaway, of one embodiment of a cabinet with sliding drawer, constructed according to the present invention.
FIG. 2 is a fragmentary, front elevational view of the embodiment of FIG. 1.
FIG. 3 is a fragmentary, side elevational view, partially cutaway, of another embodiment of a cabinet and sliding drawer, constructed according to the present invention.
FIG. 4 is a cutaway, side elevational view of a cabinet with sliding drawers showing another aspect of the present invention.
FIG. 5 is a side elevational view, in cross-section, of an external wrap for a cabinet, constructed according to one aspect of the present invention.
FIG. 6 is a fragmentary, top plan view showing a step in the manufacture of the cabinet.
FIG. 7 is a front elevational view showing a partially completed cabinet.
FIG. 8 is a cutaway side elevational view of the completed cabinet.
FIG. 9 is a side elevational, cross-sectional view of a partially completed cabinet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference should now be made to the drawing figures, on which similar or identical elements are given consistent identifying numerals throughout the various figures thereof, and on which parenthetical references to figure numbers direct the reader to the view(s) on which the element(s) being described is (are) best seen, although the element(s) may be seen also on other views.
FIG. 1 illustrates one embodiment of a cabinet and sliding drawer constructed according to the present invention, the cabinet being generally indicated by the reference numeral 20 and the drawer being generally indicated by the reference numeral 22. As shown, drawer 22 includes a compartment parts box 30 mounted covered with a hinged lid 32 for access to the interior of the box. Box 30 is attached to front and rear cradle members 34 and 36, respectively, by means of tabs, as at 38, the front and rear cradles being connected by a centrally disposed crossmember 40 extending therebetween and attached thereto. Cabinet 20 and drawer 22 are arranged so that box 30 may be fully withdrawn from the cabinet. It will be understood that the above is only one of a number of conventional cabinet/drawer arrangements with which the present invention may be employed.
Attached to the inner surface of cabinet 20 is a horizontal outer slide member 50 and attached to the one side of drawer 22 is an inner slide member 52. As with conventional drawer slides, inner slide 52 telescopingly engages the interior of outer slide 50. Accidental complete withdrawal of drawer 22 from cabinet 20 is prevented by the engagement of a loop 54 formed on inner slide 52 engaging a stop 56 attached to outer slide 50.
In the case of the present invention, there is no roller disposed between outer and inner slides 50 and 52. Rather, the present invention provides a roller 60 engaging inner slide 52, but having its axis disposed externally to outer slide 50. Roller 60 has its axle 62 attached to the inner surface of cabinet 20 and contacts the lower edge of inner slide 52 through an opening 64 defined through the lower edge of outer slide 50. FIG. 2 more clearly illustrates aspects of this arrangement. A ball bearing (not shown) may be disposed between roller 60 and axle 62.
FIG. 3 illustrates the elements of FIGS. 1 and 2 with the addition of a second roller 70, having its axle 72 disposed externally to outer slide 50, and contacting the upper edge of inner slide 52 through an opening 74 defined through the outer slide. Such an arrangement is particularly useful when the drawer is to contain heavy materials and, especially, when it is to be fully withdrawn as is shown on FIGS. 1 and 3. When used with two or more drawers, roller 70 can be offset rearwardly from roller 60 (as shown) to nest behind the equivalent of roller 60 (not shown) contacting an inner slide (not shown) above roller 70, in space not otherwise used.
The use of external rollers 60 (FIGS. 1 and 2) or rollers 60 and 70 (FIG. 3) offers several advantages over conventionally constructed cabinet/drawer arrangements. One of these is that wider rollers may be employed. In the typical construction, tabs 38 protrude into inner slide 52, limiting the width of a roller disposed within the inner slide. Use of external rollers 60 or 60 and 70 permits use of rollers of much larger diameters than internally disposed rollers. This permits a significantly higher O.D./I.D. ratio with inherently reduced friction. With the use of an external roller 60 or rollers 60 and 70, the rollers can be made wider, thus providing more stability while decreasing the I.D. requirement for a given load and enhancing the above ratio and reducing friction.
FIG. 4 illustrates a cabinet with sliding drawers, generally indicated by the reference numeral 80, and constructed according to another aspect of the present invention.
Cabinet 80 is shown as having a plurality of drawers, as at 82, which are similar to drawer 22 (FIGS. 1-3), although it will be understood that this aspect of the invention is not so limited and the invention may be used, as well, with other types of drawers and any number of drawers, including a single drawer. Cabinet 80 is also shown as employing external rollers, as at 84, although it will be understood that the invention may be used, as well, in cabinets using no rollers or cabinets with conventional rollers disposed internally of slides.
Cabinet 80 includes a plurality of outer and inner slides 90 and 92, respectively, having the same form and function of outer and inner slides 20 and 22 (FIGS. 1-3). Again, the present invention is not limited to the types of slides shown. As can be observed from FIG. 4, slides 90 and 92 are canted such that they slope downwardly inwardly from the front of cabinet 80. The angle of cant is chosen such that, when drawer 82 is withdrawn fully or nearly fully from cabinet 80, the drawer will be essentially horizontal, the angle of cant compensating for any wear or intentional design clearances.
In the present case, the fronts of boxes 94 remain orthogonal to the major axes of the boxes, the lips 96 of the lids 98 of the boxes offsetting the canted fronts appearancewise. With drawers having greater height and/or with a cabinet with a front panel, it may be desirable to mount the fronts of the drawers at an angle so they lie in the same plane as the front of the cabinet.
FIGS. 5-9 illustrate an aspect of the present invention whereby construction of a cabinet with sliding drawers is easily performed, while minimizing the amount of defective materials that must be discarded.
FIG. 5 illustrates an external wrap for a cabinet constructed according to the present invention, the wrap being generally indicated by the reference numeral 110. Wrap 110 includes a back panel 120 which will become the back panel of the cabinet and top and bottom panels 122 and 124 which will become, respectively, the top and bottom panels of the cabinet. The front edges of top and bottom panels 122 and 124 have rearwardly open U-shaped channels 126 and 128, respectively, formed therealong. It should be noted that wrap 110 is symmetrical about its central axis such that bottom panel 124 can serve as the top panel of the cabinet. This feature is advantageous when, for example, panel 122 is found to contain a visual defect that would preclude its use as a top panel for the cabinet. Wrap 110 can then be inverted 180 degrees, thus avoiding discarding the wrap. FIG. 5 also shows inwardly bent tabs 130 formed in back panel.
FIG. 6 illustrates back panel 120 with a right side panel 140 spot welded to the right edge of the back panel. It will be understood that there is a left side panel (not shown on FIG. 6), which is a mirror image of right side panel 140, and which is similarly attached to the left edge of the back panel. Right side panel 140 includes a rearwardly facing U-shaped channel 142 formed along the front edge thereof.
An inner panel 144 has an outer slide 146 attached thereto and has a sidewardly offset lip 148 formed along the front edge of the panel. To attach inner panel 144 to right side panel 140, lip 148 is inserted in channel 142, as indicated by the broken arrow on FIG. 6. Then, inner panel 144 is rotated about lip 148, as indicated by the solid arrow on FIG. 6 and until the rear edge (not shown) of the inner panel snaps behind the ends of tabs 130. Inner panel 144 can be easily removed by depressing tabs 130 and swinging the inner panel away from right side panel 140.
FIG. 7 illustrates wrap 110 with right side panel 140 attached thereto and inner panel 144 attached to the right side panel. Also shown is a left side panel 150 attached to wrap 110 in the same manner as right side panel 140 and an inner panel 152 attached to the left side panel. The front edge of inner panel 152 is attached to left side panel 150 in the same manner as inner panel 144 is attached to right side panel 140; however, the rear of inner panel 152 is removably attached to wrap 110 by means of tabs 154 formed on inner panel 152 snapping behind tabs 156 formed on the wrap. It will be understood that to maintain wrap 100 in a symmetrical shape, only one type of attachment means will be used on both sides of the wrap. No slides are shown; however, the usual method of construction is to attach slides to inner panels before attachment of inner panels to cabinet sides.
FIG. 8 illustrates that inner panels 144 and 152 are symmetrical and identical. It will be understood that, although drawers and rollers are shown which are identical to those described above, this aspect of the invention is applicable to cabinets with any type of drawers and with or without rollers. Registration holes, as at 160 are defined through the front and rear ends of the slides and through inner panel 152 to properly align the slides on the panel with a suitable fixture (not shown). When inner panel 152 is used as inner panel 144 (FIG. 6 and 7), the same registration holes 160 will be used for the same purpose; however, when rollers are used, a second set of holes, at 162, are provided in the panel for the axles of the rollers so that the panel can be used on either side of the cabinet. Outer and inner slides 164 and 166 are also symmetrical about their major axes, so that they may be used on either right or left inner side panels.
FIG. 9 illustrates that symmetry can be provided even when inner panels are to be used with canted slides (FIG. 4). Here, a left side inner panel 170 has attached thereto a canted outer slide 172. Inner panel 170 is provided with registration holes 174 defined therethrough for locating the front ends of outer slides 172 regardless of whether the inner panel is used on the left or the right side of a cabinet. If rollers are to be used, axle holes 176 are provided for use when panel 170 is used on the left side of a cabinet and axle holes 178 are provided for use when the panel is used on the right side of a cabinet. In a similar manner, registration holes are provided for the rear end of outer slides 172 so that panel 170 can be used on either the left or the right side of a cabinet, with registration holes 180 for left side use and registration holes 182 for right side use.
In conventional cabinet construction, final painting is done after assembly. This means that sliding surfaces are painted also; however, this increases friction between the surfaces. The present invention permits the slides and inner panels to be "finished" with zinc primer which provides greatly improved sliding friction.
The snap-in feature of the inner panels provides for more economical manufacturing and permits the inner panels to be easily removed for repair or replacement. Virtually all components are "mirrored" designs, such that right and left side components are the same parts used twice and the wrap can be used right side up or upside down. Repairs at the manufacturing, distributor, or consumer level can be made via panel or shell replacement, as required. Conventional cabinets cannot be repaired or, at least, not easily repaired in most cases, resulting in discarded completed or partially completed cabinets. The decision whether to use or not to use rollers in a particular cabinet can be made near the final step in manufacture or even easily changed in the event of a mistake, making overall production control a more efficient task.
It will thus be seen that the objects set forth above, among those elucidated in, or made apparent from, the preceding description, are efficiently attained and, since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown on the accompanying drawing figures shall be interpreted as illustrative only and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. | A a cabinet with a sliding drawer, including: a housing; two opposing outer slides attached to inner surfaces of opposite sides of the housing; two inner slides attached to the sliding drawer and disposed in and telescopingly engaging the outer slides; and two first rollers contacting the inner slides and having their axes attached to the sides of the housing, with the axes of the first rollers spaced below a lower edge of the outer slide. Further, a cabinet with a sliding drawer, including: a housing having opposite side panels and front and rear ends; two opposing slide mechanisms attached to inner surfaces of the side panels and to sides of the sliding drawer; and the slide mechanisms being downwardly sloped from the front end of the housing toward the rear of the housing a degree sufficient to compensate for sagging from horizontal the sliding drawer may experience when extended from the housing. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
SEQUENCE LISTING OR PROGRAM
[0003] Not Applicable
BACKGROUND
[0004] 1. Field of Invention
[0005] Functional, and more importantly, sanitary storage for a toilet plunger poses a difficult problem for nearly every household. This invention, the sanitary bathroom item storage unit provides a manner to store these common and necessary items in a sanitary manner and in a practical, condensed and easily accessible location. Furthermore the design of the proposed invention would allow storage of other bathroom cleansing items, such as cleansers and gloves, in its space saving, organized, and aesthetically pleasing manner. This unit would also store and provide convenient access to additional toilet tissue when needed. As a result, it would eliminate those embarrassing moments of being caught without toilet tissue nearby. With the sanitary bathroom item storage unit, a plunger, toilet bowl brush, bathroom cleansing agents, etc., would be readily available and easily accessible when needed. This decorative storage unit would be easy to use, clean and hygienic.
BACKGROUND
[0006] 2. Prior Art
[0007] Examples of prior art patents include U.S. Pat. No. 4,008,993, U.S. Pat. No. 5,984,100, U.S. Pat. No. 6,193,059, U.S. Pat. No. 6,769,542, U.S. Pat. No. 3,429,474, U.S. Pat. No. 5,887,818, U.S. Pat. Des. 403,906, and U.S. Patent Application 2002/0125168. Evidently, there have been a number of patents and applications that suggest similar bathroom storage devices, but they all lack one very important characteristic that this invention, the sanitary bathroom item storage unit, embodies. That common characteristic and disadvantage that all of the aforementioned prior art shares is that they don't provide the toilet plunger a unique encapsulated space to preserve the sanitary and hygienic integrity that would be so desired in a bathroom environment.
[0008] In conclusion, insofar as I am aware, no bathroom storage device effectively stores a plunger, toilet bowl brush, and other bathroom items/accessories in a space saving, decorative, and easily accessible manner while preserving the hygienic and sanitary qualities needed in such an environment by totally isolating the toilet plunger in its own sealed cavity.
SUMMARY
[0009] The invention, sanitary bathroom item storage unit, is comprised of a cylindrical plunger canister with an inner central tube, a base, and a lid. The plunger canister, the base, and the lid all attach via a mechanical means (friction-fit, latches, screw-on, etc.) to form the assembled storage unit. Despite prior inventions that are similar to the sanitary bathroom item storage unit, there remains a need for an improved storage unit that will fulfill the following needs:
1. provide for the sanitary storage of a toilet plunger 2. provide for the convenient storage of additional bathroom items/accessories 3. provide for the storage of multiple rolls of toilet tissue 4. provide for an aesthetically pleasing container that totally conceals a toilet plunger and stores a toilet bowl brush and additional bathroom accessories in a self-contained, free-standing, and portable/moveable storage device
[0014] The sanitary bathroom item storage unit and its features and advantages will become more apparent from the following detailed description, which proceeds with reference to the accompanying drawings.
DRAWINGS
Figures
[0015] FIG. 1 is a perspective exploded view of the invention, showing the components and their relationship.
[0016] FIG. 2 is a perspective view of the assembled invention, but showing the top not installed.
[0017] FIG. 3 is a cross-sectional view of the assembled completely assembled invention.
DRAWINGS
Reference Numerals
[0000]
10 Sanitary bathroom item storage unit
11 lid
12 toilet tissue
13 inner centralized tube
14 toilet plunger canister
15 base
16 toilet plunger
30 plunger cavity
DETAILED DESCRIPTION
[0026] As shown in the detailed drawings, the sanitary bathroom item storage unit 10 shows a concept for sanitarily storing a toilet plunger and toilet tissue rolls 12 in a centralized and organized manner. Sanitary integrity in the unit is maintained by the use of the plunger canister 14 with the inner centralized tube 13 in conjunction with the base 15 . As shown in FIG. 1 the inner centralized tube 13 has one open end positioned at the bottom of the plunger canister 14 , and oppositely has one closed end. The plunger canister 14 has a convex-curved baseplate located at the bottom of the assembly. The baseplate permits clearance to fit the profile of any commercially available toilet plunger. As shown in FIG. 1-3 , a toilet plunger 16 is placed inside the bowl-bottomed base 15 , and the plunger canister 14 on top of the toilet plunger 16 with the toilet plunger handle inserted into the opening on the bottom of the inner centralized tube 13 . As shown in the cross-sectional drawing of FIG. 3 , when the plunger canister 14 is secured to the base 15 , the plunger 16 is isolated in its own cavity 30 inside the unit. This feature maintains the hygienic and sanitary qualities of the sanitary bathroom item storage unit. The bowl-bottomed base 15 provides for the collection of any water from the use of the toilet plunger in its normal operation. The end of the plunger canister 14 opposite the base is open except for the closed end of the inner centralized tube 13 . The inner centralized tube 13 is located inside the plunger canister at the vertex to allow toilet tissue rolls 12 to be place about it as shown in FIG. 2-3 .
[0027] The plunger canister 14 , the lid 11 , and the base 15 of this invention can be made out of metal, such as aluminum or stainless steel, a molded plastic, ceramic, or any material deemed well-suiting by anyone skilled in the art.
[0028] In the preferred embodiment, the sanitary bathroom item storage unit is used as a toilet plunger, toilet brush, bathroom accessory, and toilet tissue roll storage device. The toilet plunger canister employs two pockets to store cleansing gloves and a can of a commercially available cleansing solution. The plunger canister and removable base also employs a mechanical latching mechanism to secure the two pieces in a rigid manner. This latching feature would maintain the isolation of the plunger inside the unit and also facilitate moving the entire unit from location to location. The plunger canister would employ two handles on the opposite end of the base, which would pass through two corresponding openings in the lid. When the lid is placed on the canister these handles would also facilitate moving the assembled unit from location to location.
[0029] In another embodiment of the proposed invention, the top of the storage unit would provide a means to dispense a toilet roll.
[0030] In another embodiment of the proposed invention, the toilet tissue storage compartment would employ a spring loaded base to automatically advance the next roll of toilet tissue in storage to the top of the compartment.
[0031] In another embodiment of the proposed invention, unit would employ pockets on the exterior of the plunger canister to provide additional storage locations for bathroom items/accessories.
[0032] The above description(s) has described specific details in the embodiment of the invention. However, one having skill in the art can make modifications without departing from the spirit and scope of the underlying inventive concept of the sanitary bathroom item storage unit.
[0033] To use the sanitary bathroom item storage unit 10 , one would first place the base 15 on a floor and then place any commercially available plunger 16 on the base 15 . Next, the toilet plunger canister 14 would be placed on top of the base and plunger with the plunger's handle inserted into the inner centralized tube 13 . Any commercially available toilet tissue rolls would then be inserted into the top of the toilet plunger canister with the inner centralized tube inserted into the center hole of each roll. To access the plunger at a time when its use is needed the toilet plunger canister would simply be lifted vertically to uncover the plunger and its handle. It would be set aside so the plunger could be accessed. Normal cleaning and disinfecting of the base would be routine maintenance of the invention. | A bathroom storage device that effectively stores a plunger, toilet bowl brush, and other bathroom accessories in a space saving, decorative, and easily accessible manner while preserving the hygienic and sanitary qualities needed in such an environment by totally isolating the plunger in its own compartment. | 0 |
TECHNICAL FIELD
This invention pertains to gas turbine engines and pertains more particularly to improved structure and associated tooling for facilitating assembly/removal of modular subassemblies of the engine.
BACKGROUND OF THE INVENTION
Gas turbine engines such as utilized in aircraft are characterized by a relatively highly complex mechanical design of a variety of components. Assembly, aftermarket support, repair and overhaul of such complicated machinery may be time consuming and relatively expensive. To facilitate field support of such engines, more modern designs are modular in concept. This means the engine is designed into a plurality of subassemblies or modules, few in number, which may be individually removed or assembled to the remainder of the engine modules. Thus, such a modularly designed engine allows the removal and replacement of a single module in the field so that the engine may be returned to service as rapidly as possible. The removed module may then be fully disassembled, repaired and/or overhauled at a remote site with minimal overall engine or aircraft down time.
An important consideration in such modularly designed engines is that the components designed to be carried as a single modular subassembly be interrelated to one another regarding frequency of required overhaul and/or susceptibility of failure or damage during the life of the engine. From this it will be apparent that there are economic disadvantages in designing into a single module a group of components having significantly greater life expectancy or overhaul frequency, than another group of components therewithin, since the components with greater life expectancy would be required to be disassembled and replaced from the operating engine at the same frequency as the components with lower life expectancy.
One complexity in designing a modular gas turbine engine relates to the central through shaft assembly which may be typically supported to the engine stationary structure at locations adjacent the forward and aft ends of the engine. The design of a modular subassembly disposed wholly intermediate these shaft supports often leads to difficulties in accessibility and tooling for assembly and disassembly of the intermediate module without disturbing the central shaft assembly.
SUMMARY OF THE INVENTION
Accordingly it is an important object of the present invention to provide a gas turbine engine structure, method, and associated tooling facilitating assembly and removal of a modular engine section having a central shaft assembly extending substantially therethrough.
A more particular object of the present invention is to provide a gas turbine engine module assembly, method and apparatus which may be removed independently of a central shaft assembly extending axially therethrough even though the module has no stationary support structure at one end of the central portion thereof.
More particularly, the invention contemplates a modular gas turbine engine structure wherein a plurality of rotating engine stages are surrounded by a shell-like stationary housing structure, with the inner forwardmost first stage rotor having an internally threaded bore of smaller diameter than the diameters of the other rotor stages in the module. A radial space between the inner diameters of these latter rotors and the outer diameter of the shaft assembly can accept a tubular tool which can be slipped therethrough with its inner end engageable with the threaded smaller diameter central bore of the first stage assembly. The rearward end of the tubular tool is retained in a readily accessible location for subsequent intersecurement with the rearward end of the rotating assembly as well as with the stationary housing structure. Upon such intersecurement the entire modular assembly then may be moved, i.e. assembled or disassembled from the remaining engine while leaving the central shaft assembly in place.
These and other objects and advantages of the present invention are specifically set forth in or will become apparent from the following detailed description of the following preferred embodiments of the invention when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded plan view of a modular gas turbine engine incorporating the present invention;
FIG. 2 is an enlarged, partial, cross-sectional plan view of the compressor module, and associated portions of the front frame module and high pressure turbine module, all as assembled in operational arrangement;
FIG. 2A is an enlarged cross-sectional plan view of the portion encircled by the line 2A of FIG. 2;
FIG. 3 is a partial cross-sectional plan view of opposite ends of the compressor assembly along with tooling for assembly/disassembly of the compressor module;
FIGS. 4, 5 and 6 are plan views, with portions broken away for clarity of details, of the three tooling tubular members shown in FIG. 3;
FIG. 7 is a perspective view of the collar tooling of FIG. 3;
FIG. 8 is an elevational depiction of the front frame module as prepared for further assembly of the compressor module;
FIG. 9 is a elevational view of the compressor module assembly with associated tooling preparatory to assembly thereof upon the front frame module;
FIG. 10 is a view similar to FIG. 8 but showing the compressor module assembled on to the front frame module; and
FIG. 11 is a view similar to view FIG. 3 but showing an alternate embodiment of the assembly tooling as contemplated by the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to FIG. 1, a modularly constructed gas turbine engine 20 is shown with six major modules thereof in exploded arrangement for clarity. The engine 20 includes sequentially from a forward end to an aft end, a forward fan module 22, a front frame module 24, a compressor module 26, a burner module 28, a high pressure turbine module 30, and a low pressure turbine module 32. Not illustrated are additional modular portions of the engine which are typically included such as an exhaust module. Forward fan module 22 may typically include the front fan receiving the major air inlet flow of a turbo fan or turbo jet engine. Front frame module 24 is characterized by inclusion of various gearing and associated drive mechanisms of the engine accessory drive and includes an elongated tie shaft 34, partially illustrated in FIG. 1, which extends axially rearwardly to the rearward end of the high pressure turbine module 30 as will be discussed in greater detail below. Compressor module 26 includes a plurality of compressor stages and is described in greater detail below, while burner 28 includes the stationary combustor section of the engine. High pressure turbine module 30 includes, in addition to the first stage turbine 36, a hollowed coupling drive 38 that interconnects and drives the various stages of the compressor module 26. Low pressure turbine module 32 includes an elongated inner shaft 40 which extends through all intermediate modular sections to be in driving interengagement with the forward fan in fan module 22.
The present invention is illustrated in association with compressor module 26 which, it will be noted, includes a central shaft assembly (tie shaft 34 and inner shaft 40) which extends completely through the compressor module 26. FIG. 2 illustrates, portions in schematic form, the internalities of the compressor module 26 and associated portions of front frame module 24 and high pressure turbine module 30 as assembled in operational condition. More particularly, for purposes of the present invention the compressor module can be characterized as having an outer, stationary housing support structure or casing 42 which extends circumferentially around in shell-like fashion. The forward end of housing support structure 42 may include a mounting flange 44 for intersecurement with the mating outer housing structure (not shown) of the forwardly positioned front frame module 24. At the rearward end of the compressor module 26 the stationary housing support structure includes a radial inner housing structure 46 which extends axially along and radially inwardly of the burner module 28 located rearwardly of the compressor module 26. Typically the housing support structure 42 carries axially spaced sets of nonrotating vanes 48 which extend radially inwardly from housing structure 42 into an axially extending engine fluid flow path.
Compressor module 26 further includes a plurality of axial compressor stages including first, second, third, and fourth axial compressor rotors 50, 52, 54 and 56, as well as a final stage centrifugal impeller compressor 58. The associated axial compressor blades 51, 53, 55, and 57, are disposed in axial interdigitated relationship between the associated adjacent stationary sets of vanes 48. Blading 59 of the centrifugal compressor impeller 58 directs pressurized air flow across a compressor diffuser 60 to a diffuser outlet 62 for delivery to the combustor of the burner module 28 in well-known fashion. A plurality of rotating shroud seals 64 are included in driven relationship to the compressor rotors and in sealing arrangement with the radially inwardly depending ends of the vanes 48.
A portion of the stationary housing structure 64, disposed near the central portion of the gas turbine engine adjacent the shaft assembly, is also illustrated in FIG. 2. The housing structure 64 is constructed as a part of the forwardly located front frame module 24 and carries a bearing and associated oil seal respectively schematically illustrated at 66 and 69, upon which tie shaft 34 is rotatably mounted and carried. Note tie shaft 34 has an upstanding cylindrical boss 68 in axial interengagement with the forward end face 70 of the first stage compressor rotor 50. The intersecurement of tie shaft 34 with the front frame module housing 64 establishes that for assembly, disassembly, replacement purposes, the tie shaft 34 is a portion of the front frame module 24.
FIG. 2 also illustrates a portion of the high pressure turbine module 30 disposed rearwardly of the compressor module 26, including the hub section of the high pressure turbine rotor 36. Through a coupling 72 the high pressure turbine rotor 36 is intersecured with tie shaft 34 by a shaft nut 74 threadably advancable upon tie shaft 34 for interengagement with coupling 72. The inner shaft 40 of the low pressure turbine module 32 extends axially through the interior of hollow tie shaft 34.
Each of the more rearward compressor rotors 52, 54, 56 and 58 include an internal central through bore 76 of somewhat greater diameter than the outer diameter of tie shaft 34 to define a radial space 78 therebetween for receiving assembly tooling as will be described later. On the other hand, the forwardmost first stage compressor rotor 50 has a radially depending boss portion 80 having a central through bore 82 whose diameter is intermediate the central bore diameter 76 of the other compressors and the outer diameter of tie shaft 34. As clearly shown in FIG. 2A the smaller internal diameter bore 82 is threaded. It is important, of course, that threads 82 be included at a location on rotor 50 wherein stress fisers associated with the threads are acceptable. Near the hub portions of the compressor rotors but at a greater radial location are included axial extending tubular torque transmitting sections having Curvic couplings or radial end face spline configurations 84. The adjacent radial end face or Curvic coupling splines 84 of the compressor rotors are in torque transmitting interengagement with one another, and radially inwardly depending metal ring seals 86 are included to cover the openings between the intermeshing teeth of the Curvic couplings 84 for fluid sealing purposes. At the rearward or outer end 88 of the last centrifugal compressor stage 76 the associated radial end face spline 84 is similarly arranged in torque transmitting interengagement with the torque tube coupling 38 associated with the high pressure turbine section 30. The opposite end of torque coupling 38 is similarly interconnected through a Curvic coupling 84 with the high pressure turbine rotor 36.
Such Curvic couplings 84 operate to transmit torque through the rotating components but do not axially rigidly intersecure the rotating stages with one another. In this regard, engine tie shaft 34 provides the axial intersecurement of the rotor stages 50, 52, 54, 56, 58 with the torque coupling 38 and high pressure turbine rotor 36 during engine operation. More particularly, conventional engine assembly contemplates that prior to the mounting of nut 74, the tie shaft 34 is axially stretched in a rearward direction (rightwardly in the FIG. 2 orientation) while being held upon housing 64 to place the tie shaft 34 in high axial tension. Upon snugly threading shaft nut 74 into engagement with coupling 72 the rotating group of the compressor section 26 as well as the high pressure turbine rotor hub of high pressure turbine rotor 36 are all placed in complementary axial compression to rigidly axially intersecure this rotating group.
Upon viewing the operational arrangement of the compressor module 26 as shown in FIG. 2 it will be apparent that certain difficulties arise in attempting to disassemble the module 26 from the forward rotor module 4 (with its associated tie shaft 34) without disturbing the tie shaft 34 and without disassembly or relative motion of any of the internal components of compressor module 26. To this end, during disassembly which occurs from the rearward end of the engine, the low pressure turbine module 32 (with inner shaft 40), high pressure turbine module 30 and burner module 28 are sequentially removed as units from the engine. For subsequent removal of compressor section 26, the mounting flange 44 of the stationary housing support structure 42 is readily accessible for release from the front frame module. Similarly, the inner housing section 46 is at a readily accessible location at the rearward end of the compressor module. However, there exists no centrally located stationary housing structure near the first stage compressor rotor 50 which is associated with compressor module 26. In this respect the central housing portion 64 is a part of and is to remain with the front frame module 24 upon removal of the compressor module 26. Additionally, it will be apparent that after removal of the high pressure turbine module 30 the outer end of the rotating group of components of compressor module 26 becomes the rear portion 88 of impeller compressor 58.
FIGS. 3-7 illustrate the forward or inner end and rearward or outer end of the compressor module 26 in association with the modular handling and transport tooling as contemplated by the present invention. More particularly this transport tooling includes an elongated tubular tool 90 having a threaded inner end 92. Tube 90 is hollow and is sized with a wall thickness capable of being inserted over the outer diameter of tie shaft 34 and fittable within the radial space 78 (FIG. 2) between the compressor rotor central bore 76 and the outer diameter of tie shaft 34. The threaded inner end 92 after insertion of the tool 90 through space 78 is threadably engageable with the threaded smaller diameter bore 82 of the forward most compressor rotor stage 50 by simple rotation of tubular tool 90. An outer end portion 94 of the tubular tool 90 remains in a readily accessible location exteriorly of stationary structure 46 and in surrounding relationship to the tie shaft 34 disposed within the interior of tool 90.
Additional handling and assembly tooling as illustrated in FIG. 3 includes a second tubular tool member 96 threadably received on outer end portion 94 and acting axially through an optional bearing 98 to bear against a radially inwardly depending flange 100 of a third tubular tool 102. An inner face of flange 100 is axially engageable with the radial end face spline 84 associated with the outer end 88 of the compressor impeller 58. Further, the tooling includes an adjustable collar 104 having an axially extending cylindrical portion 106 securable to third member 102 through bolts 108 passing through arcuate slots 110 in cylindrical section 106. Collar 104 also includes a radially upstanding flange 112 securable through bolts 114 to the stationary structure 46 of the compressor module 26. The arcuate shaped slots 110, allow adjustable intersecurement of the stationary housing structure 46 to the rotating components of the compressor module. This affords fine relative axial location of the rotating group in relation to the stationary structure by rotation of collar 112 before intersecurement thereof through bolts 108 and 114. Collar 104 further includes lifting eyelet-type hooks 116 which may be secured to hoisting mechanism to effect the axial shifting and movement of the entire compressor module 26 as a unitary module.
To facilitate mounting of the threaded internal end 92 of the tubular tool 90 onto and off of the threaded central bore 82 of the first compressor stage, a pair of wrenches 118, 120 may be utilized. Wrench 118, in addition to a graspable radial arm 122, includes axially extending prongs 124 which are insertable into one or more complementary grooves 126 in the tubular tool 90. Similarly, the wrench 120 has a radial arm 128 and axially inwardly depending prongs 130 receivable in complementary grooves 132 in the second tool 96. The two radial arms 122, 128 of the wrenches may be relatively rotated to facilitate rotation of tool 90 into threaded interengagement with the threaded bore 82.
As shown in FIG. 3, the tubular tool 92 axially intersecures the various rotating components of the compressor module by virtue of the threaded interengagement at its inner end 92 with the innermost compressor wheel 50, and by virtue of the axial engagement of the associated second tool 96 acting through flange 100 against the outer end 88 of the rotating components. Thus tubular tool 90 intersecures the rotating group as a unitary group.
Tool 102 also operably intersecures both the entire rotating group and the tubular tool 90 to the outer stationary structure 46. Tool 102 thereby interlocks all components of the compressor module 26 in the disposition illustrated in FIG. 3. Subsequent removal and/or assembly of the entire compressor module 26 relative to the forward front frame module 24 is accomplished by axial lifting or lowering of the compressor module 26 through hoist mechanism (not shown) coupled to eyelet hooks 116. The compressor module 26 is readily removed from the front frame module 24 by rearward shifting of the unit to move the end face 70 of the first compressor stage away from the adjacent land 68 of the tie shaft 34.
Assembly and handling of the compressor module is further illustrated in FIGS. 8-10. In FIG. 8 the forward front frame module 24 is illustrated in vertical assembly position upon an assembly stand 140. The vertically upstanding tie shaft 34 appears prominently in FIG. 8. FIG. 9 shows the compressor module 26 and associated tooling 90 in vertical disposition preparatory to assembly. In FIG. 10 it will be apparent that the compressor module 26 has been hoisted by hooks 116, slipped over tie shaft 34 and then lowered onto the front frame module 24. After placement on the front frame module as shown in FIG. 10 the tooling 90, 96, 102, and 106 are removed in reverse fashion from that described.
Thus, even though the compressor module 26 includes centrally disposed rotating elements wherein there is no stationary structure adjacent the innermost central portion of the compressor module, the module is transportable as a single unit for assembly/disassembly to the other engine modules without disturbing the tie shaft 34. Additionally, with the tooling 90 carried therewith the compressor module 26 is readily transportable without impacting the internal interrelationships of the preassembled components thereof.
FIG. 11 illustrates another embodiment of the handling/assembly tooling as contemplated by the present invention for handling the same compressor module 26 as illustrated in FIG. 3. The tooling of FIG. 11 includes a single hollow tubular tool 190 with threaded inner end 192 engageable with the threaded bore 82 of first compressor 50, and further includes an upstanding radial collar 194 near the mid length thereof which is engageable with the central hub section of the last compressor impeller 58 upon axial advancement of end 192 upon threaded bore 82. Contact of collar 194 with compressor impeller 58 axially intersecures the rotating group of compressor module 26. Additionally, the tubular tool 190 is outfitted with a radial end face member 196 which is rigidly securable to the stationary structure 46 of compressor module 26 by bolts 198 or the like. Again, a grasping hook 199 is associated with the tooling 190 to facilitate axial shifting of the compressor module 26 as a unit. During assembly/disassembly the tooling of FIG. 11 operates as discussed previously with respect to the FIG. 3 embodiment.
Various alterations and modification to the present invention will be apparent to those skilled in the art. Accordingly the foregoing detailed description of preferred forms of the invention should be considered exemplary in nature and not as limiting to the scope and spirit of the invention as set forth in the appended claims. | A gas turbine engine compressor module subassembly construction and associated assembly method and tooling includes a threaded inner bore on the first stage compressor adapted to receive a tubular tool that slips axially between the compressor bores and the engine central shaft. Securement of the accessible tooling to the module's stationary structure permits assembly and handling of the module independently of the engine shaft. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to handheld devices, and more particularly toward incorporating a camera into a handheld device.
[0003] 2. Discussion of Background Art
[0004] Handheld devices, such as Personal Digital Assistants (PDAs), are information appliances geared toward mobile users. They have been evolving very quickly as users are demanding, and manufacturers are adding, new features and functionalities at an increasing pace.
[0005] Basic handheld devices are commonly used for maintaining personal information, such as schedules, lists of names and phone numbers, performing basic calculations, and note taking. However some enhanced handheld devices may further include: a cell phone, modem, a wireless connection, e-mail, and Web browsing capabilities. Most have tiny keyboards, while others include touch pads.
[0006] Many of the enhanced handheld features, however, have been hastily added, and thus tend to be unrefined, bulky, and difficult to use. For example, recent handhelds have included a still camera as a next “must have” feature. These cameras tend to be tacked wherever there is space left, but often are very awkward to use and/or have limited capabilities.
[0007] In response to the concerns discussed above, what is needed is handheld computer that overcomes the problems of the prior art.
SUMMARY OF THE INVENTION
[0008] The present invention is a handheld device with integral axial camera. The apparatus of the present invention includes: a top portion; a bottom portion; a hinge, rotational about a first axis and having a first end and a second end, coupling the top portion to the bottom portion; and an image capture device, coupled to the first end of the hinge and oriented to capture images aligned along the first axis of the hinge.
[0009] The method of the present invention includes: permitting a first large screen interface to rotate about a first hinge axis with respect to a second large screen interface; capturing images aligned along the first hinge axis; and setting a mode in which the device operates in response to an orientation of the first large screen interface to a second large screen interface.
[0010] These and other aspects of the invention will be recognized by those skilled in the art upon review of the detailed description, drawings, and claims set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a first pictorial diagram of one embodiment of a handheld device;
[0012] FIG. 2 is a second pictorial diagram of the one embodiment;
[0013] FIG. 3 is a third pictorial diagram of the one embodiment;
[0014] FIG. 4 is a fourth pictorial diagram the one embodiment;
[0015] FIG. 5 is a fifth pictorial diagram the one embodiment; and
[0016] FIG. 6 is a flowchart of one embodiment of a method of operation for the device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] The present invention ergonomically incorporates an image capture device into a hand held device. By placing image capture and display devices axially within the handheld device's hinge, the present invention permits users to capture and view images under any lighting condition, while holding the device in a natural and ergonomically friendly manner, and even when the device is in a folded orientation. Such an axial location also permits a variety of aftermarket lenses and filters to be attached to the image capture device for better viewing. Also the relatively long length of the hinge permits optical lenses to translate along the axis for telephoto or wide angle image captures.
[0018] FIG. 1 is a first pictorial diagram 100 of one embodiment of a handheld device 102 . FIG. 2 is a second pictorial diagram 200 of the one embodiment. FIG. 3 is a third pictorial diagram 300 of the one embodiment. FIG. 4 is a fourth pictorial diagram 400 the one embodiment. And, FIG. 5 is a fifth pictorial diagram 500 the one embodiment. FIGS. 1 through 5 are discussed together.
[0019] The handheld device 102 preferably falls into a class of devices known as Personal Digital Assistants (PDAs), and thus preferably provides certain computing and information storage and retrieval functionalities common to the class. Alternative embodiments of the present invention, however, could be embodied within other types of hinged apparatus, such as cell phones, a laptop computers, notepads, or even items of luggage.
[0020] The device 102 includes a hinge 104 which permits a top cover 106 to rotate about a first axis (A) 107 with respect to a bottom cover 108 . The hinge 104 includes a first end 110 , and a second end 111 both affixed to the bottom cover 108 , and a middle portion 112 affixed to the top cover 106 . The middle portion 112 includes a sub-hinge 114 , which permits the top cover 106 to rotate about a second axis (B) 115 with respect to the bottom cover 108 . Those skilled in the art recognize that there are an unlimited number of orientations of the top cover 106 with respect to the bottom cover 108 about the hinge 104 and sub-hinge 114 .
[0021] Rotation of the top and bottom covers 106 and 108 with respect to each other automatically determines a mode in which the device 102 operates. These modes include: a “first image capture mode,” a “first handheld mode,” a “second image capture mode,” and a “second handheld mode.” A preferred method for determining when each mode is entered and what effect each mode has on the device 102 , is described below with respect to FIG. 6 . Those skilled in the art however recognize that while the modes describe are preferred, they can be varied for different implementations of the present invention.
[0022] The hinge 104 also includes an image capture device 116 located within the first end 110 and a small screen interface 118 located within the second end 111 of the hinge 104 . The image capture device 116 includes a light sensitive sensor for acquiring optical information, and one or more lenses for focusing optical light on the light sensitive device. Some embodiments of the image capture device 116 include multiple lens which can translate with respect to each other, so as to provide an optical zoom capability. Additional lenses and/or filters (not shown) may also be attached to the image capture device 116 to provide for enhanced image capture capabilities. The small screen interface 118 is preferably capable of displaying both captured images (either in real-time like a viewfinder or which have been previously recorded) and any other information generated by the device 102 . Both the image capture device 116 and the small screen interface 118 are preferably aligned along the hinge's axis of rotation so that users may simultaneously capture and view images when the top and bottom covers 106 and 108 of the device 102 are closed.
[0023] The bottom cover 108 includes a telephoto (T) and wide-angle (W) zoom control 120 beneath the small screen interface 118 and a shutter control 122 beneath the image capture device 116 . The zoom control 120 provides for an optical and/or digital zoom feature, and the shutter control 122 instructs the device 102 to capture one or more images (i.e. a still picture or a video clip) using the image capture device 116 . The bottom cover 108 also includes a bottom large screen interface 124 and a touch sensitive pad 126 . The bottom large screen interface 124 is at a minimum preferably capable of receiving input commands from users of the device 102 , but may also display any information generated by the device 102 , including captured images. The bottom large screen interface 124 preferably accepts a pen inputs, while user selections are made with the touch sensitive pad 126 . In alternate embodiments, the bottom large screen interface 124 may be wholly replaced with another input device, such as a keyboard or touch sensitive pad.
[0024] The top cover 106 includes a top large screen interface 128 and a set of selection buttons 130 . The top large screen interface 128 preferably functions as an image display for either captured images or other information generated by the device 102 . However, since the top cover 106 can be rotated and flipped back onto the bottom cover 108 such that the top large screen interface 128 faces away from the bottom large screen interface 124 , the top large screen interface 128 preferably can also accept user inputs so that the device functions as a tablet computer.
[0025] Other features of the device 102 include: a sound capturing device, so that sounds may be recorded by the device 102 along with images; a biometric fingerprint recognition pad 132 for unlocking the device 102 ; wireless phone and networking capabilities; and spatial locational device.
[0026] FIG. 6 is a flowchart 600 of one embodiment of a method of operation for the device. The method begins in step 602 where the device 102 identifies a current orientation of top and bottom covers 106 and 108 , and top and bottom large screen interfaces 128 and 124 .
[0027] Next in step 604 , the device 102 enters a “first image capture mode” and displays information on the small screen interface 118 , if the top cover 106 is folded onto bottom cover 108 , and top and bottom large screen interfaces 128 and 124 are facing each other. FIGS. 1, 3 and 4 show the device in the “first image capture mode.” In this mode, users are capturing images with the image capture device 116 while looking through the small screen interface 118 at what is being captured. Users may prefer this mode out of convenience or due to bright lighting conditions which would otherwise obscure images displayed on one of the large screen interfaces 124 and 128 .
[0028] In step 606 , the device 102 enters a “first handheld mode” and displays information on the top large screen interface 128 in a first (preferably portrait) orientation, if the top cover 106 is not folded onto the bottom cover 108 , and there is less than +/−45 degrees of rotation about the sub-hinge 114 with respect to home position. The home position is herein preferably defined as the orientation of the top and bottom covers 106 and 108 about the sub-hinge 114 as shown in FIG. 2 . FIG. 2 shows the device in the “first handheld mode.” In this mode, users are primarily using the device 102 as a handheld PDA, whereby commands and inputs are received on the bottom large screen interface 124 and information is displayed on the top large screen interface 128 .
[0029] In step 608 , the device 102 enters a “second image capture mode” and displays information on the top large screen interface 128 in a second (preferably landscape) orientation, if top cover 106 is not folded onto bottom cover 108 , and there is more than +/−45 degrees of rotation about the sub-hinge 114 with respect to the home position. FIG. 5 shows the device in the “second image capture mode” after the top cover 106 as been rotated approximately 90 degrees about the sub-hinge 114 . In this mode, users are capturing images with the image capture device 116 while looking through the top large screen interface 128 at what is being captured. Users may prefer this mode when viewing images on the top large screen interface 128 would be more convenient than viewing them on the small screen interface 118 .
[0030] Then in step 610 , the device 102 enters a “second handheld mode” and displays information on the top large screen interface 128 in a third (preferably portrait) orientation, if top cover 106 is folded onto the bottom cover 108 , and the top and bottom large screen interfaces 128 and 124 are facing away from each other. The third orientation is upside-down with respect to the first orientation. This mode is not shown in the Figures, however, in this mode, users are primarily using the device 102 as a handheld tablet computer, whereby commands and inputs are received and information is displayed on the top large screen interface 128 .
[0031] Those skilled in the art will know that the values given for degrees of rotation, home position, image orientation, and information displayed and/or received on the screen interfaces, as discussed herein are preferred but not required. Other embodiments of the present invention may vary these elements to fit any particular design. Such other embodiments can perhaps include replacing the “second handheld mode” in step 610 with a “simultaneous handheld and image capture mode” which displays information on both the top large screen interface 128 and the small screen interface 118 , when the top cover 106 is folded onto the bottom cover 108 , and the top and bottom large screen interfaces 128 and 124 are facing away from each other.
[0032] Next in step 612 , the device 102 adjusts zoom of the image capture lens 116 in response to user command (e.g. rocking the zoom control 120 ). And in step 614 , the device 102 captures a set of image in response to user command (e.g. pressing the shutter button 122 ).
[0033] While one or more embodiments of the present invention have been described, those skilled in the art will recognize that various modifications may be made. Variations upon and modifications to these embodiments are provided by the present invention, which is limited only by the following claims. | A handheld device with integral axial camera is disclosed. The apparatus discloses: a top portion; a bottom portion; a hinge, rotational about a first axis and having a first end and a second end, coupling the top portion to the bottom portion; and an image capture device, coupled to the first end of the hinge and oriented to capture images aligned along the first axis of the hinge. The method discloses: permitting a first large screen interface to rotate about a first hinge axis with respect to a second large screen interface; capturing images aligned along the first hinge axis; and setting a mode in which the device operates in response to an orientation of the first large screen interface to a second large screen interface. | 7 |
PRIOR RELATED APPLICATIONS
This application is a division of U.S. Ser. No. 08/904,665, filed Aug. 1, 1997, which is a continuation-in-part application of U.S. Ser. No. 08/620,471, filed Mar. 22, 1996, abandoned and U.S. Ser. No. 08/904,665 is also a continuation-in-part of U.S. Ser. No. 08/451,398, filed May 26, 1995, now U.S. Pat. No. 5,711,194.
This invention relates to an improved hand tool and to an improved multibit folding screwdriver tool; and more particularly to a hex key tool having in addition to a set of conventional hex keys, a 4-in-1 or 8-in-1 driver tool, such as disclosed in our copending U.S. patent applications Ser. Nos. 08/451,398, filed May 26, 1995, and 08/620,471, filed Mar. 22, 1996, both of which are intended to be and are hereby incorporated herein by reference. Also, this application relates to our copending U.S. patent application, entitled "Improved Hand/Survival Tool Having Multiple Implements" serial number (not yet known), filed concurrently with the instant patent application on Aug. 1, 1997.
BACKGROUND OF THE INVENTION
Heretofore, hex key tools made and sold by various well-known manufacturers, such as Allen, a Daneher Group of West Hartford, Conn. 06110, comprise either a set of loose hex keys in a pouch, or a set of hex keys pivotably mounted on one or both ends of a small handle, whereby the hex keys are stored between the sides of a handle, and individually pivoted outwardly to be used either in a right angle position or in an extending position axially aligned with the longitudinal axis of the handle. Other fold-up hex key sets include at most two or three separately pivoted screwdriver blades, such as a slotted blade and a Phillips type screwdriver. While such conventional tools are handy, they have limited use and do not have multiple drive bits of different shapes and/or sizes or one or more pivoted drive tools embodying an outer sleeve and an inner sleeve removably fixed relative thereto, and having therein replaceable drive bits for torquing fasteners or nuts.
SUMMARY OF THE INVENTION
The improved hand tool of the invention incorporates with or without a hex key set, a 4-in 1 or 8-in-1 driver tool which is pivotable at an end of the tool handle. With such a driver tool and its multiple drive bits, removably secured to mateable drive sleeves, the tool of the present invention enables a collection of various sizes and types of drive bits, such as Phillips, flat, star, etc., to be immediately available to the user of such tool, thereby eliminating the need for seeking out a different tool. Mechanics, machinists and other tradespeople, as well as "do-it-yourselfers," have a clear need for such improved hand tool since it eliminates having to have in hand on any job multiple tools of various sizes and types, and contributes to saving space in one's toolbox, besides being of economic benefit in that fewer overall tools need be purchased by the user. In addition, other pivotable tools, such as a flashlight and/or telescoping magnetic pick-up may also be employed in the practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view, partly broken away, of the improved hex key hand tool of the present invention with various sized hex keys pivoted to both ends of the tool handle, and with a 4-in-1 driver tool pivotably mounted at one end thereof.
FIG. 2 is a plan view looking into the cavity/compartment of the improved hand tool of FIG. 1, but with the 4-in 1 driver tool, and all of the set of hex keys, shown in the stored condition, except for the set of hex keys grouped at one end which keys are shown extending downwardly out of view, but at right angles to the handle.
FIG. 3 is another embodiment of the improved hex key hand tool shown in a side elevational view, partly in section, but with a formed cut-away handle allowing for an improved grip by the user's fingers, and for a bigger/wider bit holder, with all hex keys and the 4-in -1 driver tool, at opposite ends of the tool handle, and with a conventional U-shaped loop for use in hanging the tool on a peg or chain.
FIG. 4 is a side-elevational view, similar to that of FIG. 3, and also partly in section, but showing the hex keys pivoted out of the way for access to the 4-in 1 driver tool.
FIG. 5 is a side elevational view partly in section of the hex key hand tool of FIGS. 3 and 4, but showing the 4-in 1 driver tool in its fully extended operative position.
FIG. 6 is an alternative embodiment of the improved hex key hand tool of FIGS. 1 and 2, but with an additional pivotable tool, such as a small flashlight.
FIG. 7 is a plan view of the embodiment in FIG. 6 showing the 4-in 1 driver tool fully extended alongside the flashlight, and with one hex key at the opposite end fully extended outwardly with all other hex keys extended downwardly at right angles thereto with the cavity/compartment of the handle shown empty.
FIG. 8 is a plan view, similar to that of FIG. 7, but showing the 4-in-1 driver tool and flashlight in the stored position, with the set of hex keys extending downwardly at right angles to the handle for ease of illustration.
FIGS. 9-11 show a couple of alternate 8-in-1 pocket drive tools, with FIG. 9 showing in plan view, and partly in section, a pair of 4-in 1 drive tools offset from each other at opposite pivot axes of the handle. FIG. 10 illustrates a longitudinal section showing a pair of 4-in 1 drive tools axially in line with the longitudinal axis of the handle, but with one of the drive tools stored and the other ready for use; and FIG. 11 shows both 4-in 1 drive tools stored between the side walls of the handle.
FIGS. 12 and 13 is another modification of the improved hand tool with a set of hex keys pivotable at one end, and a 4-in 1 hand tool pivotable at the opposite end of the handle and with an adjacent telescoping magnetic pick-up for use in seeking out "loose" fasteners/nuts, etc.
FIGS. 14 and 15 are views similar to that of FIGS. 3-5, but with a "closed-type" cutout handle, and a pivotable 4-in 1 hand tool at one end thereof.
FIGS. 16 and 17 are views similar to that of FIGS. 14 and 15, but showing an 8-in-1 hand tool (in lieu of a 4-in-1 hand tool); and
FIGS. 18-20 are views similar to that of FIGS. 16 and 17, except that the 8-in-1 (or 4-in -1 if desired) drive tool is also provided with one or more crossbores for torquing the hexagonal sleeves or drive bits using the handle as a lever arm.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1-20, and in particular FIGS. 1 and 2, there is shown a hex key set 10 pivotably mounted on axes 11, suitably, at the ends of a pair of side bolsters or at opposite ends of an integrally formed one-piece handle 12. In the improved hex key hand tool of the invention, a 4-in -1 (or 8-in-1) drive tool is suitably pivotably connected at one end of an outer sleeve 14, with a removably mounted inner sleeve 16 having a pair of drive bits 18 and 20 removably retained in place by conventional biasable ball detent means, with only balls shown on the flat planar hex surfaces. Other suitable securing means, which are well known, include magnets, retaining clips, mating grooves and protrusions (ears or wings), may likewise be employed in lieu of the biasable ball detent means. The innards of the inner sleeve 16 comprise hexagonal bores which drive the hexagonal drive bits 18 or 20; and the inner sleeve 16 is also suitably connected in any conventional, removable manner, while enabling rotational transmission of torque between the inner and outer sleeves. Such well-known drive rotation connections, for example, may comprise a pair of opposite grooves (not shown) on the inner wall of the outer sleeve 14, and a mateable pair of ears (not shown) on the outer wall of the inner sleeve 16 as described hereinabove with respect to the connection between the drive bits and the inner sleeve. Alternatively, mating hexagonal elements may be used to transfer driving forces from one element or sleeve to another element or sleeve. Also, as noted herein, other more conventional means, such as the biasable ball detents, magnets, retaining clips, mating grooves and protrusions or wings (ears), etc., may be used to retain in place the drive bits in the inner sleeve and the inner sleeve in the outer sleeve, so that such elements cannot fall out or be dislodged during use.
Also shown for use with the embodiments of the improved hex key hand tool of the invention is a hexagonal crossbore 17 in the handle and side 12 where the sidewall is of a single thickness. Where a laminate of two materials are employed (see lines in phantom), dual crossbores are employed to engage both the hex drive bit and the hexagonal outer surface of the inner sleeve (not shown). Such crossbore(s) enable the tool to be used as a "T-handle" drive tool. In addition, the pivotable drive tool is preferably suitably locked in the fully extended, open, longitudinal position (or even in the right angle position or both, if desired) by any of the well known and conventional means for locking a tool or "knife blade" in place so that it cannot swing back into the closed, stored position.
It will be appreciated that a pair of 4-in 1 drive tools can be used in one end or at opposite ends of the hex key tool handle. Alternatively, in lieu of a pair of 4-in 1 drive tools, a "single" 8-in-1 drive tool could be employed, such as that disclosed in our copending U.S. patent application Ser. No. 08/620,471, filed Mar. 22, 1996, the contents of which is intended to and is hereby incorporated herein by reference. Such an 8-in-1 drive tool would, however, generally increase the length and width of the hex key tool handle to a size which would be bigger than that of a conventional hex key tool depending upon the length and diameter of the drive bits. The only difference is that a pair of inner or servant sleeves would mate with a single master sleeve, with each of the inner or servant sleeves having a pair of drive bits and with the master sleeve mating similarly with the outer sleeve. In this connection, the drive bits may be either of the male or female types, so that both regular fasteners can be driven/undriven, and also nuts (hexagonal and the like) likewise driven to a tight condition or loosened by the various hexagon tubular-like elements (bores of the inner or servant sleeves and the master bore(s) in the master sleeve and/or pivotable sleeve itself).
FIGS. 3-5, while similar to that of FIGS. 1 and 2, embody essentially an "open" cavity in a one-piece, integrally constructed handle 30. Such open cavity facilitates access to the hex keys and/or other tool implements pivotably mounted to the handle 30. The handle 30 is further provided with a conventional U-shaped loop 32 for storing of the tool on a peg or other hook, as well as for securing the tool on a chain.
In FIGS. 6-8, which show an embodiment similar to that of FIGS. 1 and 2, there is shown the addition of a small flashlight 22 (battery operated--not shown) pivotably mounted to the handle 12' about axis 11'. Such a flashlight tool feature is convenient, and very handy, especially where the tool may be used in close dark quarters having little light source.
The improved hex key tool of the present invention provides a new tool having generally in the same single place a plurality of drive tool bits, in lieu of a plurality of separately pivoted tool blades, such as flat type, Phillips, Torx or star, pin type, etc., all of which individually take up considerable space as each only performs a single type of function, be it driving a slotted screw, Phillips head screw or other type of fastener.
Preferably, the 4-in 1 or 8-in-1 driver tool element should not normally be offset, and is centered in the tool handle so that its axis is generally in line with the rotational tool handle axis.
As shown in FIGS. 9-11, handle 12' with a pair of sides and pivot axes at opposite ends pivotably supports a pair of 4-in-1 drive tools with dual drive bits of varying styles and sizes releasably secured in a conventional manner, and preferably to a hexagonal inner sleeve 16' which is pivotably mounted about the oppositely disposed pivot axes by means of the outer sleeves 14'. Here the 4-in 1 drive tools are offset from each other to minimize the length of the tool handle, as if the pair of 4-in -1 drive tools were in the line with each other along the longitudinal axis of the handle, the tool handle would normally be twice as long.
Where it is preferred to have in-line "pressing-rotational" forces always acting along and about the drive tool axis (without any "eccentric" effect), the dual 4-in 1 hand tools may be disposed directly in line axially as shown in FIGS. 10-11, but here the dual 4-in-1 hand tools are stored obliquely inside the handle cavity or compartment (between the side walls). With this arrangement the handle length is basically of the same length as the tool handle of FIG. 9.
Referring now to FIGS. 12-13, the improved hand tool is shown with a set of pivotable hex keys at one end and with a pivotable 4-in-1 hand tool like that of FIGS. 1-2 and 9, and also with a telescoping element 36 having magnet means 38 suitably secured at the distal end of the telescoping sections, such as powerful disc magnets which are well known and conventional. This device is a very handy tool for facilitating the easy pick up of "loose" metal fasteners, nuts, or the like which are lost during assembly/disassembly of an apparatus, vehicle, etc., and have dropped into small crevices or other areas inaccessible to one's fingers.
In FIGS. 14-17 simply show the improved hand tool without a set of hex keys, with FIGS. 14-15 illustrating the 4-in 1 hand tool foldable into the handle cavity/compartment, and FIGS. 16-17 illustrating the 8-in-1 hand tool foldable into the handle cavity. It will be appreciated that the tool handles of both embodiments may be generally of the same length as the length of improved hand tools of the invention are all primarily dependent upon the particular length and diameter of the drive bits, both of which can be varied to accommodate a particular sized pocket hand tool or other type drive tool.
FIGS. 18-20 are similar to that of FIGS. 16-17, but showing the 8-in-1 drive tool with the outer "master" sleeve 40 to send its inner "servant" sleeves 42 (each having a pair of drive bits of varying styles and/or sizes) removed from the pivotable sleeve 44 shown seated in the cavity/compartment of the handle in its stored position (but without the sleeve elements and their drive bits). Here all of the sleeve elements (40 and 42 and the interior of the pivoted sleeve 44 are polygonal in shape, but preferably hexagonal as shown (in lieu of other type "rotatable connection." such as the conventional mating grooves and protruding wings/ears.
Also shown in FIGS. 18 and 20 are crossbores 46 and 48, the former of a size to mate with the inner "servant" sleeves 42, and the latter to mate with the hexagonal drive bits (not shown in either of the hex holes 48 of the figures). Crossbore 50 in FIG. 20 is shown mated with the larger outer "master" sleeve 40. With this embodiment, one obtains the lever arm advantage of the handle in achieving higher torquing power.
Although the present invention has been described in some detail by way of illustration and example for purposes of clarity and understanding, it will of course be understood that various changes and modifications may be made in the form, details and arrangements of the parts without departing from the scope of the invention as set forth in the following claims. | A hand tool includes interchangeable screwdriver bits and a pivoted sleeve which pivots from an inoperable position to an operable position, and one of the screwdriver bits is slidably non-rotatably operably disposed in the operable position. The hand tool also includes a pivoted telescoping magnet which is pivoted from an inoperable position to an operable position for extendibly magnetically holding a screw. The hand tool is alternatively operable as a screwdriver and telescoping magnet. | 8 |
PRIORITY
[0001] This application claims priority of U.S. provisional applications 61/710,234 filed on Oct. 5, 2012 and 61/788,847 filed Mar. 15, 2013, both of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to building materials, in particular to attachment of insulating board and trims on building surfaces.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to building materials in particular to attachment of insulating board and trims on building surfaces.
[0004] The selection of building siding materials today is vast. The siding may be wood, vinyl, fiber cement, fiber glass or other materials. Essential today is to have insulation underneath the siding to save in energy costs and to protect the building structures from weather elements. Customarily the insulation layer is attached to the building first and the siding is attached on top of the insulation layer.
[0005] Once the siding elements are attached on top of the insulation boards, the siding still needs to be trimmed. The trims are usually narrower boards and they are used to finalize the look. It is important that the insulation extends under the trim boards also. Lack of insulation, especially around windows allows hot and cold air to leak and may cause high energy costs.
[0006] The usual practice today is that after the insulation boards have been attached to the building sides, the siding boards are attached to the insulation boards and after this smaller board of insulation are attached around the windows, close to the roof, or at the house corners and the look is finalized by attaching trim boards. This is usually done by nailing the trim boards on their place. The trim boards are needed even if no insulation boards are used.
[0007] There is a need for an easy and economic way to attach the trim boards, and this application provides such easy and economic way. Furthermore, there is a need for attaching trim boards without leaving the nail heads visible on the board. Thus there is a need for an easy, fast, cost effective, and esthetic way to attach the trim boards.
SUMMARY OF THE INVENTION
[0008] It is an object of this invention to provide an easy, economic and an esthetic way to attach trim boards on the building.
[0009] It is another object of this invention to provide means to attach trim boards on the building without making through holes on the trim boards.
[0010] It is another object of this invention to provide a ready to use combination of trim board and insulation layer to be attached on the building side.
[0011] A further object of this invention is to provide clips for attaching trims on buildings without making through holes on the trims.
[0012] Another object is to provide an adjustable clip for attaching trim boards on building.
[0013] It is an object of this invention to provide an adjustable trim clip for attaching a siding trim on a wall structure, said clip comprising; a first part having a vertical side with a first end and a second end, said first end being attached to a flat bottom and said second end being attached to a horizontal prong extending to same direction as the flat bottom; a second part having a vertical side with a first end and a second end, said first end being attached to a flat bottom and said second end being attached to a horizontal prong extending to same or different direction as the flat bottom; and wherein the flat bottom of the second part slides on top or under the flat bottom of the first part, thereby forming a clip that has an adjustable width.
[0014] It is another object of this invention to provide a method to attach a siding trim on a wall, said method comprising the steps of: a) providing at least one trim clip having two vertical sides connected together with a substantially flat bottom having a width substantially similar to the width of the siding trim, b) attaching the trim clip on the wall structure; c) inserting the siding trim into the clip between the vertical sides; and d) providing a pressure by the vertical sides to the trim such that the trim stays securely between the sides.
[0015] It is yet another embodiment of this invention to provide a trim clip for attaching a siding trim on a wall structure, said clip comprising; two vertical sides connected together with a substantially flat bottom having a width substantially similar to the width of the siding trim, wherein the bottom has attachment holes or a female/male attachment assembly, and wherein the trim clip is attached to the wall structure with fasteners through the attachment holes or with female/male attachment means, and wherein the siding trim is inserted into the clip between the side walls and hold in place by a pressure provided by the side walls.
[0016] A further object of this invention is to provide a method to attach a siding trim on a wall, said method comprising the steps of providing a set of mounting clips having a wall mounting clip and a trim mounting clip, said clips forming a male/female attachment device; attaching said wall mounting clip on the wall and said trim mounting clip on the trim; and attaching the siding trim to the wall by allowing the wall mounting clip and the trim mounting clip form a male/female attachment.
[0017] It another object of this invention to provide building trim kit, comprising a siding trim having a front side and a back side, said back side having one or more trim mounting clips attached; one or more wall mounting clips to be attached to a wall, and said trim mounting clips and wall mounting clips forming a male/female attachment device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1A is a horizontal cross section showing a wall and a trim and the mounting clips.
[0019] FIG. 1 B is a horizontal cross section showing the trim attached to the wall with the mounting clips.
[0020] FIG. 2 is a horizontal cross section showing a wall, a trim that is attached to an insulation board and the mounting clips.
[0021] FIG. 3 is a horizontal cross section of a house corner, showing the walls, the trims and the mounting clips.
[0022] FIG. 4 . is a horizontal cross section showing a trim attached to the wall with the mounting clips. The mounting clips form a male/female attachment device.
[0023] FIG. 5 is a horizontal cross section showing a wall, a trim attached to an insulation board attached to the wall with the male/female mounting clips.
[0024] FIG. 6 . is a front view of a trim board and markings on the trim board to show where the mounting clips locate.
[0025] FIG. 7.A shows an end view of a trim attached on a wall or insulation with a trim clip having rubber lining.
[0026] FIG. 7B shows a top view of a trim clip with attachment holes.
[0027] FIG. 7C . shows a side view of a trim clip with a squeezing lever.
[0028] FIG. 8A shows a trim clip for attachment of a trim-insulation combination, where the trim is attached on the insulation with male-female attachments.
[0029] FIG. 8B shows a trim clip attached to insulation with male female attachment and a trim attached to the trim clip.
[0030] FIG. 9A shows an end view of an embodiment where the trim has attachment grooves and the trim clip have protrusions fitting into the grooves.
[0031] FIG. 9B . shows the trim attached to the clip and the clip attached to insulation.
[0032] FIG. 9C shows the trim attached to insulation and the trim-insulation combination attached to the clip with the clip protrusions fitting into the trim grooves.
[0033] FIG. 10 A and B show an embodiment where the clip of FIGS. 9A-C is formed of two parts.
DETAILED DESCRIPTION OF THE INVENTION
[0034] The preferred embodiments of the present invention will now be described with reference to FIGS. 1-10 of the drawings. Identical elements in the various figures are identified with the same reference numerals.
[0035] FIG. 1A is a horizontal cross section showing a wall and a trim and the mounting clips. The figure shows a wall 10 , a trim board 20 , wall mount clips 30 and trim mount clips 31 .
[0036] FIG. 1 B is a horizontal cross section showing the trim attached to the wall with the mounting clips. The figure shows a wall 10 , a trim board 20 , wall mount clips 30 and trim mount clips 31 .
[0037] FIG. 2 is a horizontal cross section showing a wall, a trim that is attached to an insulation board and the mounting clips. The figure shows a wall 10 , a trim 20 , an insulation board 40 , wall mount clips 30 and trim mount clips 31 . The insulation board 40 may be glued on the trim 20 .
[0038] FIG. 3 is a horizontal cross section of a house corner, showing the walls, the trims and the mounting clips. The figure shows the walls 10 , the trims 20 , the wall mount clips 30 and the trim mount clips 31 .
[0039] FIG. 4 is a horizontal cross section showing a trim attached to the wall with the male/female mounting clips. The figure shows the wall 10 , the trim 20 , the wall mount clip 30 and the trim mount clip 31 .
[0040] FIG. 5 is a horizontal cross section showing a wall, a trim attached to an insulation board attached to the wall with the mounting clips. The figure shows a wall 10 , a trim 20 , an insulation board 40 , a wall mount clip 30 and a trim mount clip 31 .
[0041] FIG. 6 is a front view of a trim board 20 showing markings 22 indicating where the mounting clips locate.
[0042] FIG. 7 A is an end view of another trim clip embodiment. The figure shows a substantially U-formed clip 50 , having two vertical sides 52 and a horizontal bottom 54 . The vertical sides have an inner rubber lining 60 . The figure shows the trim 20 inserted into the clip. The clip 50 is attached to the wall 10 from its bottom 54 .
[0043] FIG. 7B shows a top view of the clip 50 of FIG. 7A . The figure shows the vertical sides 52 , the rubber lining 60 , the bottom part 54 and attachment holes 56 in the bottom 54 .
[0044] FIG. 7C shows another embodiment of the clip 50 . The figure shows the vertical sides 52 , the horizontal bottom 54 and a squeezing lever 58 . The clip is attached to a wall 10 .
[0045] FIG. 8A shows another embodiment of the clip 50 . The figure shows the vertical sides 52 , the bottom 54 , a trim 20 , an insulation board 40 and mounting clips 30 and 31 . The trim 20 is attached to the insulation board with the mounting clips and the trim/insulation combination is inserted into the clip which is attached to the wall 10 .
[0046] FIG. 8B shows another embodiment of the clip 50 . The figure shows a trim 20 inserted into the clip. The clip has vertical sides 52 and a bottom 54 . The figure shows an insulation board 40 attached to a wall 10 and the clip attached to the insulation board with wall mounting clip 30 and trim mounting clip 31 .
[0047] FIG. 9 shows yet another embodiment of the clip 50 . FIG. 9A-C show the trim 20 with grooves 22 on both of its vertical sides 24 . The figures show the clip 50 with vertical sides 52 , bottom 54 and horizontal prong 59 . Attachments 70 are also shown
[0048] FIG. 9B shows the trim 20 inserted into the clip 50 , the prongs 59 snugly fitting in the grooves 22 . The figures shows the clip attached to insulation board 40 with attachments 70 .
[0049] FIG. 9C shows the trim 20 attached to the insulation board 40 and the trim/insulation board combination inserted into the clip 50 . The clip is attached to the wall 10 with the attachments 70 .
[0050] FIG. 10A and B show another embodiment of the trim clip. The clip now consists of two parts. The first part has a bottom 54 , a vertical side 52 and a horizontal prong 59 . The second part has a bottom 84 , a vertical side 82 and a horizontal prong 89 . The bottom portion 84 of the second part slides on top of the bottom portion of the first part 54 whereby the width of the clip is adjustable.
[0051] In FIG. 10 A the horizontal prong 89 of the second part extends to opposite direction than the bottom part 84 . In FIG. 10B the prong 89 and the bottom part 84 extend to same direction.
[0052] In FIG. 10A the trim 20 is inserted into the clip and the clip is attached to an insulation foam 40 . In FIG. 10B the trim 20 is attached to foam 40 and the trim/foam combination is attached to a wall 10 .
[0053] Referring now to FIGS. 1 A and B, one preferred embodiment of this invention provides a pair of mounting clips to attach a trim board to a building wall. The pair of clips consists of a wall mounting clip 30 and a trim mounting clip 31 . The wall mounting clip 30 is attached to the wall 10 and the trim mounting clip 31 is attached to the trim 20 . As is shown in FIG. 1B the wall mounting clip 30 forms a female partner and the trim mounting clip 31 forms a male partner. However, one skilled in the art would understand that the invention embraces also an embodiment where the wall mounting clip 30 is a male partner and the trim mounting clip 31 is a female partner. According to this embodiment, by pressing the trim mounting clip 31 toward the wall mounting clip 30 , the male/female design locks the clips together and holds the trim on the wall 10 . It is understood by one skilled in the art, that the way how the female and male partners attach to each other is not a limiting element of this invention, but that any method resulting locking of the female and male partners together is within the scope of this invention. Accordingly, the clips may for example be hooks or hooks and loops that lock together.
[0054] Referring now to FIG. 2 , another embodiment of the invention is shown. According to this invention, an insulation board 40 is glued on back of the trim 20 . The trim mounting clips 31 are attached to the insulation board, and the wall mounting clips 30 are attached to the wall 10 . Again by pressing the trim mounting clip 31 toward the wall mounting clip 30 , the male/female design of the clops locks them together and holds the foam and the trim on the wall.
[0055] Referring now to FIG. 3 it is shown how the trim is easily attached to a corner of the house. In the shown embodiment the trim 20 on the corner is formed by two separate trims, but it is also possible to provide one trim that has a right angle, so that it fits to the corner. The mounting clips are attached close to the corner and further away from the corner.
[0056] FIG. 4 shows one embodiment of the male/female attachment device of the trim mounting clip/wall mounting clip pair. As is shown in the figure the trim mounting clip 31 snugly fits in the wall mounting clip 30 . One skilled in the art would understand, that such male/female pairing can be achieved by various designs. Only illustrative design is shown here. According to a preferred embodiment the dimensions of the mounting clips is such that when the wall clip 30 is attached to the wall 10 and the trim clip 31 to the trim 20 or insulation foam 40 , and the trim wall clip 30 is attached to the wall trim clip 31 , the distance between the wall and the inner side of the trim or the insulation board is less than ¾″, more preferably less than ½″ and most preferably not more than ¼″.
[0057] According to one preferred embodiment, the female and male partners are attached to the trim board, insulation board, or the siding board by screwing mechanism. According to another preferred embodiment the female and male partners are attached by pushing. According to yet another embodiment the attachment system may include tubular elements that are attached to the trim board, insulation board, or the siding board and the female and male partners are attached to these tubular elements.
[0058] Referring now to FIG. 5 , an embodiment is shown where an insulation board 40 is glued on the inner side of the trim 20 and the trim/insulation combination is attached on wall 10 with male/female mounting clips 30 , 31 .
[0059] Referring now to FIGS. 6 , according to one preferred embodiment the location of the mounting clips may be indicated on the top surface of the trim 20 . This would help attaching the trim to the wall with the clips that remain invisible on the back side of the trim. According to a preferred embodiment the attachment with the male/female attachment device is meant to be a permanent attachment. However additional nails or other means for attachment may also be applied.
[0060] FIG. 7A shows an end view of a trim or a trim with insulation attached with the trim clip. The figure shows the trim clip 50 having a bottom 54 and two vertical sides 52 . In other words, the clip is substantially U-formed. The inner surfaces of the clip sides are covered with rubber pads 60 or similar material. The trim 20 or the trim with insulation foam is inserted in between the two vertical clip sides. The width of the trim clip (i.e. distance between the rubber pads) is such that the trim snugly fits there and the rubber pads keep the trim secured in place. When insulation is attached to the trim (shown in FIG. 8A ) the clip is attached directly to the wall 10 . When the trim does not include insulation, then the clip is installed on the insulation of the wall structure. In this case the clip may have female/male attachment assembly to attach it to the insulation board ( FIG. 8B ).
[0061] FIG. 7B shows a top view of a trim clip of this invention. The clip 50 has two vertical sides 52 and a bottom side 54 . The inner surfaces of the clip sides are covered with rubber pads 60 and the trim bottom has one or more attachment holes 56 for penetrating a nail or screw to attach the clip on the wall. The trim or the trim with insulation is then inserted in the clip between the rubber pads which securely hold the trim in its place.
[0062] FIG. 7C shows another embodiment of the invention. Here the trim clip 50 has two vertical sides 52 an a bottom 54 . A squeezing lever 58 is attached to one or both of the vertical sides 52 of the clip. The trim 20 or the trim with insulation foam is inserted in the clip between the two vertical clip sides. When the lever is pushed down the trim side will bend inward and squeezes the trim inside the clip. The lever 58 may then be attached to the wall by nailing or gluing whereby the squeezing pressure of the clip is maintained and the trim or trim with insulation remains securely in place.
[0063] According to one embodiment of this invention the clip is substantially of the same length as the trim to be attached. According to another embodiment the length of the clip may vary between about an inch to the full length of the trim. When the trim is substantially shorter than the length to the trim multiple clips may be used to attach the trim.
[0064] FIG. 8A shows a trim clip with a trim 20 that is attached to insulation foam 40 . The attachment may be done by wall clip/trim clip assembly 30 / 31 , but other methods may also be used, such as gluing. The insulation foam has either a male attachment or a female attachment and the trim has the counterpart. Pushing the counterpart attachment together will lock them together and the trim 20 will hold on the insulation foam 40 . The clip is attached directly to the wall and the rim with insulation attached to it is inserted into the trim clip.
[0065] FIG. 8B shows a trim clip without insulation. In this case the insulation board 40 is attached to the wall 10 and the insulation board has wall clip/trim clip assembly 30 / 31 . The trim clip bottom 54 has the counterpart. Now pushing the counterpart attachment together will lock the parts and the clip will hold on the insulation board. The trim is then inserted into the trim clip.
[0066] FIG. 9A shows another embodiment of this invention. The vertical sides 52 of the clip 50 have short horizontal prong 59 at their upper end. The trim 20 in this case has been modified so that it has horizontal grooves 22 in its vertical sides 24 . The prongs 59 snugly fit into the grooves 22 , thereby locking the trim into its place. The clip is attached to the wall or to an insulation board with attachments 70 . The attachments may be screws or nails but they may as well be the male/female mounting clips described above.
[0067] FIG. 9B shows the clip attached to an insulation board 40 . The trim is in its place secured by the prongs 59 which are fitted into the grooves 22 .
[0068] FIG. 9C shows an embodiment where the trim is attached to an insulation 40 and the insulation/trim combination is inserted into the trim clip. The clip is attached to a wall 10 with attachments 70 . The attachment may be screws or nails but they may also be male/female mounting clips as described above. The trim may be glued onto the foam, but it may also be attached to the foam with male/female mounting clips as described above.
[0069] FIG. 10 shows still another embodiment. In this case the clip 50 is made of two parts. The first part has a long bottom part 54 , a vertical side 52 and a short horizontal prong 59 . The second part has a short bottom part 89 , a vertical side 82 and a horizontal prong 89 . The second part slides on top or under the first part so that the width of the clip is adjustable to trims with different widths. In one embodiment shown in FIG. 10A the prong 89 of the second part points to opposite direction than the bottom part 84 and in another embodiment shown in FIG. 10B the bottom part 84 and the prong 89 point to same direction.
[0070] In the embodiment shown in FIG. 10 the clip is attached to a insulation board or directly to a wall with attachments that may be nails, screws or male/female assembly shown above in this application. The clip may have several holes in the bottom parts 84 and 54 through which the attachments are attached, or the bottom parts may have elongated slots that coincide for attachments.
[0071] According to one preferred embodiment the vertical side 52 / 82 may be 1/16″ to 1″, more preferably the prong is 2/16″ to ½″ and most preferably the prong is about 5/16″. One skilled in the art would understand that the vertical side can be of any length provided that it equals to the thickness of the trim (or trim plus insulation) or is shorter than the thickness. If the length is same as the thickness then the trim does not have the grooves but the horizontal prongs would in that case be on the trim surface.
[0072] According to one preferred embodiment the short bottom part 84 is between 1″ and 3″and most preferably about 1.5″. The long bottom part 54 is preferably 5-10″ and most preferably about 7″. However, one skilled in the art would understand that the length of the bottom parts can be adjusted to be anything and the most preferable measures are such that combination of the short and long bottom part would allow attachment of trims of any available widths.
[0073] According to one preferred embodiment the length of the horizontal prong 59 / 89 of the clip and the depth of the groove 22 in the trim is between ⅛″ and 1″, more preferably between ¼″ and ½″ and most preferably about ⅜″. Again the skilled artisan would understand that the length of the prong and the depth of the groove can be any reasonable measure as long as the prong fits into the groove and holds the trim in its position.
[0074] One skilled in the art would understand that the slidable two part clip shown in FIGS. 10 A and B may also be used in connection with other embodiments of this invention, such as the clip having rubber liners as shown in FIG. 7 . Also it is possible to use the male/female attachments in connection with the slidable two part embodiment.
[0075] It is understood by one skilled in the art that the method and devices described in this disclosure would be applicable to trim boards of any material, with or without the insulation layer and to trim boards of any size.
[0076] The trim clips 50 of this invention may be made of any feasible material, including but not limited to aluminum, plastic, fiber glass,
[0077] Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention. | This disclosure relates to building materials, in particular to attachment of insulating board and trims on building surfaces. Various embodiments of attachment clips to attach the trims on their place without nails or screws through the trim are provided. This disclosure provides an economical, fast, easy, and esthetic method to attach building trims. | 4 |
FIELD OF THE INVENTION
This invention relates generally to food supplements or supplemental food for mammals, especially, but not exclusively, humans.
BACKGROUND OF THE INVENTION
Practicing good nutrition is challenging. Even with an understanding of the current nutritional science, it can be difficult to follow a well-designed diet regularly. In addition to lapses in discipline, specific foods or foods which are good sources of a particular nutrient may be unavailable or inconvenient when needed. These challenges are compounded when attempting to obtain the benefit of helpful interactions between different foods or different nutrients.
Nutritional supplements have evolved, first from general vitamin and mineral supplements based on Recommended Daily Allowances (RDA) generally determined by studying different nutrients in isolation, to more sophisticated general vitamin and mineral supplements, to “supplemental foods” or “food supplements”. Whole-food supplementation seeks to provide the nutritional benefits of a food (as opposed to an isolated nutrient, which might be derived from a food, or synthesized or isolated from a non-food product) without the volumetric or caloric intake of consuming the food itself. This approach permits convenient, concentrated nutrient uptake in a form that mimics the mixture of nutrients found in a whole food, and, therefore, the helpful interactions between different nutrients that naturally occur in a particular food.
Nutrient interactions have been the subject of extensive study over the last 25 years, but are still a highly unpredictable field. Extrapolations from interactions between individual nutrients to classes of nutrients often fail, sometimes with no synergy observed for closely related class members, and sometimes with deleterious effects when substituting one nutrient for another class member. A supplemental food approach may help reduce variability in response by preserving naturally occurring interactions. Of course, even with a supplemental food approach, removing bulk and calories from a food necessarily involves decisions about extraction and processing that can unintentionally change the types and relative amounts of nutrients in a supplement, which can, in turn, unintentionally change the presence or degree of the nutritional benefit of the supplement. These challenges, too, are exacerbated when a supplement aims to provide the benefit of multiple food components, e.g., to mimic benefits from consuming several types of foods together. Ayurvedic medicine, for example, addresses hundreds of herbs which may be helpful for maintaining or restoring health, often used in combinations of 3 or more herbs.
There remains a need for dietary supplements which provide specific combinations of nutrients in desirable ratios. There remains a need for dietary supplements which support specific aspects of health and well-being.
SUMMARY OF THE INVENTION
In some aspects, the invention relates to a supplement for maintaining healthy immune response. The supplement may comprise an extract of rosemary. The supplement may comprise an extract of turmeric. The supplement may comprise an extract of green tea. The supplement may comprise an extract of ginger. The supplement may comprise an extract of holy basil. The supplement may comprise an extract of oregano. The supplement may comprise an extract of black currant. The supplement may comprise an extract of clove. The supplement may comprise an extract of thyme. The extract of thyme may be a supercritical extract. The supplement may be suitable for oral administration. The extract of holy basil may comprise a supercritical extract and an ethanolic extract. The extract of turmeric may include supercritical extract and hydroethanolic extract in a ratio between 1:3 and 1:5, or in a ratio of about 1:4. The supplement may comprise an extract of chamomile. The extract of oregano may include supercritical extract and hydroethanolic extract. The extract of oregano may include supercritical extract and hydroethanolic extract in a ratio of about 1:1. The supplement may comprise boswellia serrata.
In some aspects, the invention relates to a method of moderating the inflammatory response to a transient pro-inflammatory stimulus, comprising administering a supplement comprising extracts of rosemary, turmeric, green tea, ginger, holy basil, oregano, black currant, and clove, optionally with an extract of thyme or chamomile, to a mammal prior to the mammal encountering a transient pro-inflammatory stimulus. The transient pro-inflammatory stimulus may be exercise, an allergen, or a transient increase in oxidative stress.
In some aspects, the invention relates to a supplement for maintaining healthy immune response. The supplement may comprise an extract of rosemary. The supplement may comprise an extract of turmeric. The supplement may comprise an extract of green tea. The supplement may comprise an extract of ginger. The supplement may comprise an extract of holy basil. The supplement may comprise an extract of oregano. The supplement may comprise an extract of black currant. The supplement may comprise an extract of clove. The supplement may comprise an extract of boswellia serrata . The supplement may comprise an extract of chamomile. The supplement may comprise an extract of thyme. The extract of thyme may be a supercritical extract. The supplement may be suitable for oral administration. The extract of holy basil may comprise a supercritical extract and an ethanolic extract. The extract of turmeric may include supercritical extract and hydroethanolic extract in a ratio between 1:3 and 1:5, or in a ratio of about 1:4. The extract of oregano may include supercritical extract and hydroethanolic extract. The extract of oregano may include supercritical extract and hydroethanolic extract in a ratio of about 1:1.
In some aspects, the invention relates to a method of moderating the inflammatory response to a transient pro-inflammatory stimulus, comprising administering a supplement comprising extracts of rosemary, turmeric, green tea, ginger, holy basil, oregano, black currant, clove, and boswellia serrata , optionally with an extract of thyme or chamomile, to a mammal prior to the mammal encountering a transient pro-inflammatory stimulus. The transient pro-inflammatory stimulus may be exercise, an allergen, or a transient increase in oxidative stress.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the term “supplement” refers to a composition intended to supplement a diet of food and water, where the diet is sufficient to support life. A supplement may contain vitamins, minerals, herbs or other botanicals, amino acids, enzymes, organ tissues, glandular metabolites, or combinations thereof. A supplement may be an extract or concentrate of a particular food source or a particular nutrient. Supplements may be administered by any convenient means, including parenteral or enteral routes. Enteral routes may include oral, gastric, or subgastric administration, including rectal administration.
In a preferred form, the supplements of the present invention are administered orally. Oral administration forms include, without limitation, tablets, capsules, softgels, gelcaps, liquids, powders, and films, as well as food-like forms such as bars, candies, lozenges, beverages, and the like.
As used herein, the term “supercritical gas” or “supercritical fluid” refer to a gas is that heated to a temperature critical point, over which the gas will maintain its gaseous state and not turn to a liquid regardless of pressure. A gas heated to a temperature above its critical point will become very dense on compression, so that its characteristics resemble those of a fluid, but will not become liquid. Carbon dioxide is commonly used in applications requiring a supercritical fluid. The general properties of supercritical fluids and the general use of supercritical fluids in extraction processes are described in, e.g. Taylor, Supercritical Fluid Extraction, Wiley, 1996; McHugh and Krukonis, Supercritical Fluid Extraction: Principles and Practice, 2nd ed., Butterworth-Heinemann, 1994; and Williams and Clifford, Supercritical Fluid Methods and Protocols, Humana Press, 2000.
As used herein, the term “supercritical extraction” refers to the technique in which hydrophobic compounds can be extracted from samples utilizing a supercritical fluid. The solvation power of a supercritical fluid is increased as the pressure and temperature are increased above their critical points, producing an effective solvent for the isolation of hydrophobic molecules.
As used herein, the terms “hydroalcoholic extraction” or “hydroethanolic extraction” refer to the technique in which hydrophilic compounds can be extracted from a sample utilizing a solution of alcohol and water, followed by evaporation of the solution to produce an extract consisting of dissolved solids. In the case of hydroethanolic extraction, the alcohol can be ethanol.
As used herein, the term “mammal” refers to any vertebrate of the class Mammalia. The term “mammal” includes the sub-classes of humans and companion animals. “Companion animals,” as used herein, include dogs and cats of all ages (e.g., puppies or kittens, adults between 1 and 6 years of age, seniors between 7 and 10 years of age, and super-seniors 11 years of age or older), and other mammals of like nutritional needs to dogs and cats. For example, other domesticated animals of like nutritional needs to a cat may include minks and ferrets, who can survive indefinitely and healthily on a nutritional composition designed to meet the nutritional needs of cats. It will be appreciated by one of skill in the art that dogs and cats have nutritional needs which differ in key aspects. At a fundamental level, dogs are omnivores, whereas cats are obligate carnivores. Further, nutritional needs are not necessarily consistent with phylogenetic or other non-nutritional classifications.
As used herein, “complete and nutritionally balanced” refers to a composition that provides all of a typical animal's nutritional needs, excepting water, when fed according to feeding guidelines for that composition, or according to common usage, if no feeding guidelines are provided. Such nutritional needs are described, for example, in Nutrient Profiles for dogs and cats published by the Association of American Feed Control Officials (AAFCO).
The inventive composition is a mixture comprised of herbal extracts. The compositions may moderate inflammatory processes. As used herein, “moderate” refers to a chemically measurable change in one or more physiological markers of inflammation. In humans, moderation of inflammatory processes may be measured by self-reporting of symptoms of inflammation, such as pain or swelling. In non-human mammals or humans who cannot communicate effectively about their inflammatory symptoms, moderation of inflammatory processes may be measured from reports from a care provider regarding physical signs of inflammation, such as perceived tenderness, pain, swelling, or range or ease of motion. In any mammal, moderation of inflammatory processes may be measured by biochemical analysis of tissue or fluid samples, such as samples of skin, blood, tears, or other body tissues or fluids. Suitable biomarkers for comparison and analysis include pro-inflammatory cytokines (such as IL-1B, IL-6, IL-8, MIP-1α, and TNFα), 5-lipoxygenase, 12-lipoxygenase, Leukotriene B4 (LTB4) receptors, Prostaglandin E2 (PGE2), NF-kβ, COX peroxidase activity, and combinations thereof. It is not necessary to see a change in all relevant biomarkers to obtain effective moderation of an inflammatory response.
The compositions may help maintain or support a healthy immune response. For example, the compositions may help moderate normal, short-term increases in inflammation, such as those that may follow exercise or other physical activity.
The compositions are unique in the herbs selected, in the combinations and ratios thereof, in the synergies and activities amongst the herbs, and in that they are prepared via a supercritical CO 2 extraction process. Unlike traditional solvent based extraction methods, supercritical CO 2 extraction allows the natural products in the herbs to be obtained without leaving chemical residues behind in the preparation. A combination of extracts from hydroalcoholic extraction and supercritical CO2 extraction can produce a constituent profile similar to the native herb in a more concentrated state.
Supercritical extraction can be performed according to known supercritical extraction methods, such as disclosed, e.g., in E. Stahl, K. W. Quirin, D. Gerard, Dense Gases for Extraction and Refining, Springer Verlag 4 1988. The plant, or suitable portion thereof, such as, for example, the rhizome in the case of ginger, which can be cryogenically ground to preserve heat sensitive components, is subjected to supercritical extraction to obtain: (i) an oil extract, referred to herein as “the supercritical extract” of the plant, containing delicate lipophilic components, and (ii) an oil-free residue. The oil-free residue can then be extracted in a water/alcohol, for example, water/ethanol, mixture composed of 60-80 parts alcohol and 40-20 parts water. The alcohol/water liquid is then evaporated off, leaving a powdered extract residue, referred to herein as “the hydroalcoholic extract” of the plant. Alternatively, the supercritical extraction and the hydroalcoholic extraction can be performed on separate batches of plant material.
The hydroalcoholic extraction can be performed according to conventional hydroalcoholic extraction techniques. For example, the hydroalcoholic extracts can be prepared by extracting the plant portion in a water/alcohol, such as, for example, water/ethanol, mixture that can be composed of 60-80 parts alcohol and 40-20 parts water, and then evaporating off the water/alcohol liquid, leaving a powdered extract residue referred to herein as “the hydroalcoholic extract”. In certain embodiments, the water/alcohol liquid mixture can be evaporated at a temperature ≦80° C., such as, for example, by utilizing a spray-drying technique, leaving a powdered extract residue.
Some extracts, such as green tea extract, are obtained by water-only extraction.
Examples
Ex. 1
Ex. 2
Ex. 3
Ex. 4
Active Ingredient
mg
mg
mg
mg
Rosemary (SCE & HE)
150
150
150
150
Rosemary SCE
100
100
100
100
Rosemary HE
50
50
50
50
Turmeric (SCE and HE)
110
125
110
110
Turmeric SCE
10
25
22
22
Turmeric HE
100
100
88
88
Green Tea
100
100
100
100
Ginger (SCE & HE)
100
75
100
100
Ginger SCE
54
15
54
54
Ginger HE
46
60
46
46
Holy Basil (SCE & HE)
100
50
50
50
Holy Basil SCE
—*
8
8
8
Holy Basil HE
100
42
42
42
Chamomile (SCE & HE)
—
15
—
—
Chamomile SCE
—
4
—
—
Chamomile HE
—
11
—
—
Oregano (SCE & HE)
40
20
20
20
Oregano SCE
40
10
10
10
Oregano HE
—
10
10
10
Boswellia serrata
—
150
—
100
Black currant
—
30
30
50
Clove SCE
—
7
7
7
Hu Zhang ( Polygonum cuspidatum )
80
—
—
—
(root and rhizome) HE
Chinese Goldthread ( Coptis chinesis )
40
—
—
—
(root) HE
Barberry ( Berberis vulgaris ) (root) HE
40
—
—
—
Chinese Skullcap ( Scutellaria baicalensis )
20
—
—
—
(root) HE
Thyme SCE
—
—
10
5
*Throughout this chart,
“—” indicates no addition (zero content) of a particular ingredient in a particular example.
In preparation for the following seven assays, pre-encapsulated formulas according to Examples 1-4 were dissolved in dimethyl sulfoxide (DMSO) and evaluated at semi-log dilutions of 100, 30, 10, 1, 0.1, and 0.03 μg/mL.
Cytokine Panel
Human Peripheral Blood Mononuclear Cells (PBMCs) from 3 different donors are exposed to Lipopolysaccharide (LPS) to stimulate secretion of inflammatory agents IL-1b, IL-6, IL-8, MIP-1α and TNFa. Levels of cytokines are detected through luminex quantitation and inhibition by Zyflamend formulations is reported as pg/mL for the strength of the response. The positive control for this assay is Dexamethasone.
Donors used for this trial include a female, Caucasian, age 30-40 yrs; a male, Mixed Asian, age 30-40 yrs; and a male, African American, age 50-60 yrs. Increased percent inhibition is preferred.
Inflam-
matory
Total Active
Agent
Concentration
Results
IL-1B
10 ug/ml
Percent inhibition of IL-1B was higher
for each of Examples 3-4 than for
Example 1. Percent inhibition of IL-1B
was higher for Example 2 than for
Example 1 in PBMCs from 2 of the 3
donors. The percent inhibition of Example
2 was lower than for Example 1 in PBMCs
from the African American donor; it is
unclear whether this result is related to
individual variance or a possible difference
in ethnic/racial or age group response to
Example 2.
30 ug/ml
Percent inhibition of IL-1B was higher for
each of Examples 3-4 than for Example 1.
Percent inhibition of IL-1B was higher for
Example 2 than for Example 1 in PBMCs
from 2 of the 3 donors. The percent
inhibition of Example 2 was lower than
for Example 1 in PBMCs from the African
American donor; it is unclear whether
this result is related to individual variance
or a possible difference in ethnic/racial or
age group response to Example 2.
IL-6
10 ug/ml
Percent inhibition of IL-6 was higher for
each of Examples 3-4 than for Example 1.
Percent inhibition of IL-8 was higher for
Example 2 than for Example 1 in PBMCs
from 2 of the 3 donors. The percent inhibition
of Example 2 was comparable to or lower than
Example 1 in PBMCs from the donor of Mixed
Asian ancestry, although it is unclear whether
this result is related to individual variance or a
possible difference in ethnic/racial group
response to Example 2.
30 ug/ml
Percent inhibition of IL-6 was higher for each
of Examples 2-4 than for Example 1.
IL-8
10 ug/ml
Percent inhibition of IL-8 was higher for each
of Examples 3-4 than for Example 1. Percent
inhibition of IL-8 was higher for Example 2
than for Example 1 in PBMCs from 2 of the 3
donors. The percent inhibition of Example 2
was comparable to Example 1 in PBMCs
from the donor of Mixed Asian ancestry,
although it is unclear whether this result is
related to individual variance or a possible
difference in ethnic/racial group response to
Example 2.
30 ug/ml
Percent inhibition of IL-8 was higher for each
of Examples 2-4 than for Example 1.
MIP-1A
10 ug/ml
Percent inhibition of MIP-1A was higher for
each of Examples 2-4 than for Example 1.
30 ug/ml
Percent inhibition of MIP-1A was higher for
each of Examples 2-4 than for Example 1.
TNF-α
10 ug/ml
Percent inhibition of TNF-α was higher for
each of Examples 2-4 than for Example 1.
30 ug/ml
Percent inhibition of TNF-α was higher for
each of Examples 2-4 than for Example 1.
Surprisingly, the variations in the compositions of Examples 2-4 provided generally improved pro-inflammatory cytokine inhibition compared to Example 1, even though all of the ingredients of Example 1 are known (in traditional medicine and/or the scientific literature) as anti-inflammatory agents. The relatively better performance of Examples 3-4 relative to Example 2 further suggest that the addition of a supercritical extract of Thyme, even at low inclusion levels, may help reduce pro-inflammatory cytokine response. Further, the similar performance of Examples 3-4 suggest that boswellia is not a critical ingredient for reducing pro-inflammatory cytokine response, at least among the cytokines studied here. This is surprising, since boswellia is considered a medicinal herb, and thyme is generally considered a culinary herb.
5 Lipoxygenase
5-Lipoxygenase catalyzes the oxidative metabolism of arachidonic acid to 5-hydroxyeicosatetraenoic acid (5-HETE), the initial reaction leading to formation of leukotrienes. Human recombinant 5-Lipoxygenase expressed in insect sf9 cells is used. Test compound and/or vehicle is preincubated with 5 U/ml enzym in Tris buffer for 15 minutes at 25° C. The reaction is initiated by addition of 3 μM Arachidonic acid for another 5 minute incubation period and is terminated by further addition of 1 N HCl. An aliquot is removed and determined the amount of Leukotriene B4 (LTB 4 ) formed spectrophotometrically by Enzyme ImmunoAssay (EIA) kit. Compounds are screened at 10 μM. Nordihydroguaiaretic acid (NDGA) is used as the standard reference for this assay.
At 10 and 30 ug/ml, the percent inhibition of 5-lipoxygenase was comparable for all of Examples 1-4.
12 Lipoxygenase
12-Hydroxyeicosatetraenoic acid (12-HETE) is formed from arachidonic acid either by 12-lipoxygenase or by a cytochrome P450 monooxygenase. 12-Lipoxygenase is generally localized in the soluble cytosolic fraction, and the cytochrome P450 monooxygenase is a microsomal enzyme. There are three isoforms of arachidonate 12-lipoxygenase in mammals: platelet, leukocyte, and epidermal types Inhibitors of 12-lipoxygenase may be of benefit for the treatment of hypertension and inflammation.
12-Lipoxygenase isolated from human platelets is used. Test compound or vehicle with 150 mg/ml enzyme ‡ is preincubated for 15 minutes at 25° C. in modified Tris-HCl buffer pH 7.4. The reaction is initiated by addition of 30 mM arachidonic acid for another 15 minute incubation period. Enzyme activity is determined spectrophotometrically by measuring the formation of 12-HETE. Compounds are screened at 10 mM. Baicalein is used as the standard reference for this assay.
At 10 and 30 ug/ml, the percent inhibition of 12-lipoxygenase was comparable for all of Examples 1-4.
LTB4
Leukotriene (LT) receptors most sensitive to the endogenous ligand BLT 4 are named BLT receptors, whereas those preferentially activated by the CysLTs are named LTC 4 , D 4 and E 4 . LT receptors belong to the superfamily of G protein-coupled seven transmembrane proteins. G-protein-coupled receptors constitute one of the major signal transduction systems in eukaryotic cells. Coding sequences for these receptors, in those regions believed to contribute to the agonist-antagonist binding site, are strongly conserved across mammalian species. LTB 4 receptors are found in leukocytes, spleen and thymus and also reported to be present in peritoneal macrophages and eosinophils.
Human U-937 (histiocytic lymphoma) cells are used to prepare membranes in modified Tris-HCl buffer at pH 7.4. A 60 mg ‡ aliquot is incubated with 0.2 nM [ 3 H] Leukotriene B 4 for 30 minutes at 25° C. Non-specific binding is estimated in the presence of 2 mM leukotriene B 4 . Membranes are filtered and washed 3 times and the filters are counted to determine [ 3 H] Leukotriene B 4 specifically bound. Compounds are screened at 10 μM.
At 10 ug/ml, the percent inhibition of Leukotriene B4 was higher for Examples 2-4 than for Example 1. At 30 ug/ml, the percent inhibition of Leukotriene B4 was higher for Example 4 than for Examples 1-3, higher for Example 3 than for Examples 1-2, and higher for Example 2 than for Example 1.
PGE2
Tert-Keratinocytes are plated out and are supplemented with arachidonic acid upon treatment with dilutions of Zyflamend or DMSO control. The DMSO content is kept at 0.1% in all groups. 20 Hours post-treatment, the supernatants are collected for PGE2 determination. The cells are assessed for viability using the Cell Titer Glo system (Promega) according to manufacturer instructions. The ATP values are normalized to the values from the DMSO-treated group. Prostaglandin E2 (PGE2) levels are determined using the PGE2 Assay Kit from CisBio according to directions. PGE2 values are normalized to the corresponding ATP levels and are expressed as a % of PGE2 produced by DMSO-treated control. As can be seen in table and graph below, dilutions of Zyflamend exhibit a dose-response inhibition of PGE2 production with an estimated IC50 occurring near 1,250,000 dilution. Zyflamend is clearly demonstrating an anti-inflammatory effect that is easily detectable using the PGE2 assay in keratinocytes.
The IC50 (w/v %) for inhibition of PGE2 Release was comparable for all of Examples 1-4.
NFkB
A Nuclear Factor kappa-light-chain-enhancer of activated B cells (NFkB) reporter system detected by beta-lactamase activity was purchased from Invitrogen. The substrate system (ToxiBlazer) is also purchased from Invitrogen and used per instructions. Cells are plated and treated with Zyflamend dilutions and controls for 30 minutes before being stimulated with Tumor Necrosis Factor alpha (TNFα). After 4.5 hours, the ToxiBlazer substrate is added and incubated for 2 more hours. The various fluorescent output at the prescribed wavelengths are then measured using an Envision Plate reader. We found that the ToxiBlazer cytoxicity system signal was interfered with by the Zyflamend (run 1) so we use the Cell Titer Glo system to measure viability (run 2). Data was kept when the ATP measured was ≧80% of the amount measured in the DMSO-treated control. As can be seen in both assay runs, the Zyflamend is inhibiting the TNFα-induced NFkB activation with an apparent IC50 near 1,562,500 dilution.
The IC50 (w/v %) for NF-kβ activation was lower for Examples 2-4 than for Example 1, and lower for Examples 2-3 than for Example 4.
COX-2
The COX-2 assay was an enzyme based assay. The kit used measures the peroxidase activity of COX. The peroxidase activity is assayed colorimetrically by monitoring the appearance of oxidized N,N,N′,N′-tetramethyl-p-phenylenediamine (TMPD) at 590 nm. The kit includes isozyme-specific inhibitors for distinguishing COX-2 activity from COX-1 activity.
The IC50 (w/v %) for COX-2 inhibition was lower for Examples 2-3 than for Examples 1-4. The IC50 (w/v %) for COX-2 inhibition was comparable, but slightly higher, for Example 4 than for Example 1.
The active ingredients (amounts listed in milligrams) of any of examples 2-4 can be combined with a carrier into a softgel, tablet, capsule, or other form suitable for oral administration. The oral dosage form may be intended for administration once daily, or twice daily, or three or more times daily. In preferred forms, the oral dosage form is intended for administration once or twice daily. The carrier may be any inert or pharmaceutically acceptable carrier, as known in the art. The active ingredients of any of examples 2-4 can be incorporated into a food product, such as snack bars, candies, lozenges, beverages, and the like.
The active ingredients of any of examples 2-4 can be combined with a food for companion animals. The companion animal food may be complete and nutritionally balanced. The companion animal food may be raw or may be cooked, as by extrusion, steam, boiling, ohmic heating, retort, baking, frying or combinations thereof.
The active ingredients of any of examples 2-4 can be combined with a food, beverage, or other composition intended for ingestion. For example, the active ingredients of any of examples 2-4 can be combined with a meal-replacement beverage, a milk shake, juice, a juice-containing beverage, or a juice-flavored beverage. The active ingredients of any of examples 2-4 can be combined with a snack bar, such as a meal replacement bar, candy bar, energy bar, or the like.
A composition comprising the active ingredients of any of examples 2-4 may be free of inhibitors of inflammation recognized as drugs, such as meclofenamic acid, niflumic acid, indomethacin, mefenamic acid, phenylbutazone, alclofenac, aspirin, paracetamol, steroids, salicylate, prostacyclin, aurothiomalate, aurothioglucose, colchicines, ibuprofen, ketoprofen, naproxen sodium, or combinations thereof. A composition comprising the active ingredients of any of examples 2-4 may be substantially free of pharmacologically active inhibitors of inflammation. For example, a composition comprising the active ingredients of any of examples 2-4 may comprise less than 5%, or less than 3%, or less than 1% by weight of the composition inhibitors of inflammation recognized as drugs.
A composition comprising the active ingredients of any of examples 2-4 may be free of certain herbal inhibitors of inflammation, including hu zhang ( Polygonum cuspidatum ), Chinese goldthread ( Coptis chinensis ), barberry ( Berberis vulgaris ), Chinese skullcap ( Scutellaria baicalensis ), or combinations thereof. A composition comprising the active ingredients of any of examples 2-4 may be substantially free of certain herbal inhibitors of inflammation, including hu zhang, Chinese goldthread, barberry, Chinese skullcap, or combinations thereof. For example, a composition comprising the active ingredients of any of examples 2-4 may comprise less than 5%, or less than 3%, or less than 1% by weight of the composition certain herbal inhibitors of inflammation, including hu zhang, Chinese goldthread, barberry, Chinese skullcap, or combinations thereof. These herbal inhibitors may be excluded as whole herbs or plant parts, extracts, powders, concentrates, or combinations thereof.
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. | Supplements for maintaining a healthy immune response include one or more extracts from rosemary, turmeric, green tea, ginger, holy basil, oregano, boswellia, black currant, and clove. The supplements may include an extract of thyme. The supplements may exclude anti-inflammatory drugs and certain anti-inflammatory herbs. | 0 |
RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. §119 to both U.S. Provisional Application No. 62/306,386, filed Mar. 10, 2016, and U.S. Provisional Application No. 62/201,186, filed Aug. 5, 2015, the contents of which are hereby expressly incorporated by reference.
FIELD OF THE INVENTION
[0002] The present application primarily addresses difficulties and safety issues encountered when work pieces of such small dimensions as to be difficult to grasp are desired to be shaped, trimmed, or otherwise processed with a tool, such as a woodworking router, which is mounted below a work surface, or router table, the cutter or other attachment projecting upward through the work surface.
BACKGROUND OF THE INVENTION
[0003] It is a common, if not pervasive, practice in the woodworking field to employ routers that are mounted under a work surface, or table-top, i.e., inverted, with the cutter projecting upward through an opening in said work surface to engage the work piece being processed. An inverted router is in essence a small shaper, and many shops large and small employ routers in this manner in the production of cabinet doors, mouldings, and many other products. In the case of curved or contoured work pieces, the process is executed without the use of a fence, relying on a guide bearing which is an integral part of the router bit. However, most work is done using a fence to limit the depth of engagement of the work piece into the bit. There are many suppliers of such fences, and many designs, usually marketed in conjunction with a router table as mentioned above.
[0004] In that this application includes a fence as a component of the total embodiment, the following U.S. Patents disclose fences by others: U.S. Pat. Nos. RE38612; 5,779,407; 6,398,469; and 6,481,477. Another exemplary fence of the prior art, the Kreg Precision 36″ Router Table Fence, is seen as Item #148836 in the 2014 Edition of the Woodcraft Supply Catalog.
[0005] The referenced publications above, as well as many others, demonstrate embodiment of many meritorious features and innovations in the field of router table fences; however, the features and combinations of elements to be presented herein were found lacking, as will be made apparent in the following description and drawings.
SUMMARY OF THE INVENTION
[0006] This application presents a system for use with inverted routers or small shapers which incorporates an electrically powered work piece feeder component with a router table fence having improvements in adjustability which enhances accuracy, convenience, and safety in the use of such power tools. More generally, the powered work piece feeder may be used with a workpiece support fence mounted on a table having a power tool cutter projecting upward therefrom. The power tool cutter may be an inverted router, a shaper, a table saw, or even a band saw.
[0007] The fence has a working face above the table extending adjacent the power tool cutter to define a longitudinal feed axis. A powered feeder element is adapted to rigidly mount on the fence and has an inverted roller suspended over the table on the same side of the face as the power tool cutter. The powered feeder element has fence mounting structure permitting positional adjustment of the roller in spatial relation to the power tool cutter and a workpiece on the table. The powered feeder element is further configured to position the roller in contact with the workpiece and rotate the roller so as to transfer pressure and motion to and propel the workpiece on the table over the power tool cutter and along the longitudinal feed axis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Features and advantages of the present invention will become appreciated as the same become better understood with reference to the specification, claims, and appended drawings wherein:
[0009] FIG. 1 is a perspective/isometric overview of a preferred embodiment of the complete fence-and-feeder system of the present application;
[0010] FIG. 2 is an elevation as viewed from the left, or out-feed, end of the system positioned on a work surface with a router bit projecting up through an opening in said surface and engaging the work piece;
[0011] FIG. 3 is a top down plan view of the exemplary fence-and-feeder system, showing all components in neutral, “at rest” positions;
[0012] FIG. 4 is a variation of FIG. 3 's plan view in the preferred embodiment of the application in operation position, provided to clarify the spatial relationships of the components and adjustability features, showing the feeder component slightly “crabbed” in relation to the fence body and work piece, as this is how it is used in practice;
[0013] FIG. 5 is an elevation viewed from the rear, i.e., the side opposite the operator's normal position, provided to further clarify the adjustments to the feeder component;
[0014] FIG. 6 is a close-up detail view of the same elevation in FIG. 5 , showing more clearly the mini-feeder handle unit's components; and
[0015] FIG. 7 is an exploded view of the interior mechanics of one embodiment of a functional in and out feeder ramp assembly required for safe and smooth operation of the mini-feeder. Other ramps, either commercial or custom made, may be used, alternatively to this customized variation, to insure straight motion of the feed stock both before (in) and after (out) router cutting operations.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] There are no examples in the art of a feeder mechanism incorporated into a router fence. The feeder element in the present application is perhaps the most outstanding aspect in this endeavor, and has apparently not been addressed before. The feeder element has been developed and conceived in response to the safety problem, and difficulty of work, related to use of the inverted router, especially when dealing with small work pieces. A built prototype deals suitably with this problem, producing excellent results and keeping the operator's hands well away from the cutters, and is represented in the drawings and description as the preferred embodiment of the feeder element. The fence herein described also has advantageous features regarding adjustability, safety, and convenience even if employed without its companion, the feeder element.
[0017] The following provide a glossary of terms used in reference to the drawings:
[0018] 20 . Pressure lever arm
[0019] 21 . Pressure adjustment screw
[0020] 22 . Pressure adjustment wing nut
[0021] 23 . Body of hold-down
[0022] 24 . Pressure spring
[0023] 25 . Pressure spring anchor roll pin
[0024] 26 . Lever arm fulcrum pin
[0025] 27 . Lateral adjustment base
[0026] 28 . Lateral adjustment locking knobs
[0027] 29 . Lateral adjustment base sub-plate
[0028] 30 . Rotary adjustment bearing
[0029] 31 . Rotary adjustment bearing sub-plate
[0030] 32 . Rotary adjustment locking knob(s)
[0031] 33 . Height adjustment screw
[0032] 34 . Height adjustment knob
[0033] 35 . Height adjustment lock nut
[0034] 36 . Fore-and-aft positioning track
[0035] 37 . Fore-and-aft positioning locking knob(s)
[0036] 38 . Fore-and-aft positioning locking knob nut
[0037] 39 . Main fence body
[0038] 40 . Drive component mounting nuts
[0039] 41 . Drive component mounting plate
[0040] 42 . Primary drive gear
[0041] 43 . Idler gear
[0042] 44 . Idler gear shaft
[0043] 45 . Idler gear snap ring (circlip)
[0044] 46 . Final driven gear
[0045] 47 . Final driven gear stop collar
[0046] 48 . Driven shaft
[0047] 49 . Feed roller, or tire
[0048] 50 . Work piece
[0049] 51 . Gearmotor component
[0050] 52 . Switch
[0051] 53 . Router table
[0052] 54 . Router bit
[0053] 55 . Sliding infeed fence
[0054] 56 . Infeed sacrificial face
[0055] 57 . Slotted plates
[0056] 58 . Sliding fence face locking screws
[0057] 59 . Sliding fence face locking knobs
[0058] 60 . Sliding fence face locking nuts
[0059] 61 . Inner outfeed ramp
[0060] 62 . Outer outfeed ramp
[0061] 63 . Outfeed sacrificial face
[0062] 64 . Outfeed ramp adjustment bracket
[0063] 65 . Outfeed ramp adjustment screw
[0064] 66 . Outfeed ramp adjustment knob
[0065] 67 . Sliding fence face alignment splines
[0066] In broad terms the present application combines a router/small shaper fence which has improved adjustment features with a powered feeder which is especially adapted to extremely small work pieces, those work pieces being the ones that are most dangerous and most difficult to produce satisfactorily. But the use of the system here presented is not limited to the small work at all, providing efficiency, convenience, and safety when applied to larger work. When work is passed over the cutters of this type of tool by hand, as is now done almost exclusively, there is inevitably variation in feed speed and pressure, pauses occur when the hands of the operator are repositioned, and other inconsistencies arise which result in imperfect results.
[0067] The parts in the drawings and description here presented which are parts of said device are 20 through 28 , and 33 , 34 , and 35 , and 48 and 49 . As seen most readily in FIG. 2 , these parts provide a basic framework upon which to develop the system in the preferred embodiment here represented.
[0068] An example of the usefulness of the present system is in the production of a large amount of very small ¼-round moulding involved in a restoration job. The aforementioned hold-down on the router table fence was installed, as the square stock was too small to grip, and therefore impossible to feed across the fence. While providing sufficient holding pressure, the difficulty of feeding is not alleviated, and made still worse because the hold-down is in the way. Thus, the roller, or tire, of the device is motorized. Since the base of the hold-down is a single-position fixture, adjustment facility in other ways is also desirable.
[0069] One of skill in the art having basic skills of measuring and fabrication, and access to the necessary tools, can build this feeder apparatus, and the entire feeder-fence system, as shown here in a preferred embodiment.
[0070] As a first step the builder could cut the mounting plate 41 for the drive component (gearmotor) 51 FIG. 2 , FIG. 3 , and drill a clearance hole to slide onto the threaded portion of the roller shaft 48 where said shaft is screwed into the lower end of the pressure lever arm 20 . This threaded section was provided by the hold-down manufacturer to allow adjustment of the length of said shaft. Two nuts 40 which fit these threads are employed to lock the mounting plate 41 firmly in a position perpendicular and away from the lever arm 20 . Next, it is necessary to determine the position of the gearmotor, or drive component 51 in relation to the shaft 48 , which is to be driven. The builder must obtain appropriate small spur gears, roughly 1″ in diameter, with appropriate bores for use: The primary driven gear 42 must have a bore equal to the diameter of the output shaft of the gearmotor. A method of affixing to the output shaft must be used such as a keyway configuration. Otherwise the person skilled in the art could use a rollpin.
[0071] The final driven gear must be affixed to the driven shaft by keyway, roll pin, or other means, and as shown in FIG. 2 , retained with a stop collar 47 . As the tire, or roller, is in a free rotary state when manufactured, the hub of said roller must be affixed to its shaft. This was accomplished in the prototype by drilling through the stop collar and into the hub of the roller so as to allow the use of a roll pin. Now by careful measurement of the distances between centers of the gears being used when properly enmeshed, the relative positions of the three shaft centers can be determined. These drive units are consistently provided with threaded mounting holes.
[0072] Appropriate holes drilled in the mounting plate 41 will allow secure attachment of the gear-motor to the mounting plate 41 . A hole must be drilled in the mounting plate for interference fit of the idler gear's shaft 44 , which is pressed in. A person skilled in the art will readily see that it is best to establish the idler gear position relative to the final driven assembly first, then establish the position of the gear-motor.
[0073] The drive component 51 utilized in the prototype, represented here as a preferred embodiment, was selected by estimating the desired rate of feed, that being a moderate, if not conservative, proven approximate rate of 12-15 feet per minute.
[0074] By some simple calculations integrating the circumference of the roller at its outer edge the desired rpm of the roller 49 was determined to be about 15-20 rpm.
[0075] For simplicity the decision was made to transfer the rotational force of the gear-motor 51 through a series of spur gears 42 , 43 , 46 in which the primary drive gear 42 was identical to the final driven gear 46 , allowing the selection of a gear-motor 51 with an output rpm within the desired range. The idler gear 43 is present to obtain clearance between components, and is provided with a simple shaft 44 pressed into the mounting plate 41 , said shaft 44 having been machined to provide a groove to receive a snap ring, or circlip 45 , to retain the idler gear. The gear-motor 51 used in the prototype was thus selected from the Grainger' s catalog. One was chosen of an appropriate size and amperage for this application, and with a reversible feature, for reasons which will be explained.
[0076] The particular unit used in the prototype is catalog #4Z455 on page 108 in catalog 404 at Grainger' s. It has an output rpm of 18, requires capacitor cat. #2MDV3, and has 1/100 hp. input. Although 1/100 hp. sounds very small, at the gear ratio 173:1, tests indicate it is very difficult to cause a stall in practice. This gearmotor includes a built-in brake, as these are commonly used in motion control situations; the brake has occasionally caused trouble in starting, and it would be preferred to locate a similar unit sans brake. An added bonus would be a gearmotor which was also of variable speed. Clearly a more powerful unit could be incorporated, as long as the bulk and scale of the component was appropriate in relation to the other elements.
[0077] The roller 49 shown is exemplary only and various types are contemplated. For instance, an existing static hold-down, or work piece guide, is marketed under the name Board Buddies™. It will be observed that the conical form of the roller on this device is useful in that it facilitates the positioning of the point of pressure into a very narrow corner where the table and fence meet. The roller 49 is desirably formed of an elastomer of various densities depending on the workpiece and power tool being used. In a preferred embodiment the roller 49 is formed of an elastomer of 50 durometer rating, most often employed in the industry for smooth workpieces. A denser roller may be used for rougher workpieces.
[0078] It will be obvious that this preferred embodiment could be made more sophisticated in the interest of durability and other qualities; such as cosmetic appearance, and that various methods of assembly could be employed to achieve the same purposes. The exemplary embodiment represents production of a working prototype while minimizing expense. Also, various methods could be employed for the transference of rotary force to the driven roller 49 , roller chain and sprockets, for instance, these possibilities not detracting from the novelty or function of the invention nor avoiding infringement on the claims to follow.
[0079] Once the builder has combined the gear train, driven shaft and roller, it only remains to do some simple wiring, including a 3 pole switch 52 , mounted in a convenient place, and a powered roller has been established on the lower end of the pressure lever arm 20 .
[0080] Now our builder can move to the area where the hold-down's base 27 is attached to the rotationally adjustable platform, which is subsequently mounted to the main sub-plate 31 , which in turn is slidable along the track 36 on top of the fence. Here 3 components are involved: The sub-plate 29 below the base 27 , which is attached to the underside of the base by the use of short flat head machine screws through the sub-plate threaded into tapped holes in the hold-down base. Likewise the upper part of the rotary bearing 30 is attached to the underside of the sub-plate, and the lower part of the rotary bearing to the rotary adjustment bearing sub-plate. Prior to final assembly of the rotary element, the builder should do some drilling and tapping to accommodate the rotary adjustment locking knobs 32 , which simply press down onto the rotary adjustment sub-plate 31 , and clearance holes for the locking knobs 37 that engage nuts 38 trapped in the fore-and-aft positioning track 36 , which is firmly embedded in the main fence body 39 .
[0081] It should be mentioned for clarity that in this text “fore-and-aft” adjustment refers to the movement of the rotary bearing sub-plate along the longitudinal axis of the fence, and “lateral” adjustment refers to the movement available between the hold-down's body 23 and the hold-down's base 27 . These terms were adopted because the elevation FIG. 2 is a view from the left end in relation to the operator's position, and this drawing is most easily understood regarding these features. Upon assembly of the elements discussed above the builder has created a motorized hold-down that can be adjusted to suit the task at hand, positioning the roller's height from the table, its distance from the fence, its angle of attack on the work piece, and it's position along the fence. These features avail the operator of versatile and precise set-up options to optimize his safety and the quality of results.
[0082] Once again, certain features and elements represented in this preferred embodiment could be altered. For instance, the rotary adjustment could be provided by simply allowing two plates in a rotatable relation to face each other, eliminating the bearing 30 . This would result in a less satisfactory assembly, fabrication difficulties, and shorter durability. Under any circumstances, such omissions or alterations do not detract from the innovation of the invention, or its function, nor would such alterations avoid infringement of the claims to follow, no more than changing, say, a roll pin to a bolt, or the pitch of threads of a screw.
[0083] Now this description and our person skilled in the art can move down to the fence itself, upon which the feeder assembly rests and slides fore and aft. The fence and its parts and function will be discussed and described exclusively here to allow the reader, or person skilled in the art, to focus on the advantages and assembly of said fence until, as it were, it is ready to receive the powered feeder element and “go to work”.
[0084] The building of the fence begins with its main body 39 , which must be substantially robust in dimensions and stability to provide means of mounting to the router table, of which there are many, and ample room for various grooves and holes essential to the introduction of other parts. In this preferred embodiment illustrated and discussed it will be assumed to be made of a suitably stable and strong hardwood blank, likely of one of the exotic species known for strength, durability, and stability, for instance Ipe or Cumaru. Fabricating with wood lends itself to ease of machining for our builder skilled in the art having limited means or access to tools. Clearly metallic or even man-made materials could be used so long as the desired configuration could be produced.
[0085] This main body 39 will need a cross-section of approximately 2″ in height×4″ in width (50 mm.×100 mm.) and a length of about 2½ feet (75 cm.). This length is about normal, as is appropriate for use on ordinary sized router tables. As readily seen, the location of the opening for dust extraction, and thus the relation to the router bit itself, is determined by the particular table in use. This issue is related to the method, or means, of attachment of the entire assembly to the router table, which will be left open to the many options to be developed, and those methods already revealed in prior art. One exemplary method of fence attachment is a version of what is commonly called a “T-square fence”, such as fence model PRS 1015 sold by the Kreg Company, Huxley, Iowa.
[0086] Perhaps our builder wishes to proceed first with the provision of a recessed channel which receives the track 36 along which the feeder assembly travels. These tracks are readily available from many sources and typically require a channel ¾″ wide and (various) ⅝″ deep. They are designed to accommodate companion locking knobs threaded into a trapped ¼″/20 pitch nut. Thus the feeder system's fore-and-aft adjustment would employ this conventional hardware.
[0087] This track will also accommodate the use of various accessories such as finger-boards and stops, and could be equipped with two feeder assemblies, one at in-feed and one at out-feed.
[0088] Next we come to the adjustable in-feed and out-feed fence faces that together form a working face against which the workpiece abuts. As illustrated in the plan view of FIG. 3 , the in-feed section, to the right hand of the operator, is a separate part which is able to slide fore and aft along the main fence body, and is locked into position by the tightening of two knobs whose screws extend through the main fence body from behind. This feature allows the in-feed section, or face, to be retracted away from, or advanced toward the router bit. The alignment in relation to the main body is retained by splines 67 similar to those seen in the out-feed section in FIG. 2 .
[0089] Also shown on both in-feed and out-feed faces are sacrificial auxiliary faces. These are made of any plausible material and easily replaced by the operator. The point of these sacrificial parts is that they can be advanced right up to the router bit, even being machined by said bit, to obtain “zero clearance” at the cutter's exposure. This condition in use provides reduced chipping, better dust removal, and prevents a work piece from entering the gap. These sacrificial surfaces could be provided with any sort of quick-change conveniences, made of fancy materials, and provided as consumables, or simply screwed onto the fence sections by the owner. Often in shaper and router work it is necessary to fabricate a receiver piece to be attached to the out-feed section which fits the profile being cut, to prevent rolling or other problems as the work piece emerges from the shaping operation at the cutter. Therefore the sacrificial face of the out-feed section is often modified, and regarded as a disposable part. In practice ½″ plywood known in the trade as “Baltic birch” is quite suitable. The sacrificial contact faces are secured to the face of the fence so as to be easily removed or replaced, e.g. with Dzus fasteners.
[0090] Now if we proceed to the out-feed section with its sacrificial face 63 , our builder will observe in FIG. 3 , in plan, that this out-feed section is comprised of two wedge-shaped parts, or ramps, inner ramp 61 and outer ramp 62 , which are again aligned with splines 67 , and locked together with knobs from behind. FIG. 7 shows the inner ramp 61 and outer ramp 62 and the locking knobs 59 on the face of the fence opposite the working face against which the workpiece abuts. In FIG. 2 , elevation, is illustrated a ramp adjustment bracket 64 attached to the outer ramp 62 , and provided with an adjustment screw 65 and knob 66 , which threads into the end of inner ramp 61 , thus allowing slow and precise advancement of the outer ramp toward the router which results in moving the plane of the outfeed section forward, i.e., toward the operator. When the desired position is achieved, the ramps are locked together by knobs in the back, just as the two fence sections are.
[0091] Half of Fence Moves
[0092] This feature allows the operator to advance the outfeed fence face forward relative to the infeed, while not losing parallelism. This is often a desired setting, such as when the router is used as a jointer. The ramp system provides a highly accurate and positive “fine tuning” capability of infinite calibration, and has not been found in prior art. In a preferred embodiment, the ramp adjustment screw, with its knob, passes through a snug clearance hole in the bracket, then through a well-fitting “wave washer,” sometimes called a Belleville, through another washer, all being held tight with a snap ring, or stop nut, the wave washer being in a slightly compressed state. Perhaps the most thoughtfully developed fences are from the Kreg Co., and even these developers have failed to provide this infinitely-adjustable outfeed feature, relying on the use of spacers or shims of definite dimension for this operation.
[0093] To build the fence's two sliding face assemblies, the builder will observe in the exploded view of FIG. 7 , that the back side of each part has been provided with a plate of rigid material, preferably a good grade of aluminum, of the same dimensions as the face parts, except in thickness. An appropriate thickness which is readily available is ⅛″.
[0094] These plates are introduced to form in essence a track which is trapping the lock nuts 60 which are engaged with the locking screws 58 and knobs 59 , the nuts sliding along in a slot milled into the fence parts. This approach was assumed to avoid the bulk of most readily available tracks, as the ramp sections preferably are not bulky themselves. These plates will necessarily be slotted, like a track, for some distance along their length, to allow the fore and aft adjustment.
[0095] They will also be slotted in strategic areas to allow the insertion of the splines 67 which maintain alignment between parts. The splines can be conveniently supplied by using common keystock, the grooves to receive them being milled out on a table saw. The plates can be screwed to their respective components, the ramps and fence sections, or attached with epoxy. The locking screws that pass through the main fence body should do so in a relatively tight bore to prevent irritating bind-up. For better ergonomic relationship, a flat washer and a wave washer, or Belleville, should be under the knobs of the locking screws. An enhancement here would be the sleeving of said bores to eliminate the tendency of the locking screws to wear away the bores.
[0096] With these sub-assemblies made ready, the entire fence can be assembled, basically a stacking of the parts and threading of the locking screws into the trapped nuts. The fence can be affixed to the router table by clamps or other means, and the feeder assembly attached to its track. Now our operator has the facility to position the fence in relation to the router bit, then position the feeder roller precisely where desired, according to the size of work piece. The height of the roller, controlled by the height adjustment screw 33 , is to be set so that the work piece can be nudged into the gap between the roller and the table, at which moment it begins to be fed. The angle of attack, or bias, some say “crab”, is set at about 5-10 degrees, to ensure the roller is urging the work piece toward the fence. By sliding the feeder assembly along its track, the roller is set very near the opening in the fence, but avoiding contact with the router bit (!) and production can begin.
[0097] In operation, the material which is to be machined into a final product is first dimensioned and laid by for the operator to access conveniently in the work area. The entire fence is positioned over the router bit, allowing the desired amount of bit, or cutter, to protrude forward of the fence. Of course the height of the bit has also been adjusted in protrusion through the opening in the table. These settings are likely to have been estimated and may require adjustment once a first work piece has been milled. A first work piece is brought to the router table against the in-feed fence, allowing the operator to move the feeder assembly into its desired relation to the work piece, as discussed above.
[0098] The feeder and the router can now be turned on and the end of the work piece nudged into engagement with the roller, under the roller and against the in-feed fence. Said workpiece will advance over the cutter, material will be removed, and the finished product will continue onto the out-feed side. If in the milling process some of the entire height of the work piece has been removed, the operator will utilize the adjustment feature whereby he can advance the out-feed section of the fence to the point where the new surface of the workpiece is in contact with the out-feed section. He may also wish to slide both fence sections toward the cutter to minimize the clearance, as was previously discussed. With very little practice regarding setting up, perfect results can be produced, while the hands of the operator are never in close proximity to the cutter.
[0099] As is the case with any power tool, the operator must at all times exercise caution, ensuring that the machines are firmly affixed, the work area is uncluttered, and that loose clothing such as shirt-tails and sleeves are not in proximity to the action of the machines. The prototype in this preferred embodiment was equipped with a shroud over the gearmotor and another was placed over the geartrain. These shrouds are not shown in the drawings.
[0100] A second embodiment is also presented which concerns the unification of the two major elements, the fence as a whole as already described, and the feeder assembly. Where in the preceding description the feeder assembly is mounted to its track 36 which is embedded in the main fence body, and said feeder assembly has a rotary adjustment platform, an alternative embodiment could also prove effective in providing the same advantages of adjustability and versatility. In this second embodiment, the rotary adjustment element 30 , 31 below the lateral adjustment base 27 are eliminated, and the plate beneath the lateral adjustment base is increased in size to provide ample space to accommodate installation of two switchable magnets, substantially on each side of and in close proximity to said base.
[0101] These small but powerful magnets are contained in a sleeve made of non-magnetic material, say aluminum or phenolic board, and carried loosely within the sleeves with machine screws that pass through the sleeves and into the body of the magnet. The sleeves themselves are firmly attached to the plate upon which the base is mounted. An opening beneath each magnet is cut in the enlarged plate slightly larger than the magnet itself. These remarkable rare earth magnets are available from the Magswitch TM Company of Westminster, Colo. The version to be used here is Magsquare 150, sku 8100054, which has a holding force of 150 pounds in contact with substantial ferrous material.
[0102] Now a steel plate of the same width and length as the main fence body, in thickness ⅛″, or 3 mm, is attached firmly to the main fence body, say with countersunk wood screws. In this embodiment the operator positions the feeder assembly to his desire in relation to the router bit and switches the 2 magnets on. This second embodiment would provide all the advantages of the first embodiment in regard to the positioning of the roller, although perhaps with a bit less feeling of control. Though this version has not been prototyped, previous experience indicates the magnet strength to be more than adequate.
[0103] In summary, herein has been described and illustrated a fence system for use with inverted routers or small shapers which incorporates improvements in adjustability over prior art, and combines the fence with a feeder element designed specifically for use with such machines, having characteristics especially advantageous for use with work pieces of small dimensions, thus greatly enhancing operator safety and product quality.
[0104] While the invention has been described in its preferred embodiments, it is to be understood that the words which have been used are words of description and not of limitation. Therefore, changes may be made within the appended claims without departing from the true scope of the invention. | An electrically powered work piece feeder for use with inverted routers or small shapers incorporates improvements in adjustability which enhances accuracy, convenience, and safety in the use of such power tools. The powered feeder element mounts on a table fence and has an inverted roller suspended over the table adjacent a working face. Mounting structure permits positional adjustment of the roller in spatial relation to the power tool cutter and a workpiece on the table so as to propel the workpiece on the table over the power tool cutter and along the working face in the direction of the longitudinal feed axis. An out-feed section may be provided on the fence that includes inner and outer wedge-shaped ramps movable with respect to one another along the longitudinal feed axis and adapted to be locked together, thus allowing slow and precise advancement of the outer ramp toward the router. | 1 |
BACKGROUND OF THE INVENTION
Rapid advances in fiber optics and VLSI technologies have made intelligent, high-speed telecommunication transport systems increasingly available to network providers. In such high-speed optical fiber networks carrying, for example, multiple gigabits per second of information, the failure of a key carrier link can result in an enormous loss of bandwidth and correspondingly great loss of service to users. Consequently, automatic network restoration is one of the most essential elements in the effective operation of these telecommunicatin networks.
A number of restoration systems have previously been proposed, but none has the capability of providing the economies of both time and facilities that are required in the expanding telecommunication fiber networks. For example, while the technique of diversely routed automatic protection switching can provide substantially complete recovery with a response time of about 50 milliseconds, the required redundancy of dedicated bandwidth results in a most inefficient utilization of equipment and network facilities. Somewhat more effective systems have been made possible, however, as highly intelligent digital cross-connect equipment is being broadly deployed throughout the networks, yet these generally are lacking in speed or are excessively complex.
One such recovery system which relies upon centralized management to reconfigure a network around a failure is described by Hasegawa et al. in "Dynamic Reconfiguration of Digital Cross-Connect Systems with Network Control and Management," Proc. of Global Communications Conference, November 1987. While such a centralized method can recover from individual logical switch problems as well as physical link failures, the extensive communication necessary between the control and operating elements of the system taxes available facilities and extends response time to as much as thirty minutes. On the other hand, a distributed recovery method, such as discussed by Grover in "The Selfhealing Network: A Fast Distributed Restoration Technique for Networks Using Digital Cross-Connect Machines," Proc. of Global Communication Conference, November 1987, with its inherent parallel processing achieves significantly higher response times, yet it suffers from message overloading due to the uncontrolled "flooding" (see Stallings, "Data and Computer Communications," Macmillan, 1985, pp. 256-261) employed in intrasystem message propagation.
Unlike these prior systems, the present invention utilizes a method of selective message propagation among digital cross-connect devices to yield a distributed control technique that provides an effective network restoration system having a degree of rapid response time and minimal communication congestion not previously available.
SUMMARY OF THE INVENTION
The present invention is particularly adapted to restoring communication between nodes that terminate a failed link in a high-speed transport system, such as the Synchronous Optical Network (SONET) prescribed by American National Standard, ANSI T1.105-1988, "Digital Hierarchy Optical Interface Rates and Formats Specification," 10 Mar. 1988. Such a network may normally be a fiber optic arrangement comprising broadband digital cross-connect systems (DCS) connecting network links at the STS-1 level (Synchronous Transport Signal level 1, 51.84M bit/s). Since the network will not uncommonly be utilized in applications, such a broadband ISDN, requiring multiple STS-1 bands, it is of particular advantage that the present network recovery procedure is designed to locate the restoration path, or paths if necessary, having the largest contiguous bandwidth to thereby economically restore the interrupted service.
Restoration of a network failure employing the distributed selective broadcast processing of the invention utilizes the embedded SONET overhead channels to conveniently provide the necessary communication among the DCSs which will be involved in the recovery procedure. It is by means of these channels that the various processing messages may be exchanged between node DCSs in the course of reconfiguring the necessary path or paths between the terminating nodes of the failed network link.
Once a terminating node recognizes a failure in its communication link that is not otherwise remedied, as by an Automatic Protection Switching System, the present recovery system is initiated. Of the two terminating nodes one is arbitrarily designated, for example on the basis of having the lower identification or address number, to assume the role of Sender (SND) and the other becomes the Chooser (CHS) for the given recovery situation. At the outset, SND transmits a "help" message to all other adjacent nodes whose links with SND currently having at least STS-1 uncommitted bandwidth. This message identifies the SND-CHS pair and requests the receiving node to commit all its spare bandwidth, up to a maximum of the bandwidth lost in the failure, to recovery of the failed network link. In addition, the message includes a "hop" number, i.e. an indication of the position of the transmitting node in the chain of communication. Node SND thus notes a hop number of "1".
Each receiving node records the message data, namely the SND-CHS identification, the identification of the node from which the message was received, the bandwidth requested, and the hop number. Each such node examines the recorded data, selects the message with the highest bandwidth request, and prepares messages to its adjacent nodes requesting all spare bandwidth available on the respective links up to the maximum specified in the selected message. The node then substitutes its own identification in each message, increments the hop number by one and broadcasts the messages. In like manner each further receiving node adds request data to its chart record and forwards the appropriate maximum bandwidth request messages to its adjacent nodes. Thus the ultimate request messages eventually reaches the CHS node to be charted there in its table.
Upon expiration of a predetermined time after initiation of the recovery process, CHS examines its data chart and chooses from among the recorded messages the one specifying the greatest bandwidth. CHS then transmits an acknowledgement message to the node from which that request message was received and that requester node (RQR) confirms the availability of the specified bandwidth. RQR then likewise exchanges acknowledgement/confirmation messages with the node from which it received the message specifying the greatest available bandwidth. This procedure is repeated back along the broadcast links until the acknowledgement reaches SND, thereby establishing the highest capacity restoration path between SND and CHS. After completion of the confirmation phase of the process, the involved nodes complete the cross-connections and the SND-CHS link is restored.
In the event that the bandwidth thus restored is insufficient to recover all that was lost in the failure, SND initiates a second wave of request messages under the same guidelines as noted above. The selected path through the network will then naturally follow, in most instances, the second highest capacity links initially identified during the first wave. This selective broadcast procedure may be repeated as many times as needed to recover the entire failed link, provided the allotted processing time is not exceeded. In this respect, the process parameters will ordinarily be set to recover most anticipated failures in the approximately two second period before trunk conditioning occurs.
THE DRAWING
The present invention will be described with reference to the accompanying drawing of which:
FIG. 1 shows a map diagram of a simplified telecommunications network to which the recovery procedure of the present invention is to be applied;
FIG. 2 shows a map diagram and hop chart listings for the initial stage in the recovery procedure;
FIG. 3 shows a map diagram and hop chart listings for further stages in the recovery procedure;
FIG. 4 shows a map diagram for concluding acknowledgement and confirmation stages in the recovery procedure;
FIG. 5 is a flow diagram of the steps of the recovery procedure carried out at the Sender node;
FIG. 6 is a flow diagram of the steps of the recovery procedure carried out at intermediate nodes;
FIG. 7 is a flow diagram of the steps of the recovery procedure carried out at the Chooser node;
FIG. 8 is a diagrammatic representation of an exemplary network showing bandwidths of internodal links; and
FIG. 9 is a graphic representation of the comparative network loading during recovery procedures of the prior art and of the present invention.
DESCRIPTION OF THE INVENTION
A simplified telecommunication network, as represented in FIG. 1, comprises a number of nodes, 101-105, variously interconnected by communication links, such as optical fiber cable. Each such link will ordinarily be designed to carry significant transmission bandwidth of a multiplicity of basic STS-1 capacity. Since these internodal links will rarely be committed to their capacity in active communication transmission, some bandwidth will normally be available for assignment to such transmission. Such spare bandwidth is indicated in the exemplary network of FIG. 1 as multiples of the basic STS-1 (51.84M bits/sec.) unit, for example STS-12 (622.08M bit/s) being available in the link between nodes 101, 102. Completing the setting for the following description of this example of the network recovery process of the invention is the interruption, shown at 107, in the STS-9 link between nodes 101, 105. The object of this process is thus to utilize the bandwidth available in selected ones of the various network links to most economically reroute the communication between nodes 101, 105 with complete STS-9 bandwidth.
At the outset of the procedure, the nodes terminating the interrupted link, here 101, 105, are arbitrarily designated, such as on the basis of a numerical ranking of address, as the Sender (SND) and the Chooser (CHS) nodes. In our example then, node 101 is SND and node 105 is CHS. Having been thus selected, SND 101 begins to construct an initial request message, as at step 501 in FIG. 5, which includes the respective addresses of SND and CHS, and a control identification. SND then identifies each of its linked neighbors, i.e. nodes 102, 103, and their available link bandwidth, respectively STS-12, STS-3, and completes specific request messages which are individually transmitted to each of them.
Based on the fact that STS-9 bandwidth was lost due to the interruption at 107, SND requests all, or as much as is available, of that bandwidth from each of its neighbors. As depicted in FIG. 2, the message to node 102 thus requests only STS-9 of the STS-12 spare bandwidth on that link. The message additionally identifies node 101 as the transmitter of the request, i.e. the requester (RQR), and specifies the number of links, i.e. "hops" encountered in reaching the addressee, node 102. The message sent to node 103, on the other hand, requests only STS-3 bandwidth, the maximum available on that link.
Upon receiving a request, each node records in a table, such as shown in FIG. 2, the pertinent message data, namely the hops (HOP), the identity of the message transmitter (RQR), and the requested bandwidth (BW), provided that such bandwidth is not less, nor the hop count greater for the same bandwidth, than any previously requested. Thus, the table of node 102 records the receipt, after one hop, of a request from node 101 for STS-9 bandwidth, and that of node 103 notes an initial request for STS-3 from SND 101. As depicted in FIG. 3, each recipient node constructs its own request messages in which it identifies itself as RQR, requests the maximum needed or available bandwidth, and increments the hop count by one. These messages are transmitted to all neighboring nodes, and the data are recorded in the node tables where appropriate. Node 103 thus records the request from node 102 for STS-9 bandwidth after two hops, i.e. 101-102-103. Node 102, however, upon receiving the request for STS-3 from node 103, does not record that message data, since its table shows a prior request for STS-9. As a result, the message is in effect discarded and its propagation terminated for the current wave of requests.
During the course of the process preceding a predetermined timeout for the current spread stage of a wave of request messages, node 105 (CHS) records, according to the noted guidelines, all incoming request messages that have been able to propagate through the network to its terminus. The table of CHS, as shown for node 105, records in that time span requests from node 104 for STS-3 on three hops (101-103-104-105) and for STS-9 on four hops (101-102-103-104-105). Note, that these messages were obviously received in that order, since the lesser BW request would otherwise have been discarded.
At the occurrence of the spread stage timeout, CHS selects from its table the entry indicating the request for the greatest bandwidth and returns to the requester (RQR) identified in that entry an acknowledgement (ACK) message specifying such bandwidth. If the indicated bandwidth remains available, RQR confirms (CFM) the acknowledgement message and forwards to its greatest bandwidth requester, according to its data table, an ACK message of its own for the confirmed bandwidth. Should the link, however, be unavailable for any reason, such as commitment or loss of contention to a contemporary recovery process, SND will timeout and begin a new spread wave after a reasonable delay from the current wave timeout. In this manner, assuming satisfactory CFM messages throughout, each link in the most effective propagation chain is traced back to SND along the reconstructed communication line from CHS. Upon confirmation by SND, the cross-connect equipment at the confirmed nodes then complete the link connections to recover the STS-9 bandwidth communication between nodes 101 and 105 along the four-hop path 101-102-103-104-105.
In the event that the entire bandwidth of the failed link is not recovered in a single wave of request messages, SND simply initiates a second wave by requesting the balance of the bandwidth loss over available links. Additional waves are likewise initiated until all bandwidth is recovered, or until the procedure is terminated upon a process timeout just prior to the onset of trunk conditioning at about two seconds after the original link failure. In view of this time constraint, consideration must be given to the basic timing factors influencing the selection of the timeout for the wave spread process of the recovery procedure, namely the algorithm execution time at each node and the time for message transmission between nodes. Significant leeway is normally allowable in setting this timeout parameter; however, it should be borne in mind that while a shorter processing timeout may enable more waves, the restoration paths will be short and often incomplete, resulting in limited recovery. A similar undesirable result will unfortunately occur if the timeout is excessive, since fewer of the possibly necessary waves may be completed prior to trunk conditioning.
From a series of emulations of failure recovery utilizing a Motorola 68000 based UNIX microcomputer for a sample network such as depicted in FIG. 8, we estimate that a mean processing time of about 10-20 msec. is generally sufficient to execute the message preparation and transmission algorithm at each node. Further, we have determined that messages of about 80 bytes are sufficient in carrying out the recovery process, thus requiring about a ten msec. transmission time on a SONET 64 kb/s overhead channel for each such message. The additional variable parameter of a hop limit for each message chain provides a final major consideration. In our emulations we have employed a five hop limit which appears to be an economical selection in that it provides for a maximum number of messages in any wave, as may be observed in curve 902 of FIG. 9. From these factors we have been able to conclude that a wave spread timeout period in the range of about 200-500 msec. will generally enable complete bandwidth recovery of a failed communication link.
The recovery procedure of the present invention may be implemented in the process steps depicted in the flow diagrams of FIGS. 5-7. This procedure is initiated when the terminating nodes of a failed link, for example nodes 4 and 8 of the sample network of FIG. 8, are alerted by existing switch elements that the failure has not been recovered by alternate means, such as an automatic switch protection system. As indicated in FIG. 8, this node 4-8 link failure involves STS-59 of active bandwidth and STS-15 of spare bandwidth, i.e. bandwidth not currently in use. The bandwidth status, i.e. active and (spare), for each of the other links in the network at the time of the failure is likewise designated in FIG. 8. According to the arbitrary selection criterion suggested previously, the lower address node 4 assumes the role of Sender (SND) during the process, while node 8 is CHS.
In FIG. 5, which lists its primary operations during the recovery process, SND constructs, at step 501, an initial request message according to the earlier-noted guidelines. This message specifies in addition to a basic control designation and the failed link identity, 4-8, the address of SND and the hop number of the message, i.e. "1" since the message is originating with SND. To these data SND adds further information peculiar to the node to which it is to be directed, e.g. node 1, namely the address of node 1 and the bandwidth requested. In the initial wave of the present example, SND requests of node 1, in the transmission of step 502, STS-33 of the lost STS-59 bandwidth, since that is the maximum available on the 4-1 link. In like manner, SND requests STS-15 of node 5 and STS-27 of node 9. After transmitting its request messages, SND waits until an acknowledgement (ACK) message is received, at step 503. It will be apparent upon close analysis of the application of the present procedure in this example that a single acknowledgement message, specifying the greatest available bandwidth, will be received by SND in any one wave of request messages.
SND compares, at 504, the recovered bandwidth specified in ACK with its recorded table of outstanding lost bandwidth to determine if all such bandwidth has been recovered. If a complete bandwidth recovery has been achieved, or if the two second timeout, at 505, preceding trunk conditioning occurs, the process ends, at step 506; otherwise it loops back to another request message construction, at step 501, to begin a second wave of requests. In the example under consideration, the first ACK indicates a recovery of only STS-27 (path 4-9-11-8) of the STS-59 lost in the failure; therefore, in an attempt to recover the outstanding STS-32, SND initiates a second wave with a request for STS-32 of node 1 (the maximum required of the STS-33 available), STS-15 of node 5 (the maximum available on that link), and nothing of node 9 since that link was completely utilized in the first wave. An responding ACK of STS-20 (path 4-1-5-8) causes SND to begin a third wave which completes the recovery of the balance of STS-12 (path 4-5-9-8).
Each intermediate node in the network performs the operations depicted in FIG. 6, beginning with the receipt of a request message, at 601, and comparison of its data with that currently recorded in the node table. The specified maximum hop parameter common to all nodes during the process has been noted in each table and is compared, at 602, with the hop count carried by the incoming message. If the hop count exceeds the maximum, the message is discarded, at 605, thereby terminating further attempts to complete a recovery via that overextended path. A satisfactory message is next examined, at 603, to ensure that the requested bandwidth is not less than that which has previously been requested of the node, in which case the message is likewise discarded, at 605. It is this selective character of the algorithm that distinguishes in great measure the present recovery process from previous flooding procedures which allow substantially unlimited request message propagation and lead to congestive queueing and processing delays at hub nodes.
In the event that the message requests a bandwidth that is equal to one earlier recorded, thus qualifying it for retention, the message hop count is compared, at 604, with that of the prior table entry. A greater recorded hop count request is deleted from the table, at 606, in favor of entry of the new request, at 607, to update the node table, thus providing a further facet of selectivity in the recovery process. Incoming requests of greater or equal hop count are simply entered as a table update, at 607. The node then constructs a request message, at 608, based upon the maximum bandwidth request then recorded in the table and, in the same manner as SND, increments the hop count and transmits the message to neighboring nodes, at 609, requesting the greatest available bandwidth up to that maximum. The process then returns to step 601 where the node awaits further requests which may be forthcoming in subsequent waves.
The operations at CHS follow the chart of FIG. 7 in which each message received, at 701, is evaluated, in the manner used at intermediate nodes, for maximum bandwidth and minimum hop count and is added to the CHS table, all as indicated as table updating at 702. Since CHS does not further propagate the request messages, the procedure loops back to 701 to receive and process additional such messages until such time as the process-specified wave timeout occurs, as at 703. CHS then examines its table of request data and selects, at 704, a request with the greatest bandwidth and transmits, at 705, an acknowledgement (ACK) message to the identified RQR. Upon receiving a confirming (CFM) message from RQR, CHS clears its table, at 706, and returns to step 701 to await a subsequent wave of requests. Each RQR in turn responds similarly to the ACK message by executing steps 704-706 to select a maximum recorded bandwidth and acknowledge the same to the appropriate RQR until the request path ultimately returns to SND. As noted previously, the approximately two second recovery process timeout 707 may occur at any stage, thereby causing the procedure to abort, at 708.
In common network arrangements the several fibers connecting one node to another may be situated within a single conduit. Thus, there may be several logical connections between the two nodes, yet only one physical connection. It will be apparent, then, that many network failures will occur in the event of damage to the single conduit. In such a multiple failure situation, numerous recovery processes are initiated, and each involved node responds to requests in the manner described above, maintaining a separate table for each SND-CHS pair process. Allocation of spare bandwidth is decided on a simple first-come, first-served basis with confirmation failures due to prior link allocation resulting in a SND timeout and spread wave renewal, as earlier noted. Contentions for a single link allocation are likewise resolved by the transmission of repeated ACK messages after a commonly-employed random "back-off" waiting period.
The failure recovery process of the present invention has the ability of uniting the distributed intelligence of digital cross-connect systems to autonomously restore SONET communications in near real time with economical use of available facilities. The key advantage of the procedure is its ability to intelligently use surviving connectivities and spare bandwidth to respond to a variety of failure situations, including multiple link failures. Unlike the uncontrolled flooding of previous distributed network restoration procedures, the selective message broadcasting of the present process enables cross-connect facilities to achieve fast response times with minimal message transmission and the avoidance of congestion delays. This critical distinction is readily apparent in FIG. 9 which shows the comparative message generation resulting, at 901, from earlier unlimited flooding procedures and, at 902, from the selective broadcasting employed in the present invention. Whereas the present process is self-limiting in its use of the network switching and transmission facilities, prior methods propagate restoration request messages at an exponential rate that quickly saturates the network and prevents effective failure recovery.
Having thus disclosed the invention, we anticipate that other embodiments will be apparent from the foregoing description to those of ordinary skill in the art. Such embodiments are likewise to be considered within the scope of the invention as set out in the following appended claims. | Rapid restoration of a telecommunication path between network nodes after an interrupting network link failure utilizes a distributed system of selective flooding for dynamically reconfiguring the internodal path in a manner which will ensure the most economical use of intermediate links. A help message transmitted from one of the terminating nodes to each contiguous neighboring node requests use of the uncommitted bandwidth of each respective link. This wave of messages is propagated selectively, along paths having maximum available bandwidth and least number of links, through the network by each successive receiving node until the help message reaches the other terminating node of the failed link. An acknowledgement message returned to the initial terminating node via propagation links offering the maximum bandwidth establishes a reconfigured path providing the greatest bandwidth recovery. In the event that such a path does not completely satisfy the original bandwidth requirement, additional paths are established by successive waves of request messages until the balance of the requirement is met. | 8 |
BACKGROUND OF THE INVENTION
This disclosure relates generally to the field of surgical instruments and in particular to those instruments that are designed to occlude tissue, primarily hollow organs such as blood vessels and ducts, via ligation. More specifically, the disclosed instrument has been designed to meet the most demanding requirements of laparoscopic surgery with features a sealing system to prevent the seepage of insufflated gas from body cavities. The interlocking jaws of the disclosed instrument initially isolate the tissue to be occluded, offering the option of opening and closing numerous times; and, with sequential activation, effect ligation at precisely the desired location with virtually no chance of damage to the surrounding tissues and minimal trauma to the ligated tissue.
DESCRIPTION OF THE PRIOR ART
Relevant patent references to the device disclosed herein include U.S. Pat. No. 4,101,063 to Kapitanov et al. which discloses a surgical instrument for ligating tubular organs in deep body cavities, which when utilized in a manner most relevant to the instrument disclosed herein, has a needle-shaped die for grasping the hollow organ to be ligated and a spring-loaded fork mechanism for pressing the hollow organ against the needle-shaped die to effect ligation.
U.S. Pat. No. 5,431,668 to Burbank et al. describes a ligating clip applier with a jaw closure mechanism that allows the jaws to contact the legs of the ligating clip sequentially: first distally and then proximally to close the clip in said order to ensure that the angle of the clip legs at the crown is eliminated.
U.S. Pat. No. 5,431,669 to Thompson et al. discloses a surgical clip applying device having a hook for engaging and retaining, under tension, a tissue structure to be ligated while a clip advancing means moves a U-shaped clip into a pair of axially movable jaws and a jaw advancing means moves the jaws and clip so that the tissue structure is disposed between the jaws and ligated upon closure of said jaws.
U.S. Pat. No. 5,192,288 to Thompson et al. describes an apparatus with a shaft for applying surgical clips to normally inaccessible body tissue notably including a means for closing the clips by employing an anvil mounted at the distal end of the shaft and a hammer movable against the anvil.
SUMMARY OF THE INVENTION
The presently disclosed ligating device is distinguished from and improves upon the instruments in the prior art by providing a means for applying ligating clips which isolates the tissue to be ligated, providing an opportunity to inspect the tissue to be ligated and reposition the instrument, if needed, without damage to the tissue. The device comprises a handle assembly, including an activating mechanism; an elongated shaft connected to said actuating mechanism and extending distally from said handle and a pair of jaws responsive to sequential activation to close, then to interlock forming an enclosure for the isolation of tissue to be ligated and providing coordinated tracks for guiding activated clips into the distal end of said locked jaws where the distal ends of said clips are converged unopposed to ligate tissue with minimal damage.
This disclosure also describes various embodiments of the ligating clip applier, especially with regard to jaw closure and clip size adjustment. It is also the purpose of this disclosure to describe a metallic, surgical grade, biocompatable clip that is designed to ligate effectively a wide range of tissue thicknesses. The clips are formed from an extruded wire, generally having a circular cross section. This clip will essentially have a U-shape and a flat crown substantially perpendicular to the distally extending parallel legs which terminate in rounded or blunt ends.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 & 2 are perspective views of the upper and lower jaws in the open and closed positions.
FIG. 3 is a cross sectional view through the upper and lower tracks of the interlocking jaws.
FIG. 4 is the same as view of FIG. 3 with the clip driver and clip partially advanced.
FIG. 4a is a cross section of FIG. 4 taken along line A--A.
FIG. 5 is a cross sectional view of the interlocking jaws with the clip driver fully extended and the clip fully formed.
FIG. 6 presents side views of (a) clip showing a minimally closed configuration and (b) clip showing a maximally closed configuration.
FIG. 7 is a perspective view of the ligating device.
FIG. 8 is an exploded view of jaws, shaft, clip-size adjustment, shaft rotation mechanism and their components.
FIG. 9 is a schematic exploded view of the jaw assembly and clip cartridge.
FIG. 10 is a perspective cross sectional view of the cartridge assembly.
FIG. 11 is a perspective cross sectional view of the handle, clip-size adjustment and shaft rotation mechanisms.
FIG. 12 is a perspective view of an alternative embodiment of the ligating device.
FIG. 13 is an exploded view of the jaw and shaft components for the device of FIG. 12.
FIG. 14 is an exploded view of the handle, clip-size adjustment and shaft rotation components for the device of FIG. 12.
FIG. 15 is a perspective view of the open and closed jaws for the device of FIG. 12.
FIG. 16 is a perspective cross sectional view of the clip feeding mechanism for the device of FIG. 12.
FIG. 17 is a perspective view in cross section of the handle, clip-size adjustment mechanism and shaft rotating mechanism for the device of FIG. 12.
FIG. 18 is a perspective view of the activating mechanism for transforming a single trigger motion into two simultaneous, controlled actions: one action for closing the jaws and the other for clip-size adjustment, said mechanism compatible with the device of FIG. 12. The depiction in FIG. 18 would have the jaws open and the clip driver retracted.
FIG. 19 is the same view as FIG. 18, but in this depiction, the jaws would be closed and the clip driver extended distally.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the most basic and general terms, the disclosed instrument ligates tissue in two steps: Tissue is secured within the jaws of the clip applier, and ligation occurs with an adjustable U-shaped clip formed within the inner surfaces of the jaws. In somewhat greater detail, the blunt-tipped legs of a metallic U-shaped clip are advanced by a driver and guided in grooves within the inner surfaces of the jaws surrounding the tissue without penetrating it. With continuing distally-directed pressure, the clip completely encircles the tissue and encounters the anvil surface of the lower jaw where the legs converge unopposed, forming a ligating clip.
The disclosed instrument performs these steps of isolating and ligating tissue with the interaction of three structural elements:
1. A handle assembly which includes an activating mechanism for jaw closure, clip feeding and formation, shaft rotation and clip size adjustment.
2. A shaft, containing a supply of U-shaped clips, which is rotatable and connected to:
the handle assembly
the jaw closing mechanism
clip feeding and forming mechanisms
a clip-size adjustment mechanism.
3. A pair of interlockable jaws which surround the tissue to be ligated and provide tracks for clip guiding and a clip forming anvil located, preferably, within the lower jaw.
The first step in the operation of the instrument is to isolate the tissue to be ligated by containing it within the interlocking upper and lower jaws. This permits the surgeon to visually inspect the tissue in the jaws and reposition the instrument as necessary to ensure proper placement of the clip. If a significant amount of repositioning is necessary at this point in the procedure, the jaws can be opened by simply releasing pressure on the trigger. The rotatable shaft is designed to facilitate better positioning of the jaws and observation of the tissue.
When the jaws are properly positioned, a clip can be advanced until the legs of the unformed clip surround the jaw-enclosed tissue and are bent by an anvil in the interlocking jaws. In preferred embodiments, the anvil will be located in the lower jaw and double tracked to accommodate the converging clip leg from the upper jaw. The size of the formed clip can be adjusted by an adjusting mechanism, not through continued, uncontrolled trigger-initiated force on the clip.
For a better understanding and appreciation of the disclosed instrument, reference should be made to the drawings. Referring to FIGS. 1 and 3, a hollow organ 1 to be ligated is positioned between jaws 2 & 3 of the instrument. With compression on the trigger 10, the jaws are closed around the organ and ultimately interlocked. It should be noted from FIGS. 3 & 4 that the enclosed tissue is only slightly compressed, and the device can be repositioned around the tissue without opening the jaws, or the jaws can be opened simply by releasing the trigger, without advancing or forming a clip, and re-positioned around the tissue without damaging the tissue. In FIGS. 3 & 4, it is apparent that the tissue has been positioned to be ligated. In FIG. 4, the clip driver 6 has been activated by further compression of the trigger, and has advanced an unformed clip 7 along tracks 4 recessed within the inner surface in both the upper and lower jaws. In FIG. 5, the driver has been fully activated and extended distally to the clip-forming surface identified as the anvil 5 in the distal end of the lower jaw so that the clip has been fully formed around the tissue and ligation is complete. Note that the blunt tipped U-shaped clip is designed to surround the tissue, not penetrate it. FIG. 6 illustrates schematically how clip-size formation can be adjusted to effect different degrees of closure using the same clip size. FIG. 6a shows a formed clip ligating a relatively large tissue cross-section and FIG. 6b shows the same sized clip ligating a smaller cross-section. The formed clip size is determined by the distance between the anvil 5 and the front surface of the clip driver 6 in its full-forward position. This distance is pre-set by the clip-size adjustment knob which will be described later.
FIG. 7 provides a perspective view of one embodiment of the disclosed instrument. Elements of the device that have not yet been fully described include the outer tube 8, which houses the shaft and its various actuating mechanisms, and the handle assembly 9 including other activating components such as the trigger 10 and the crank 11, as well as the shaft rotation knob 13 and the clip adjustment knob 14.
The trigger 10 and crank 11 are connected by pins 12 to the handle 9. The forked end 119 of the crank is designed to transmit force to the driver 6 through ring 23 which is held in place by screws 24. Spring 26, located between rings 25 and 23, is compressed on activation so as to decompress on relaxation of the trigger at the end of the firing sequence thereby opening the jaws and returning the driver to its initial position.
FIG. 8 presents an exploded view of the instrument showing all the parts necessary for a preferred embodiment of the clip applier to function as described.
A clip adjustment knob 14 is screwed into the distal end of handle 9. As mentioned, knob 14 controls clip size and tissue compression by transmitting a force through spacer 27 and ring 25 to shift the position of the outer tube 8 and jaws 2 & 3 relative to driver 6. The shaft rotation knob 13, positioned at the proximal end of handle 9, is connected to outer tube 8 by locking pin 28.
The clip cartridge 18, replaceable if desired, contains clips 19 and the clip stack driver 20. The cartridge can be permanently attached to the outer tube 8, if desired. When cartridge replacement is desired, it can be held in place with appropriate fastening means.
To initiate activation of the instrument, the trigger 10 is compressed and rotated around pin 12 to cause crank 11 to rotate as well. The fork 119 of crank 11 pushes ring 23 which moves driver 6 forward compressing return spring 26. Spring 21 is also compressed, forcing clip stack pusher 22 forward to keep tension on the clip stack. When driver 6 is advanced, the ribs 107 at the distal end of the driver 6 force apart the proximal ends of the jaws, thus closing the distal ends around the tissue to be ligated. To enable the distal ends of said jaws 2 and 3 to close, the proximal ends of said jaws pivot around pins 104 of anchor 15. Pins 104 first protrude through holes 102 of jaws 2 and 3 and then continue through holes 103 of anchor mate 16. Tongue 101 of anchor mate 16 enters pockets 100 of jaws 2 and 3, and aligns holes 103 with pins 104, which also protrude through holes 105 of element 18, thus creating a housing from elements 15, 16 and 18 within which jaws 2 and 3 pivot to enable distal closing of said jaws. In order to interlock and to ensure proper alignment of the jaws, this embodiment has protrusions 108 on lower jaw 2 which are designed to fit the cut-outs 109 in the upper jaw 3. The mating of the jaws provides the structural rigidity necessary to eliminate the possibility of jaw mis-alignment during clip formation. This rigidity also enables the use of small, thin, easily positioned jaws. As driver 6 retracts, its ribs 107 also retract allowing the jaw opening spring 17 on pins 106 to decompress, opening the jaws, releasing the tissue and returning the jaws to their initial position. Note that the jaws close at the start of the initial forward movement of the driver 6, prior to the release of a clip from cartridge 18. The ribs 107 in the driver hold the jaws closed for the duration of the driver's distal motion. Groove 110 is the track on which the driver ribs travel. When the jaws are closed, the recession 111 mates with the protrusion 113 of cartridge 18. This protruding part 113 of the cartridge holds the next clip to be activated. The tapered surface 112 guides the legs of the clip from the protruding part 113 into grooves 4 in the jaws.
Clip stack 19 and the clip stack driver 20 are situated within the cartridge 18. In this embodiment, the clips are positioned in an angled side-to-side configuration in order to facilitate ejection form the cartridge. The distal end 115 of the clip stack driver 20 is angled to permit the movement of the clip to be ejected from the cartridge and into the grooves 4 in the jaws and matches the angle of the clip stack 19. As the clip leaves the clip stack, edge 117 of the driver 6 advances a clip into protrusion 113 of the cartridge, provides for its distal movement, and prevents clip stack 19 from advancing another clip. At this point, driver 6 can advance the clip from protrusion 113 into the jaw grooves 4. Prior to clip activation, of course, the ribs 107 of the driver 6 have entered the proximal ends of the jaws 2 & 3, thus closing the distal ends.
While the driver 6 advances the clip to be formed toward the anvil 5, it prevents clips in the clip stack 19 from progressing farther, keeping them in position while the driver ribs 107 keep the jaws in a closed configuration. When the driver is in its full forward position, the clip is formed and the tissue ligated. In the return stroke, driver 6 retracts past the cartridge clip stack and releases the most distal clip in stack 19 which is advanced forward by clip stack driver 20. The driver ribs 107 retract, allowing the jaw opening spring 17 to decompress and open the jaws.
The shaft is easily rotatable during surgery. The shaft rotation knob 13, positioned at the proximal end of handle 9, can be rotated, which correspondingly, rotates outer tube 8 through locking pin 28. The rotating outer tube causes screws 24 to simultaneously rotate driver 6 and ring 23. In the same manner, both the driver 6 and the outer tube 8 turn all of the components within the tube including jaws 2 and 3.
Turning the clip size adjustment knob 14, which is threaded on the distal end of the handle body, transmits a force through spacer 27 and ring 25. The extensions 122 of spacer 27 enter the corresponding grooves in the body of the handle and advance ring 25 which is permanently attached to tube 8. The overall effect of turning the clip adjustment knob 14 is to move outer tube 8 and the jaws relative to the driver 6. The closer the anvil 5 in the interlocking jaws is to the driver 6, the smaller will be the final size of the formed clip.
Another embodiment of the disclosed device features different mechanisms for jaw closing and clip-size adjustment. Referring to FIG. 12, the rotating shaft of the device consists of jaw closure outer tube 51, lower jaw 52 and upper jaw 53. The shaft joins the stationary handle 54 which is connected to the trigger 56 and crank 59 through pins 55. The proximal end of the device contains the clip adjustment knob 57 and the shaft rotation knob 58.
The shaft for this embodiment of the device has a retaining spring 64 which is permanently affixed to the proximal end of the outer tube 51. The lower jaw 52 contains head-to-tail stacked clips 60, a clip stack driver 61 and a spring 62 for the clip stack driver.
With reference to FIG. 14, the trigger 56, crank 59 and pins 55 are connected to the handle 54 in the same manner as in the other embodiment of the device. Spring 65 returns the jaws and driver to their initial positions at the end of the activation sequence. The forked end of crank 59, within the handle 54, activates connector 66 and advances it forward. The locking pin 69 joins connector 66 to clip forming driver 63.
The shaft rotation knob 58 is located at the proximal end of the handle 54. It interacts with and is connected to the lower jaws 52 with a locking pin 70. The upper and lower half-rings 67 and 68 are fitted in the groove in the handle to respond to the shaft rotation knob 58.
Control of formed clip size and consequent vessel compression is achieved by moving lower jaw 52 with its anvil 5 relative to pusher 63. The upper and lower half-rings 67 & 68 are positioned in the groove of the shaft rotation knob 58 and the inner cylindrical surface of the handle 54. The clip size adjustment knob 57 is attached to the upper half-ring 67. It passes through the angled slot 203 in the handle 54. A ball 71 is located in the detente in lower half-ring 68. The ball is supported by retaining spring 72 and rests in the radial grooves 204 of the handle 54. In FIG. 17, the detent permits the use of discrete settings and reduces the likelihood of movement during clip formation.
Shifting knob 57 in the angled groove 203 causes movement of the jaw 52 relative to the handle. As a result, the distance between the lower jaw anvil 5 and pusher 63 changes, permitting the formation of different clip sizes when the device is activated.
Knob 58 is used by the surgeon to rotate the shaft of the instrument during surgery to re-orient the jaws without having to change the position of the handle.
Forward directed linear movement of the outer tube 51 over the upper and lower jaws causes them to close. The proximal end of upper jaw 53 acts as a spring, allowing the jaws to open when the outer tube 51 retracts. The jaw shanks mate together and require no additional fastening..
In FIG. 16, clips 60 are shown stacked in a head-to-tail configuration. Spring 62 forces stack driver 61 distally, pushing it against the rearward clip in the stack. The proximal end of the spring interacts with the clip forming driver 63 to maintain tension on the clips during clip forming and advancing procedures.
When the instrument is actuated, outer tube 51 and pusher 63 are advanced together. The outer tube slides over and closes the distal ends of jaws 52 & 53. With the outer tube stopped in its full forward position, the pusher continues advancing to its full forward position. On the pusher's return stroke, it re-engages with the outer tube 51 and returns it to its starting position. To ensure this sequential movement, the instrument incorporates a movement separation mechanism. Fundamental to this mechanism is the retaining spring 64 which is connected to the proximal end of outer tube 51. The spring has leaflet-like elements 205 with protrusions 206 on the ends. The protrusions fit into the groove 208 of connector 66. This groove has a tapered surface 207 permitting the protrusions to disengage from the connector during the forward stroke. This connector-spring coupling mechanism is located within a cut-out 209 in the handle 54. When the trigger 54 is pulled, actuating the device, crank 59 advances connector 66 and clip forming driver 63 attached to connector 66 with locking pin 69. The angular surface 207 of the groove in connector 66 will press against the protrusions 206 at the end of the retaining spring leaflets. The protrusions 206 of the retaining spring leaflets are forced by connector 66 to move the retaining spring 64 and outer tube 51 toward the distal end of the device. Once retaining spring 64 reaches the distal end of the cavity 209 of the handle, movement of the outer tube is stopped, thus completing jaw closure. Tapered surface 207 flares the leaflet-like elements 205 allowing connector 66 and clip forming driver 63 to advance and perform the clip forming procedure. Retaining spring 64 and outer tube 51 remain in their full forward position, keeping jaws 52 & 53 closed. When the trigger 56 is released, spring 65 returns the device to its pre-activation configuration. As connector 66 returns, the locking pin 69 pulls back pusher 63. Midway in the return stroke, the spring leaflet protrusions 206 return to the grooves in connector 66, and the jaw closure outer tube retracts allowing the jaws to open.
While the foregoing is a complete and detailed description of preferred embodiments of the disclosed device, numerous variations and modifications may also be employed to implement the purpose of the invention. And, therefore, the elaboration provided should not be assumed to limit the scope of the invention which is intended to be defined by the appended claims. | This document discloses a ligating clip applier which initially closes and locks a pair of complementary jaws around tissue to be ligated allowing the isolation of tissue for inspection, with the option to reposition, to ensure appropriate ligation. Upon further activation, a U-shaped clip having a flat crown perpendicular to a pair of parallel legs with rounded ends is advanced into the locked jaws of the instrument and converged around the isolated tissue until ligation is completed. | 0 |
[0001] This application is a divisional of U.S. Application Ser. No. 09/586,616, filed Jun. 2, 2000, which is a continuation of International Application No. PCT/CA98/01126, entitled “BREATHING MASK FOR A HELMET”, filed on Dec. 3, 1998. The International Application claims priority to Canadian Patent Application No. 2,223,345, entitled “BREATHING MASK FOR A HELMET”, which was filed on Dec. 3, 1997, the entire contents of which are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a breathing mask for a helmet which is particularly well suited for use when the temperature is below a certain point, i.e. the point under which the breath of an operator condenses inside the helmet and causes the advent of water on the lens of the eyeglasses of the operator or on the shield of the helmet.
BACKGROUND OF THE INVENTION
[0003] A prior art helmet comprises a first part which protects the head of a wearer, as a conventional helmet; a second part, which is integrated with and forms a projection with the first part and protects the lower part of the face of the wearer, more particularly the jaw; and a shield, which is situated between an upper front section of the first part and an upper section of the second part to protect the face of the wearer.
[0004] Due to its structure, the helmet has a small interior chamber where the wearer can breath. This interior chamber is usually insulated from the atmosphere to protect the wearer from cold air. At a certain temperature, air which contains saturated particles of water will condense and create condensation. Because the temperature of the lens of the eyeglasses of the operator wearing the helmet or the shield of the helmet can reach the condensation point of the breath of the wearer, water will form on the eyeglass lens or on the shield.
[0005] In order to avoid the problem of condensation, it is possible to open the shield to allow outside air to flow into the helmet until condensation is eliminated. This however presents a problem in that the wearer may be exposed to cold air which is uncomfortable and may be dangerous to health. Furthermore, the wearer has to use one hand to open the shield which may be hazardous when he or she is steering the vehicle being driven. The shield could also involuntarily close by impact or sudden movement. Thus, there is a need to provide a device which is capable of avoiding or eliminating the condensation created inside a full face helmet.
[0006] A prior art helmet provides some protection against sun rays. However, the shield of a prior art helmet is either clear or tinted and no adjustment of the tint is possible. On a bright sunny day, the wearer of a prior art helmet must also wear tinted eyeglasses to protect himself against the intensity of light if the shield of his helmet is clear. In changing weather conditions, the wearer may have to put the tinted eyeglasses on and off as the intensity of light changes. Thus, there is also a need to provide a helmet adapted to adjust the protection of the eyes of the wearer from sun rays.
OBJECTS AND STATEMENT OF THE INVENTION
[0007] It is an object of the present invention to provide a breathing mask for a helmet which reduces the formation of water on the lens of eyeglasses or the shield of the helmet.
[0008] It is an object of the present invention to provide a helmet that overcomes or at least reduces the deficiencies associated with a prior art helmet.
[0009] It is another object of the present invention to provide a helmet comprising a breathing mask which reduces the formation of water on the lens of eyeglasses or the shield of the helmet.
[0010] A further object of the invention is to provide a helmet including a tinted inner shield which is adapted to adjust the protection of the eyes of the wearer from sun rays as he or she requires.
[0011] As embodied and broadly described herein, the invention provides a breathing mask adapted to fit the contours of the face of a wearer, said breathing mask adapted to be mounted to a helmet, said breathing mask comprising at least one breathing channel through which air may circulate and a binding member; said at least one breathing channel adaptable to said helmet and said binding member adapted to connect and secure said breathing mask to said helmet, and to position said breathing mask in relation to said face.
[0012] As embodied and broadly described herein, the invention provides a helmet adapted to receive and retain a breathing mask, said helmet comprising:
[0013] a head portion;
[0014] a jaw shield mounted to said head portion, said jaw shield including at least one passage adapted to receive an exterior end of said breathing channel,
[0015] a binding member adapted to secure said breathing mask to said helmet, whereby the breathing mask is substantially hermetically adapted to the face of the wearer and the breath of the wearer may be expelled from inside said jaw shield.
[0016] In a preferred embodiment of the present invention the novel helmet comprises a head portion adapted to protect the head of the operator, a shield portion comprising a jaw shield adapted to protect the lower portion of the face of the wearer or operator; the shield portion being mounted to the head portion and adapted to move from an open position to a closed position and a optional latching mechanism which locks the jaw shield of the shield portion to the head portion. The optional latching mechanism is actuated with two lever buttons located at the front of the jaw shield and sufficiently close to one another so that one hand can actuate both buttons and in the same movement pull the jaw shield from the closed position to the open position. The jaw shield has passages that are connected, when the jaw shield is in the closed position, to a breathing mask through flexible tubes thereby linking the breathing mask to the outside through which the wearer may breath and the moisture content of his or her expelled breath can circulate and be evacuated. This arrangement prevent or at least greatly reduces condensation and fogging of the eye shield of the shield portion and of the eyeglasses of the wearer.
[0017] The breathing mask comprises a mask body, surrounding the nose and mouth of the wearer and including a port on each side adjacent the mouth; a flexible tube which connects said port to said passage when said face portion is in the closed position, a binding member adapted to secure said breathing mask to said helmet, and resilient straps.
[0018] The binding member connects said breathing mask to the helmet, wherein said breathing mask is substantially hermetically adapted to the face of the wearer and the breath is restricted from entering the inside chamber. The binding member is preferably a snap-holder located at one end of the flexible tubes. The binding member may also be a hook and loop (velcro) device, a clip or a strap; all these elements being capable of connecting and securing the breathing mask to the head portion of the helmet.
[0019] Advantageously, the shield portion further comprises an eye shield including a see-through shield and a tinted shield; said tinted shield being movable from a first position to a second position, said tinted shield adapted, in said first position, to be housed and partially hidden inside an upper chamber, and in said second position, to be in front of the eyes of the wearer whereby said tinted shield protects the eyes of the wearer from intense light. The tinted shield includes a lever protruding from a narrow slot of the upper chamber, this lever is adapted to maneuver said tinted shield from said first position to said second position.
[0020] As embodied and broadly described herein, the invention also provides a filter for a breathing mask comprising a thin layer of material adapted to isolates the skin of a wearer from said breathing mask, said layer of material shaped to fit a given contour of said breathing mask.
[0021] Another object of the invention is to provide a filter adapted to be positioned between the mask body and the face of the wearer whereby said filter isolates the skin of the wearer from the breathing mask. Advantageously, the filter is a supple thin cloth of felt-like material.
[0022] As embodied and broadly described herein, the invention also provides a breathing mask kit comprising:
[0023] a mask body adapted to fit the contours of the face of a wearer, said mask body including at least one port;
[0024] at least one hollow flexible tube including an interior end and an exterior end;
[0025] a binding member including an aperture; said binding member adapted to secure said breathing mask to a helmet and to align said aperture with a passage on said helmet;
[0026] said interior end being adapted to engage said at least one port of said mask body and said exterior end being adapted to engage said aperture of said binding member whereby when said at least one hollow flexible tube is engaged to said at least one port of said mask body and to said aperture of said binding member, said at least one hollow flexible tube acts as a conduit through which the breath of a wearer may circulate.
[0027] Other objects and features of the invention will become apparent by reference to the following description and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] A detailed description of the preferred embodiments of the present invention is provided herein below, by way of example only, with reference to the accompanying drawings, in which:
[0029] [0029]FIG. 1 is a perspective view of a full face helmet constructed in accordance with the invention;
[0030] [0030]FIG. 2 is a side elevational view of a full face helmet constructed in accordance with the invention;
[0031] [0031]FIG. 3 is a perspective exploded view of a breathing mask constructed in accordance with the invention;
[0032] [0032]FIG. 4 is a front elevational view of the breathing mask constructed in accordance with the invention;
[0033] [0033]FIG. 5 is a side elevational view of the full face helmet showing the full face helmet in an open position worn by a wearer with the breathing mask partially removed;
[0034] [0034]FIG. 6 is a side elevational view of a full face helmet in an open position worn by a wearer with the breathing mask put on;
[0035] [0035]FIG. 7 is a side elevational view of a full face helmet worn by a wearer with the jaw shield lowered into the closed position and the shield in the open position;
[0036] [0036]FIG. 8 is a front elevational view of the full face helmet constructed in accordance with the invention;
[0037] [0037]FIG. 9 is a side elevational view of the eye shield removed from the full face helmet; and
[0038] [0038]FIG. 10 is a side elevational view of the full face helmet showing the motion of the shield portion.
[0039] In the drawings, preferred embodiments of the invention are illustrated by way of examples. It is to be expressly understood that the description and drawings are only for the purpose of illustration and are an aid for understanding. They are not intended to be a definition of the limits of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0040] Referring now to the drawings, FIGS. 1 and 2 illustrate the novel helmet which is generally designated by the reference number 10 . The helmet 10 comprises a head portion 12 , a shield portion 13 pivoting about axis A, and having a pair of passages 16 through which the breath of a wearer may circulate, a see-through shield 18 , an inside chamber 20 , a breathing mask 22 , and a pair of lever buttons 23 located at the front of the shield portion 13 . The shield portion 13 comprises a jaw shield 14 pivotally connected to the head portion 12 , pivoting about axis A, and having a pair of passages 16 through which the breath of a wearer may circulate and an eye shield 52 that has a see-through shield 18 .
[0041] With reference to FIGS. 3 and 4, the breathing mask 22 comprises a mask body 24 preferably made of a supple material so as to embrace the contours of the face. The mask body 24 preferably features a port 26 on both sides, adjacent to the mouth of the wearer. Flexible tubes 28 are provided to connect the ports 26 to the passages 16 of the jaw shield 14 (FIGS. 1 and 2). As can be seen in FIG. 3, the flexible tube 28 has an interior end 30 and an exterior end 32 . The interior end 30 is adapted to be engaged into port 26 and the exterior end 32 is adapted to be hermetically connected with the passage 16 . The flexible tube 28 is assembled to the mask body 24 by inserting the last rib of the interior end 30 into port 26 . The exterior end 32 is inserted through the aperture 46 of the snap-holder 36 so that the exterior end 32 protrudes through the aperture 46 of snap-holder 36 . The exterior end 32 is provided with an annular lip 31 in order to create an hermetic seal with the passage 16 of the jaw shield 14 when these two components ( 32 and 16 ) are aligned. The flexible tube 28 is also preferably made of a supple material and features an array of ribs enabling the flexible tube 28 to assume various lengths for ease of assembly and to provide freedom of movement when the breathing mask 22 is put on or taken off. The flexible tubes 28 are of course hollow to provide adequate circulation of air.
[0042] A filter 70 adapted to fit inside the breathing mask 22 is provided optionally to isolate the skin of the wearer from the mask body 24 . The filter 70 is a supple thin layer of material like a cloth or a felt, adapted to permit airflow while stopping dust particles. The material is preferably soft so as not to irritate the skin of the wearer. The filter 70 is positioned inside the mask body 24 before the breathing mask 22 is put on. It may be discarded after use and replaced by a new one or it may be re-used as often as one wishes. The filter 70 features an opening 72 , for example a V-shaped opening, which facilitates the installation of the filter 70 into the mask body 24 and prevents folding of the filter 70 when positioned over the nose of the wearer. Folding of the filter 70 could allow the breath to escape into the inside chamber 20 . Advantageously, the filter 70 protects the skin of the wearer from possible irritation when the breathing mask 22 is worn for an extended period of time. This filter 70 also serves as an hygienic device if the full face helmet 10 is to be used by more than one person.
[0043] A frontal cover 34 is mounted to the front portion of the mask body 24 in order to hold, and maintain in position, a pair of resilient straps 40 . The resilient straps 40 are engaged at each end to slender apertures 48 of the snap-holders 36 . The resilient straps 40 are provided to adjust the length of each flexible tube 28 thereby adjusting the distance between the mask body 24 and the snap-holders 36 . The adjustment is achieved by setting the length of the resilient straps 40 using standard buckles 45 . From FIG. 3, it can be seen that snap-holders 36 are elongated components featuring at one end, a substantially circular aperture 46 , a pair of slender apertures 48 and at the other end, a snap button 38 .
[0044] Referring to FIG. 5, the head portion 12 comprises a pair of side covers 80 fastened to the side of the head portion 12 featuring an aperture 82 which opens onto a snap 84 on which the snap button 38 of the snap-holder 36 will be engaged. The side covers 39 features a second aperture 86 shown in dotted lines configured to receive an optional latching mechanism 90 also shown in dotted lines which locks the jaw shield 14 to the head portion 12 when the jaw shield 14 is in the closed position. Each of the side covers 39 has a curved section 88 provided to fit the circular contour 37 of the snap-holder 36 . The combination of configuration of the circular contour 37 of the snap-holders 36 and of the curved section 88 of the side covers 39 enables proper positioning of the snap-holders 36 in relation to the head portion 12 , to the jaw shield 14 and more specifically, to the passages 16 when the jaw shield 14 is in the closed position. FIG. 7 shows how the passage 16 and the circular aperture 46 of the snap-holders 36 are aligned when the jaw shield 14 is in the closed position.
[0045] To put the full face helmet 10 on with the breathing mask 22 , the wearer must have the jaw shield 14 in the opened position. As shown in FIG. 5, the wearer first attaches one of the snap-holders 36 to the head portion 12 and then puts the head portion 12 over his or her head. The filter 70 previously described may be positioned inside the mask body 24 before the breathing mask 22 is put on. Advantageously, the filter 70 protects the skin of the wearer from possible irritation when the breathing mask 22 is worn for an extended period of time. Once the filter is positioned inside the breathing mask 22 , the wearer then puts the breathing mask 22 over his mouth and nose and engages the remaining snap-holder 36 to the other side of the head portion 12 as shown in FIG. 6. FIG. 6 also shows the filter 70 installed thereby isolating the skin of the wearer from the mask body 24 and preventing any direct contact between the skin and the mask body 24 .
[0046] Referring to FIG. 7, once the breathing mask 22 is installed, the wearer can lower the jaw shield 14 . In the fully closed position, the optional latching mechanism 90 located on both sides of the jaw shield 14 engages the aperture 86 of the side covers 39 thereby locking the jaw shield 14 onto the head portion 12 and preventing the jaw shield 14 from unduly opening because of a wind gust or from an impact at which time, it is critical that the jaw shield 14 remains properly positioned in order to efficiently protect the wearer. The locking mechanism 90 may be disengaged by simply pressing simultaneously the two lever buttons 23 located at the front of the jaw shield 14 . The two lever buttons 23 are actuated by pressing them in the direction illustrated by the arrows in FIG. 8. Advantageously, the lever buttons 23 are positioned close enough to each other so that they can be actuated with a single hand. This feature is very useful at times when the wearer wishes to raise the jaw shield 14 while driving a vehicle. It could be dangerous to let go of the steering even for a short period of time. This feature allows him or her to keep one hand on the steering while raising the jaw shield 14 . Moreover, once the two lever buttons 23 are pressed and the latching mechanism 90 is disengaged, the same two lever buttons 23 serve as gripping elements enabling the hand to apply the necessary force to raise the jaw shield 14 .
[0047] As shown in FIG. 7, the wearer may also choose to keep the jaw shield 14 in the closed position and instead, raise the eye shield 52 which is pivotally mounted to the jaw shield 14 . The eye shield 52 comprises the see-through shield 18 and two small handle grips 54 located at the bottom of the eye shield 52 which enable the wearer to take hold of the eye shield 52 in order to raise it. Referring to FIG. 9, the eye shield 52 advantageously features a jagged surface 55 surrounding the pivoting points which enable the eye shield 52 to be partially opened and remain in a partially opened position due to the added friction provided by the jagged surface 55 .
[0048] Referring now to FIGS. 9 and 10, the eye shield 52 also advantageously comprises an upper chamber 56 in which a tinted shield 58 is housed and adapted to be raised or lowered with a lever 60 guided by a narrow slot 62 (FIG. 8). The tinted shield 58 is pivotally mounted to the eye shield 52 as the dotted lines in FIG. 9 show. The tinted shield 58 is an integral part of eye shield 52 ; if the eye shield 52 is raised or lowered, the tinted shield 58 will follow the motion. The tinted shield 58 is provided to protect the eyes of the wearer from sun rays or reflexions. The tinted shield 58 , in the closed position, is hidden away inside upper chamber 56 . To lower the tinted shield 58 , the wearer simply has to grip the lever 60 and pull it downward in order for the tinted shield 58 to come over the eyes of the wearer as shown by the dash-dot-dash arrows of FIGS. 9 and 10. The tinted shield 58 comes down inside the full face helmet 10 providing an excellent protection against sun rays. The tinted shield 58 thereby allows a practical adjustment means for eyes protection against sun rays or bright reflexions. Because it is never in contact with the exterior elements, the tinted shield 58 is protected and remains almost always clean and free of scratches.
[0049] Referring back to FIGS. 1 and 2, the full face helmet 10 also includes an air entry 63 located at the front of the jaw shield 14 that can be controlled by a gate 64 to permit or restrict air flow into the inside chamber 20 of the fill face helmet 10 . Another air passage 65 is provided at the back of the full face helmet 10 also featuring a gate 66 to permit or restrict air flow into the full face helmet 10 .
[0050] The above description of preferred embodiments should not be interpreted in a limiting manner since other variations, modifications and refinements are possible within the spirit and scope of the present invention. The scope of the invention is defined in the appended claims and their equivalents. | A breathing mask is provided for a helmet which reduces the formation of water on the lens of the eyeglasses of the wearer or on the shield of the helmet. The helmet comprises a head portion, a shield portion, and a breathing mask. The shield portion comprises a jaw shield and an eye shield. The breathing mask is hermetically adapted to the face of the wearer to evacuate the wearer's breath outside the helmet through breathing channels. The jaw shield can be pivotally opened or closed and is locked to the head portion in the closed position. The eye shield is pivotally connected to the head portion and includes a see-through shield and a tinted shield. The tinted shield can be lowered inside the helmet to protect the wearer from sun rays and reflexions. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to a family of power transmissions having two input clutches which selectively connect an input shaft to first and second pairs of planetary gear sets to provide at least six forward speed ratios and one reverse speed ratio.
BACKGROUND OF THE INVENTION
[0002] Passenger vehicles include a powertrain that is comprised of an engine, multi-speed transmission, and a differential or final drive. The multi-speed transmission increases the overall operating range of the vehicle by permitting the engine to operate through its torque range a number of times.
[0003] A primary focus of transmission and engine design work is in the area of increasing vehicle fuel efficiency. Manual transmissions typically provide improved vehicle fuel economy over automatic transmissions because automatic transmissions use a torque converter for vehicle launch and multiple plate hydraulically-applied clutches for gear engagement. Clutches of this type, left unengaged or idling, impose a parasitic drag torque on a drive line due to the viscous shearing action which exists between the plates and discs rotating at different speeds relative to one another. This drag torque adversely affects vehicle fuel economy for automatic transmissions. Also, the hydraulic pump that generates the pressure needed for operating the above-described clutches further reduces fuel efficiency associated with automatic transmissions. Manual transmissions eliminate these problems.
[0004] While manual transmissions are not subject to the above described fuel efficiency related problems, manual transmissions typically provide poor shift quality because a significant torque interruption is required during each gear shift as the engine is disengaged from the transmission by the clutch to allow shafts rotating at different speeds to be synchronized.
[0005] So called “automated manual” transmissions provide electronic shifting in a manual transmission configuration which, in certain circumstances, improves fuel efficiency by eliminating the parasitic losses associated with the torque converter and hydraulic pump needed for clutching. Like manual transmissions, a drawback of automated manual transmissions is that the shift quality is not as high as an automatic transmission because of the torque interruption during shifting.
[0006] So called “dual-clutch automatic” transmissions also eliminate the torque converter and replace hydraulic clutches with synchronizers but they go further to provide gear shift quality which is superior to the automated manual transmission and similar to the conventional automatic transmission, which makes them quite attractive. However, most known dual-clutch automatic transmissions include a lay shaft or countershaft gear arrangement, and have not been widely applied in vehicles because of their complexity, size and cost. For example, a dual clutch lay shaft transmission could require eight sets of gears, two input/shift clutches and seven synchronizers/dog clutches to provide six forward speed ratios and a reverse speed ratio. An example of a dual-clutch automatic transmission is described in U.S. Pat. No. 5,385,064, which is hereby incorporated by reference.
SUMMARY OF THE INVENTION
[0007] The invention provides a low content multi-speed dual-clutch transmission family utilizing planetary gear sets rather than lay shaft gear arrangements. In particular, the invention includes four planetary gear sets, two input/shift clutches, and nine selectable torque transmitting mechanisms to provide at least six forward speed ratios and a reverse speed ratio.
[0008] According to one aspect of the invention, the family of transmissions has four planetary gear sets, each of which includes a first, second and third member, which members may comprise a sun gear, ring gear, or a planet carrier assembly member.
[0009] In referring to the first, second, third and fourth gear sets in this description and in the claims, these sets may be counted “first” to “fourth” in any order in the drawings (i.e. left-to-right, right-to-left, etc.).
[0010] In another aspect of the present invention, each of the planetary gear sets may be of the single pinion type or of the double pinion type.
[0011] In yet another aspect of the present invention, the first member of the first planetary gear set is continuously connected with the first member of the second planetary gear set through a first interconnecting member.
[0012] In yet another aspect of the present invention, the second member of the first planetary gear set is continuously connected with the second member of the second planetary gear set through a second interconnecting member.
[0013] In yet another aspect of the present invention, a member of the first or second planetary gear set is continuously connected with the first member of the third planetary gear set and the output shaft through a third interconnecting member.
[0014] In yet another aspect of the present invention, the first member of the fourth planetary gear set is continuously connected with a stationary member (transmission housing).
[0015] In accordance with a further aspect of the invention, a first input clutch selectively connects the input shaft with a members of the first or second planetary gear set through other torque-transmitting mechanisms, such as synchronizers.
[0016] In accordance with another aspect of the present invention, a second input clutch selectively connects the input shaft with the second member of the third planetary gear set.
[0017] In another aspect of the invention, first and second torque transmitting mechanisms, such as rotating synchronizers, selectively connect members of the first and second planetary gear sets with the first input clutch.
[0018] In still a further aspect of the invention, third, fourth, fifth, and sixth torque transmitting mechanisms, such as rotating synchronizers, selectively connect members of the third planetary gear set with members of the fourth planetary gear set.
[0019] In still another aspect of the invention, seventh and eighth torque transmitting mechanisms, such as braking synchronizers, selectively connect members of the first or second planetary gear set with the stationary member.
[0020] In a further aspect of the invention, a ninth torque transmitting mechanism, such as a rotating synchronizer, selectively connects a member of the first or second planetary gear set with the first input clutch. Alternatively, the ninth torque transmitting mechanism, such as a braking synchronizer, selectively connects a member of the first or second planetary gear set to the stationary member.
[0021] In accordance with a further aspect of the invention, the input clutches and torque transmitting mechanisms are selectively engaged in combinations of at least three to provide at least six forward speed ratios and a reverse speed ratio.
[0022] In accordance with a further aspect of the invention, the first input clutch is applied for odd number speed ranges, and the second input clutch is applied for even number speed ranges, or vice versa.
[0023] In another aspect of the invention, the first input clutch and the second input clutch are interchanged (i.e. alternately engaged) to shift from odd number speed range to even number speed range, or vice versa.
[0024] In accordance with a further aspect of the invention, each selected torque transmitting mechanism for a new speed ratio is engaged prior to shifting of the input clutches to achieve shifts without torque interruptions.
[0025] In accordance with a further aspect of the invention, at least one pair of synchronizers is executed as a double synchronizer to reduce cost and package size.
[0026] In accordance with a further aspect of the invention, the first input clutch can be eliminated and the first and second torque transmitting mechanism can be used as input clutches to further reduce content.
[0027] In accordance with a further aspect of the invention, at least one of the torque transmitting mechanisms can be eliminated to realize five forward speed ratios and a reverse speed ratio.
[0028] The above objects, features, advantages, and other objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] [0029]FIG. 1 a is a schematic representation of a powertrain including a planetary transmission incorporating a family member of the present invention;
[0030] [0030]FIG. 1 b is a truth table and chart depicting some of the operating characteristics of the powertrain shown in FIG. 1 a;
[0031] [0031]FIG. 2 a is a schematic representation of a powertrain having a planetary transmission incorporating another family member of the present invention;
[0032] [0032]FIG. 2 b is a truth table and chart depicting some of the operating characteristics of the powertrain shown in FIG. 2 a;
[0033] [0033]FIG. 3 a is a schematic representation of a powertrain having a planetary transmission incorporating another family member of the present invention;
[0034] [0034]FIG. 3 b is a truth table and chart depicting some of the operating characteristics of the powertrain shown in FIG. 3 a;
[0035] [0035]FIG. 4 a is a schematic representation of a powertrain having a planetary transmission incorporating another family member of the present invention;
[0036] [0036]FIG. 4 b is a truth table and chart depicting some of the operating characteristics of the powertrain shown in FIG. 4 a;
[0037] [0037]FIG. 5 a is a schematic representation of a powertrain having a planetary transmission incorporating another family member of the present invention;
[0038] [0038]FIG. 5 b is a truth table and chart depicting some of the operating characteristics of the powertrain shown in FIG. 5 a;
[0039] [0039]FIG. 6 a is a schematic representation of a powertrain having a planetary transmission incorporating another family member of the present invention;
[0040] [0040]FIG. 6 b is a truth table and chart depicting some of the operating characteristics of the powertrain shown in FIG. 6 a;
[0041] [0041]FIG. 7 a is a schematic representation of a powertrain having a planetary transmission incorporating another family member of the present invention;
[0042] [0042]FIG. 7 b is a truth table and chart depicting some of the operating characteristics of the powertrain shown in FIG. 7 a;
[0043] [0043]FIG. 8 a is a schematic representation of a powertrain having a planetary transmission incorporating another family member of the present invention;
[0044] [0044]FIG. 8 b is a truth table and chart depicting some of the operating characteristics of the powertrain shown in FIG. 8 a;
[0045] [0045]FIG. 9 a is a schematic representation of a powertrain having a planetary transmission incorporating another family member of the present invention;
[0046] [0046]FIG. 9 b is a truth table and chart depicting some of the operating characteristics of the powertrain shown in FIG. 9 a;
[0047] [0047]FIG. 10 a is a schematic representation of a powertrain having a planetary transmission incorporating another family member of the present invention;
[0048] [0048]FIG. 10 b is a truth table and chart depicting some of the operating characteristics of the powertrain shown in FIG. 10 a;
[0049] [0049]FIG. 11 a is a schematic representation of a powertrain having a planetary transmission incorporating another family member of the present invention; and
[0050] [0050]FIG. 11 b is a truth table and chart depicting some of the operating characteristics of the powertrain shown in FIG. 11 a.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] Referring to the drawings, wherein like characters represent the same or corresponding parts throughout the several views, there is shown in FIG. 1 a a powertrain 10 having a conventional engine 12 , a planetary transmission 14 , and a conventional final drive mechanism 16 .
[0052] The planetary transmission 14 includes an input shaft 17 continuously connected with the engine 12 , a planetary gear arrangement 18 , and an output shaft 19 continuously connected with the final drive mechanism 16 . The planetary gear arrangement 18 includes four planetary gear sets 20 , 30 , 40 and 50 .
[0053] The planetary gear set 20 includes a sun gear member 22 , a ring gear member 24 , and a planet carrier assembly member 26 . The planet carrier assembly member 26 includes a plurality of pinion gears 27 rotatably mounted on a carrier member 29 and disposed in meshing relationship with both the sun gear member 22 and the ring gear member 24 .
[0054] The planetary gear set 30 includes a sun gear member 32 , a ring gear member 34 , and a planet carrier assembly member 36 . The planet carrier assembly member 36 includes a plurality of pinion gears 37 rotatably mounted on a carrier member 39 and disposed in meshing relationship with both the sun gear member 32 and the ring gear member 34 .
[0055] The planetary gear set 40 includes a sun gear member 42 , a ring gear member 44 , and a planet carrier assembly member 46 . The planet carrier assembly member 46 includes a plurality of intermeshing pinion gears 47 , 48 rotatably mounted on a carrier member 49 and disposed in meshing relationship with the ring gear member 44 and the sun gear member 42 , respectively.
[0056] The planetary gear set 50 includes a sun gear member 52 , a ring gear member 54 , and a planet carrier assembly member 56 . The planet carrier assembly member 56 includes a plurality of pinion gears 57 rotatably mounted on a carrier member 59 and disposed in meshing relationship with both the sun gear member 52 and the ring gear member 54 .
[0057] As a result of the dual clutch arrangement of the invention, the four planetary gear sets 20 , 30 , 40 and 50 are divided into first and second transmission subsets 60 , 61 which are alternatively engaged to provide odd number and even number speed ranges, respectively. Transmission subset 60 includes planetary gear sets 20 and 30 , and transmission subset 61 includes planetary gear sets 40 and 50 . The output shaft 19 is continuously connected with members of both subsets 60 and 61 .
[0058] As mentioned above, the first and second input clutches 62 , 63 are alternatively engaged for transmitting power from the input shaft 17 to transmission subset 60 or transmission subset 61 . The first and second input clutches 62 , 63 are controlled electronically, and the disengaged input clutch is gradually engaged while the engaged input clutch is gradually disengaged to facilitate transfer of power from one transmission subset to another. In this manner, shift quality is maintained, as in an automatic transmission, while providing better fuel economy because no torque converter is required, and hydraulics associated with “wet” clutching are eliminated. All speed ratios are preselected within the transmission subsets 60 , 61 prior to engaging the respective input clutches 62 , 63 . The preselection is achieved by means of electronically controlled synchronizers. As shown, the planetary gear arrangement includes nine torque transmitting mechanisms 64 , 65 , 66 , 67 , 68 , 69 , 70 , 71 and 72 . The torque transmitting mechanisms 64 and 65 comprise braking synchronizers, and the torque transmitting mechanisms 66 , 67 , 68 , 69 , 70 , 71 and 72 comprise rotating synchronizers.
[0059] The braking synchronizers and rotating synchronizers are referenced in the claims as follows: first and second torque transmitting mechanisms 66 , 67 ; third, fourth, fifth and sixth torque transmitting mechanisms 69 , 70 , 71 , 72 ; seventh and eighth torque transmitting mechanisms 64 , 65 ; and ninth torque transmitting mechanism 68 . Other family members are similarly referenced in the claims (i.e. two torque transmitting mechanisms from left transmission subset, four torque transmitting mechanisms from right transmission subset, two brakes from left transmission subset, and then additional torque transmitting mechanism (clutch or brake) from left transmission subset).
[0060] By way of example, synchronizers which may be implemented as the rotating and/or braking synchronizers referenced herein are shown in the following patents, each of which are incorporated by reference in their entirety: U.S. Pat. Nos. 5,651,435; 5,975,263; 5,560,461; 5,641,045; 5,497,867; 6,354,416.
[0061] Accordingly, the input shaft 17 is alternately connected with the first and second transmission subsets 60 , 61 (i.e. through the clutch 62 to the synchronizers 66 , 67 , 68 and through the clutch 63 to the ring gear member 44 ). The planet carrier assembly member 26 is continuously connected with the ring gear member 34 through the interconnecting member 74 . The ring gear member 24 is continuously connected with the sun gear member 32 through the interconnecting member 76 . The planet carrier assembly member 36 is continuously connected with the planet carrier assembly member 46 and the output shaft 19 through the interconnecting member 78 . The ring gear member 54 is continuously connected with the transmission housing 80 .
[0062] The sun gear member 22 is selectively connectable with the transmission housing 80 through the braking synchronizer 64 . The planet carrier assembly member 26 is selectively connectable with the transmission housing 80 through the braking synchronizer 65 . The sun gear member 22 is selectively connectable with the input shaft 17 through the input clutch 62 and the rotating synchronizer 66 . The sun gear member 32 is selectively connectable with the input shaft 17 through the input clutch 62 and the rotating synchronizer 67 . The planet carrier assembly member 26 is selectively connectable with the input shaft 17 through the input clutch 62 and the rotating synchronizer 68 . The planet carrier assembly member 46 is selectively connectable with the planet carrier assembly member 56 through the rotating synchronizer 69 . The planet carrier assembly member 46 is selectively connectable with the sun gear member 52 through the rotating synchronizer 70 . The sun gear member 42 is selectively connectable with the planet carrier assembly member 56 through the rotating synchronizer 71 . The sun gear member 42 is selectively connectable with the sun gear member 52 through the rotating synchronizer 72 .
[0063] As shown in FIG. 1 b , and in particular the truth table disclosed therein, the input clutches and torque transmitting mechanisms are selectively engaged in combinations of three to provide six forward speed ratios and a reverse speed ratio.
[0064] The reverse speed ratio is established with the engagement of the input clutch 62 , the braking synchronizer 65 and the rotating synchronizer 66 . The input clutch 62 and the rotating synchronizer 66 connect the sun gear member 22 to the input shaft 17 . The braking synchronizer 65 connects the planet carrier assembly member 26 to the transmission housing 80 . The sun gear member 22 rotates at the same speed as the input shaft 17 . The planet carrier assembly member 26 and the ring gear member 34 do not rotate. The ring gear member 24 rotates at the same speed as the sun gear member 32 . The ring gear member 24 rotates at a speed determined from the speed of the sun gear member 22 and the ring gear/sun gear tooth ratio of the planetary gear set 20 . The planet carrier assembly members 36 , 46 rotate at the same speed as the output shaft 19 . The planet carrier assembly member 36 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the sun gear member 32 and the ring gear/sun gear tooth ratio of the planetary gear set 30 . The numerical value of the reverse speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 20 , 30 .
[0065] The first forward speed ratio is established with the engagement of the input clutch 62 , the braking synchronizer 65 and the rotating synchronizer 67 . The input clutch 62 and the rotating synchronizer 67 connect the sun gear member 32 to the input shaft 17 . The braking synchronizer 65 connects the planet carrier assembly member 26 to the transmission housing 80 . The ring gear member 24 and the sun gear member 32 rotate at the same speed as the input shaft 17 . The planet carrier assembly member 26 and the ring gear member 34 do not rotate. The planet carrier assembly members 36 , 46 rotate at the same speed as the output shaft 19 . The planet carrier assembly member 36 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the sun gear member 32 and the ring gear/sun gear tooth ratio of the planetary gear set 30 . The numerical value of the first forward speed ratio is determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 30 .
[0066] The second forward speed ratio is established with the engagement of the input clutch 63 and the rotating synchronizers 69 , 72 . The input clutch 63 connects the ring gear member 44 to the input shaft 17 . The rotating synchronizer 69 connects the planet carrier assembly member 36 to the planet carrier assembly member 46 . The rotating synchronizer 72 connects the sun gear member 42 to the sun gear member 52 . The ring gear member 44 rotates at the same speed as the input shaft 17 . The planet carrier assembly members 46 , 56 rotate at the same speed as the output shaft 19 . The sun gear member 42 rotates at the same speed as the sun gear member 52 . The planet carrier assembly member 46 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the ring gear member 44 , the speed of the sun gear member 42 and the ring gear/sun gear tooth ratio of the planetary gear set 40 . The ring gear member 54 does not rotate. The planet carrier assembly member 56 rotates at a speed determined from the speed of the sun gear member 52 and the ring gear/sun gear tooth ratio of the planetary gear set 50 . The numerical value of the second forward speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 40 , 50 .
[0067] The third forward speed ratio is established with the engagement of the input clutch 62 , the braking synchronizer 64 and the rotating synchronizer 67 . The input clutch 62 and the rotating synchronizer 67 connect the sun gear member 32 to the input shaft 17 . The braking synchronizer 64 connects the sun gear member 22 to the transmission housing 80 . The sun gear member 22 does not rotate. The planet carrier assembly member 26 rotates at the same speed as the ring gear member 34 . The ring gear member 24 and the sun gear member 32 rotate at the same speed as the input shaft 17 . The planet carrier assembly member 26 rotates at a speed determined from the speed of the ring gear member 24 and the ring gear/sun gear tooth ratio of the planetary gear set 20 . The planet carrier assembly members 36 , 46 rotate at the same speed as the output shaft 19 . The planet carrier assembly member 36 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the ring gear member 34 , the speed of the sun gear member 32 and the ring gear/sun gear tooth ratio of the planetary gear set 30 . The numerical value of the third forward speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 20 , 30 .
[0068] The fourth forward speed ratio is established with the engagement of the input clutch 63 and the rotating synchronizers 69 , 71 . In this configuration, the input shaft 17 is directly connected to the output shaft 19 . The numerical value of the fourth forward speed ratio is 1.
[0069] The fifth forward speed ratio is established with the engagement of the input clutch 62 , the braking synchronizer 64 and the rotating synchronizer 68 . The input clutch 62 and the rotating synchronizer 68 connect the planet carrier assembly member 26 to the input shaft 17 . The braking synchronizer 64 connects the sun gear member 22 to the transmission housing 80 . The sun gear member 22 does not rotate. The planet carrier assembly member 26 and the ring gear member 34 rotate at the same speed as the input shaft 17 . The ring gear member 24 rotates at the same speed as the sun gear member 32 . The ring gear member 24 rotates at a speed determined from the speed of the planet carrier assembly member 26 and the ring gear/sun gear tooth ratio of the planetary gear set 20 . The planet carrier assembly members 36 , 46 rotate at the same speed as the output shaft 19 . The planet carrier assembly member 36 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the ring gear member 34 , the speed of the sun gear member 32 and the ring gear/sun gear tooth ratio of the planetary gear set 30 . The numerical value of the fifth forward speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 20 , 30 .
[0070] The sixth forward speed ratio is established with the engagement of the input clutch 63 and the rotating synchronizers 70 , 71 . The input clutch 63 connects the ring gear member 44 to the input shaft 17 . The rotating synchronizer 70 connects the planet carrier assembly member 46 to the sun gear member 52 . The rotating synchronizer 71 connects the sun gear member 42 to the planet carrier assembly member 56 . The sun gear member 42 rotates at the same speed as the planet carrier assembly member 56 . The planet carrier assembly member 46 and the sun gear member 52 rotate at the same speed as the output shaft 19 . The ring gear member 44 rotates at the same speed as the input shaft 17 . The planet carrier assembly member 46 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the ring gear member 44 , the speed of the sun gear member 42 and the ring gear/sun gear tooth ratio of the planetary gear set 40 . The ring gear member 54 does not rotate. The planet carrier assembly member 56 rotates at a speed determined from the speed of the sun gear member 52 and the ring gear/sun gear tooth ratio of the planetary gear set 50 . The numerical value of the sixth forward speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 40 , 50 .
[0071] As set forth above, the engagement schedule for the torque transmitting mechanisms is shown in the truth table of FIG. 1 b . This truth table also provides an example of speed ratios that are available utilizing the ring gear/sun gear tooth ratios given by way of example in FIG. 1 b . The R1/S1 value is the tooth ratio of the planetary gear set 20 ; the R2/S2 value is the tooth ratio of the planetary gear set 30 ; the R3/S3 value is the tooth ratio of the planetary gear set 40 ; and the R4/S4 value is the tooth ratio of the planetary gear set 50 . Also, the chart of FIG. 1 b describes the ratio steps that are attained utilizing the sample of tooth ratios given. For example, the step ratio between first and second forward speed ratios is 1.49, while the step ratio between the reverse and first forward ratio is −1.52. Those skilled in the art will recognize that since torque transmitting mechanisms 66 , 68 ( 67 ) are connected to a common member, input clutch 62 , and they are not engaged at the same time for any of the speed ratios, the pair can be executed as a double (triple) synchronizer to reduce content and cost. Similarly, torque transmitting mechanisms pair 71 , 72 can be implemented as a double synchronizer.
[0072] [0072]FIG. 2 a shows a powertrain 110 having a conventional engine 12 , a planetary transmission 114 , and a conventional final drive mechanism 16 . The planetary transmission 114 includes an input shaft 17 connected with the engine 12 , a planetary gear arrangement 118 , and an output shaft 19 connected with the final drive mechanism 16 . The planetary gear arrangement 118 includes four planetary gear sets 120 , 130 , 140 and 150 .
[0073] The planetary gear set 120 includes a sun gear member 122 , a ring gear member 124 , and a planet carrier assembly member 126 . The planet carrier assembly member 126 includes a plurality of intermeshing pinion gears 127 , 128 rotatably mounted on a carrier member 129 and disposed in meshing relationship with the ring gear member 124 and the sun gear member 122 , respectively.
[0074] The planetary gear set 130 includes a sun gear member 132 , a ring gear member 134 , and a planet carrier assembly member 136 . The planet carrier assembly member 136 includes a plurality of pinion gears 137 rotatably mounted on a carrier member 139 and disposed in meshing relationship with both the sun gear member 132 and the ring gear member 134 .
[0075] The planetary gear set 140 includes a sun gear member 142 , a ring gear member 144 , and a planet carrier assembly member 146 . The planet carrier assembly member 146 includes a plurality of intermeshing pinion gears 147 , 148 rotatably mounted on a carrier member 149 and disposed in meshing relationship with the ring gear member 144 and the sun gear member 142 , respectively.
[0076] The planetary gear set 150 includes a sun gear member 152 , a ring gear member 154 , and a planet carrier assembly member 156 . The planet carrier assembly member 156 includes a plurality of pinion gears 157 rotatably mounted on a carrier member 159 and disposed in meshing relationship with both the sun gear member 152 and the ring gear member 154 .
[0077] As a result of the dual clutch arrangement of the invention, the four planetary gear sets 120 , 130 , 140 and 150 are divided into first and second transmission subsets 160 , 161 which are alternatively engaged to provide odd number and even number speed ranges, respectively. Transmission subset 160 includes planetary gear sets 120 and 130 , and transmission subset 161 includes planetary gear sets 140 and 150 . The output shaft 19 is continuously connected with members of both subsets 160 and 161 .
[0078] As mentioned above, the first and second input clutches 162 , 163 are alternatively engaged for transmitting power from the input shaft 17 to transmission subset 160 or transmission subset 161 . The first and second input clutches 162 , 163 are controlled electronically, and the disengaged input clutch is gradually engaged while the engaged input clutch is gradually disengaged to facilitate transfer of power from one transmission subset to another. In this manner, shift quality is maintained, as in an automatic transmission, while providing better fuel economy because no torque converter is required, and hydraulics associated with “wet” clutching are eliminated. All speed ratios are preselected within the transmission subsets 160 , 161 prior to engaging the respective input clutches 162 , 163 . The preselection is achieved by means of electronically controlled synchronizers. As shown, the planetary gear arrangement includes nine torque transmitting mechanisms 164 , 165 , 166 , 167 , 168 , 169 , 170 , 171 and 172 . The torque transmitting mechanisms 164 and 165 comprise braking synchronizers, and the torque transmitting mechanisms 166 , 167 , 168 , 169 , 170 , 171 and 172 comprise rotating synchronizers.
[0079] Accordingly, the input shaft 17 is alternately connected with the first and second transmission subsets 160 , 161 (i.e. through the clutch 162 to the synchronizers 166 , 167 , 168 and through the clutch 163 to the ring gear member 144 ). The ring gear member 124 is continuously connected with the planet carrier assembly member 136 through the interconnecting member 174 . The planet carrier assembly member 126 is continuously connected with the sun gear member 132 through the interconnecting member 176 . The planet carrier assembly member 146 is continuously connected with the ring gear member 134 and the output shaft 19 through the interconnecting member 178 . The ring gear member 154 is continuously connected with the transmission housing 180 .
[0080] The planet carrier assembly member 126 is selectively connectable with the transmission housing 180 through the braking synchronizer 164 . The ring gear member 124 is selectively connectable with the transmission housing 180 through the braking synchronizer 165 . The planet carrier assembly member 126 is selectively connectable with the input shaft 17 through the input clutch 162 and the rotating synchronizer 166 . The sun gear member 122 is selectively connectable with the input shaft 17 through the input clutch 162 and the rotating synchronizer 167 . The planet carrier assembly member 136 is selectively connectable with the input shaft 17 through the input clutch 162 and the rotating synchronizer 168 . The planet carrier assembly member 146 is selectively connectable with the planet carrier assembly member 156 through the rotating synchronizer 169 . The planet carrier assembly member 146 is selectively connectable with the sun gear member 152 through the rotating synchronizer 170 . The sun gear member 142 is selectively connectable with the planet carrier assembly member 156 through the rotating synchronizer 171 . The sun gear member 142 is selectively connectable with the sun gear member 152 through the rotating synchronizer 172 .
[0081] As shown in FIG. 2 b , and in particular the truth table disclosed therein, the input clutches and torque transmitting mechanisms are selectively engaged in combinations of three to provide six forward speed ratios and a reverse speed ratio.
[0082] The reverse speed ratio is established with the engagement of the input clutch 162 , the braking synchronizer 165 and the rotating synchronizer 166 . The input clutch 162 and the rotating synchronizer 166 connect the planet carrier assembly member 126 to the input shaft 17 . The braking synchronizer 165 connects the ring gear member 124 to the transmission housing 180 . The planet carrier assembly member 126 and the sun gear member 132 rotate at the same speed as the input shaft 17 . The ring gear member 124 and the planet carrier assembly member 136 do not rotate. The ring gear member 134 and the planet carrier assembly member 146 rotate at the same speed as the output shaft 19 . The ring gear member 134 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the sun gear member 132 and the ring gear/sun gear tooth ratio of the planetary gear set 130 . The numerical value of the reverse speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 130 .
[0083] The first forward speed ratio is established with the engagement of the input clutch 162 , the braking synchronizer 165 and the rotating synchronizer 167 . The input clutch 162 and the rotating synchronizer 167 connect the sun gear member 122 to the input shaft 17 . The braking synchronizer 165 connects the ring gear member 124 to the transmission housing 180 . The sun gear member 122 rotates at the same speed as the input shaft 17 . The planet carrier assembly member 126 rotates at the same speed as the sun gear member 132 . The ring gear member 124 and the planet carrier assembly member 136 do not rotate. The planet carrier assembly member 126 rotates at a speed determined from the speed of the sun gear member 122 and the ring gear/sun gear tooth ratio of the planetary gear set 120 . The ring gear member 134 and the planet carrier assembly member 146 rotate at the same speed as the output shaft 19 . The ring gear member 134 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the sun gear member 132 and the ring gear/sun gear tooth ratio of the planetary gear set 130 . The numerical value of the first forward speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear set 120 , 130 .
[0084] The second forward speed ratio is established with the engagement of the input clutch 163 and the rotating synchronizer 169 , 172 . The input clutch 163 connects the ring gear member 144 to the input shaft 17 . The rotating synchronizer 169 connects the planet carrier assembly member 146 to the planet carrier assembly member 156 . The rotating synchronizer 172 connects the sun gear member 142 to the sun gear member 152 . The sun gear member 142 rotates at the same speed as the sun gear member 152 . The planet carrier assembly members 146 , 156 rotate at the same speed as the output shaft 19 . The ring gear member 144 rotates at the same speed as the input shaft 17 . The planet carrier assembly member 146 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the ring gear member 144 , the speed of the sun gear member 142 and the ring gear/sun gear tooth ratio of the planetary gear set 140 . The ring gear member 154 does not rotate. The planet carrier assembly member 156 rotates at a speed determined from the speed of the sun gear member 152 and the ring gear/sun gear tooth ratio of the planetary gear set 150 . The numerical value of the second forward speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 140 , 150 .
[0085] The third forward speed ratio is established with the engagement of the input clutch 162 , the braking synchronizer 164 and the rotating synchronizer 167 . The input clutch 162 and the rotating synchronizer 167 connect the sun gear member 122 to the input shaft 17 . The braking synchronizer 164 connects the planet carrier assembly member 126 to the transmission housing 180 . The sun gear member 122 rotates at the same speed as the input shaft 17 . The planet carrier assembly member 126 and the sun gear member 132 do not rotate. The ring gear member 124 rotates at the same speed as the planet carrier assembly member 136 . The ring gear member 124 rotates at a speed determined from the speed of the sun gear member 122 and the ring gear/sun gear tooth ratio of the planetary gear set 120 . The ring gear member 134 and the planet carrier assembly member 146 rotate at the same speed as the output shaft 19 . The ring gear member 134 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the planet carrier assembly member 136 and the ring gear/sun gear tooth ratio of the planetary gear set 130 . The numerical value of the third forward speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 120 , 130 .
[0086] The fourth forward speed ratio is established with the engagement of the input clutch 163 and the rotating synchronizers 169 , 171 . In this configuration, the input shaft 17 is directly connected to the output shaft 19 . The numerical value of the fourth forward speed ratio is 1.
[0087] The fifth forward speed ratio is established with the engagement of the input clutch 162 , the braking synchronizer 164 and the rotating synchronizer 168 . The input clutch 162 and the rotating synchronizer 168 connect the planet carrier assembly member 136 to the input shaft 17 . The braking synchronizer 164 connects the planet carrier assembly member 126 to the transmission housing 180 . The planet carrier assembly member 126 and the sun gear member 132 do not rotate. The ring gear member 124 and the planet carrier assembly member 136 rotate at the same speed as the input shaft 17 . The ring gear member 134 and the planet carrier assembly member 146 rotate at the same speed as the output shaft 19 . The ring gear member 134 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the planet carrier assembly member 136 and the ring gear/sun gear tooth ratio of the planetary gear set 130 . The numerical value of the fifth forward speed ratio is determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 130 .
[0088] The sixth forward speed ratio is established with the engagement of the input clutch 163 and the rotating synchronizers 170 , 171 . The input clutch 163 connects the ring gear member 144 to the input shaft 17 . The rotating synchronizer 170 connects the planet carrier assembly member 146 to the sun gear member 152 . The rotating synchronizer 171 connects the sun gear member 142 to the planet carrier assembly member 156 . The sun gear member 142 rotates at the same speed as the planet carrier assembly member 156 . The planet carrier assembly member 146 and the sun gear member 152 rotate at the same speed as the output shaft 19 . The ring gear member 144 rotates at the same speed as the input shaft 17 . The planet carrier assembly member 146 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the ring gear member 144 , the speed of the sun gear member 142 and the ring gear/sun gear tooth ratio of the planetary gear set 140 . The ring gear member 154 does not rotate. The planet carrier assembly member 156 rotates at a speed determined from the speed of the sun gear member 152 and the ring gear/sun gear tooth ratio of the planetary gear set 150 . The numerical value of the sixth forward speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 140 , 150 .
[0089] As set forth above, the truth table of FIG. 2 b describes the engagement sequence of the torque transmitting mechanisms utilized to provide a reverse drive ratio and six forward speed ratios. The truth table also provides an example of the ratios that can be attained with the family members shown in FIG. 2 a utilizing the sample tooth ratios given in FIG. 2 b . The R1/S1 value is the tooth ratio of the planetary gear set 120 ; the R2/S2 value is the tooth ratio of the planetary gear set 130 ; the R3/S3 value is the tooth ratio of the planetary gear set 140 ; and the R4/S4 value is the tooth ratio of the planetary gear set 150 . Also shown in FIG. 2 b are the ratio steps between single step ratios in the forward direction as well as the reverse to first ratio step. For example, the first to second step ratio is 1.50. Those skilled in the art will recognize that since torque transmitting mechanisms 166 and 167 ( 168 ) are connected to a common member, input clutch 162 , and they are not engaged at the same time for any of the speed ratios, the pair can be executed as a double (triple) synchronizer to reduce content and cost. Similarly, torque transmitting mechanisms pair 172 and 170 can be implemented as a double synchronizer.
[0090] Turning the FIG. 3 a , a powertrain 210 having a conventional engine 12 , a planetary transmission 214 , and conventional final drive mechanism 16 is shown.
[0091] The planetary transmission 214 includes an input shaft 17 continuously connected with the engine 12 , a planetary gear arrangement 218 , and an output shaft 19 continuously connected with the final drive mechanism 16 . The planetary gear arrangement 218 includes four planetary gear sets 220 , 230 , 240 and 250 .
[0092] The planetary gear set 220 includes a sun gear member 222 , a ring gear member 224 , and a planet carrier assembly member 226 . The planet carrier assembly member 226 includes a plurality of pinion gears 227 rotatably mounted on a carrier member 229 and disposed in meshing relationship with both the sun gear member 222 and the ring gear member 224 .
[0093] The planetary gear set 230 includes a sun gear member 232 , a ring gear member 234 , and a planet carrier assembly member 236 . The planet carrier assembly member 236 includes a plurality of pinion gears 237 rotatably mounted on a carrier member 239 and disposed in meshing relationship with both the sun gear member 232 and the ring gear member 234 .
[0094] The planetary gear set 240 includes a sun gear member 242 , a ring gear member 244 , and a planet carrier assembly member 246 . The planet carrier assembly member 246 includes a plurality of intermeshing pinion gears 247 , 248 rotatably mounted on a carrier member 249 and disposed in meshing relationship with the ring gear member 244 and the sun gear member 242 , respectively.
[0095] The planetary gear set 250 includes a sun gear member 252 , a ring gear member 254 , and a planet carrier assembly member 256 . The planet carrier assembly member 256 includes a plurality of intermeshing pinion gears 257 , 258 rotatably mounted on a carrier member 259 and disposed in meshing relationship with the ring gear member 254 and the sun gear member 252 , respectively.
[0096] As a result of the dual clutch arrangement of the invention, the four planetary gear sets 220 , 230 , 240 and 250 are divided into first and second transmission subsets 260 , 261 which are alternatively engaged to provide odd number and even number speed ranges, respectively. Transmission subset 260 includes planetary gear sets 220 and 230 , and transmission subset 261 includes planetary gear sets 240 and 250 . The output shaft 19 is continuously connected with members of both subsets 260 and 261 .
[0097] As mentioned above, the first and second input clutches 262 , 263 are alternatively engaged for transmitting power from the input shaft 17 to transmission subset 260 or transmission subset 261 . The first and second input clutches 262 , 263 are controlled electronically, and the disengaged input clutch is gradually engaged while the engaged input clutch is gradually disengaged to facilitate transfer of power from one transmission subset to another. In this manner, shift quality is maintained, as in an automatic transmission, while providing better fuel economy because no torque converter is required, and hydraulics associated with “wet” clutching are eliminated. All speed ratios are preselected within the transmission subsets 260 , 261 prior to engaging the respective input clutches 262 , 263 . The preselection is achieved by means of electronically controlled synchronizers. As shown, the planetary gear arrangement includes nine torque transmitting mechanisms 264 , 265 , 266 , 267 , 268 , 269 , 270 , 271 and 272 . The torque transmitting mechanisms 264 and 265 comprise braking synchronizers, and the torque transmitting mechanisms 266 , 267 , 268 , 269 , 270 , 271 and 272 comprise rotating synchronizers.
[0098] Accordingly, the input shaft 17 is alternately connected with the first and second transmission subsets 260 , 261 (i.e. through the clutch 262 to the synchronizers 266 , 267 , 268 and through the clutch 263 to the ring gear member 244 ). The ring gear member 224 is continuously connected with the sun gear member 232 through the interconnecting member 274 . The planet carrier assembly member 226 is continuously connected with the planet carrier assembly member 236 through the interconnecting member 276 . The planet carrier assembly member 246 is continuously connected with the ring gear member 234 and the output shaft 19 through the interconnecting member 278 . The sun gear member 252 is continuously connected with the transmission housing 280 .
[0099] The ring gear member 224 is selectively connectable with the transmission housing 280 through the braking synchronizer 264 . The planet carrier assembly member 236 is selectively connectable with the transmission housing 280 through the braking synchronizer 265 . The ring gear member 224 is selectively connectable with the input shaft 17 through the input clutch 262 and the rotating synchronizer 266 . The sun gear member 222 is selectively connectable with the input shaft 17 through the input clutch 262 and the rotating synchronizer 267 . The planet carrier assembly member 236 is selectively connectable with the input shaft 17 through the input clutch 262 and the rotating synchronizer 268 . The planet carrier assembly member 246 is selectively connectable with the ring gear member 254 through the rotating synchronizer 269 . The planet carrier assembly member 246 is selectively connectable with the planet carrier assembly member 256 through the rotating synchronizer 270 . The sun gear member 242 is selectively connectable with the ring gear member 254 through the rotating synchronizer 271 . The sun gear member 242 is selectively connectable with the planet carrier assembly member 256 through the rotating synchronizer 272 .
[0100] As shown in FIG. 3 b , and in particular the truth table disclosed therein, the input clutches and torque transmitting mechanisms are selectively engaged in combinations of three to provide six forward speed ratios and a reverse speed ratio.
[0101] The reverse speed ratio is established with the engagement of the input clutch 262 , the braking synchronizer 265 and the rotating synchronizer 266 . The input clutch 262 and the rotating synchronizer 266 connect the ring gear member 224 to the input shaft 17 . The braking synchronizer 265 connects the planet carrier assembly member 236 to the transmission housing 280 . The ring gear member 224 and the sun gear member 232 rotate at the same speed as the input shaft 17 . The planet carrier assembly members 226 , 236 do not rotate. The ring gear member 234 and the planet carrier assembly member 246 rotate at the same speed as the output shaft 19 . The ring gear member 234 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the sun gear member 232 and the ring gear/sun gear tooth ratio of the planetary gear set 230 . The numerical value of the reverse speed ratio is determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 230 .
[0102] The first forward speed ratio is established with the engagement of the input clutch 262 , the braking synchronizer 265 and the rotating synchronizer 267 . The input clutch 262 and the rotating synchronizer 267 connect the sun gear member 222 to the input shaft 17 . The braking synchronizer 265 connects the planet carrier assembly member 236 to the transmission housing 280 . The sun gear member 222 rotates at the same speed as the input shaft 17 . The planet carrier assembly members 226 , 236 do not rotate. The ring gear member 224 rotates at the same speed as the sun gear member 232 . The ring gear member 224 rotates at a speed determined from the speed of the sun gear member 222 and the ring gear/sun gear tooth ratio of the planetary gear set 220 . The ring gear member 234 and the planet carrier assembly member 246 rotate at the same speed as the output shaft 19 . The ring gear member 234 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the sun gear member 232 and the ring gear/sun gear tooth ratio of the planetary gear set 230 . The numerical value of the first forward speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear set 220 , 230 .
[0103] The second forward speed ratio is established with the engagement of the input clutch 263 and the rotating synchronizer 269 , 272 . The input clutch 263 connects the ring gear member 244 to the input shaft 17 . The rotating synchronizer 269 connects the planet carrier assembly member 246 to the ring gear member 254 . The rotating synchronizer 272 connects the sun gear member 242 to the planet carrier assembly member 256 . The sun gear member 242 rotates at the same speed as the planet carrier assembly member 256 . The planet carrier assembly member 246 and the ring gear member 254 rotate at the same speed as the output shaft 19 . The ring gear member 244 rotates at the same speed as the input shaft 17 . The planet carrier assembly member 246 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the ring gear member 244 , the speed of the sun gear member 242 and the ring gear/sun gear tooth ratio of the planetary gear set 240 . The sun gear member 252 does not rotate. The planet carrier assembly member 256 rotates at a speed determined from the speed of the ring gear member 254 and the ring gear/sun gear tooth ratio of the planetary gear set 250 . The numerical value of the second forward speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 240 , 250 .
[0104] The third forward speed ratio is established with the engagement of the input clutch 262 and the rotating synchronizers 266 , 268 . In this configuration, the input shaft 17 is directly connected to the output shaft 19 . The numerical value of the third forward speed ratio is 1.
[0105] The fourth forward speed ratio is established with the engagement of the input clutch 263 and the rotating synchronizers 270 , 271 . The input clutch 263 connects the ring gear member 244 to the input shaft 17 . The rotating synchronizer 270 connects the planet carrier assembly member 246 to the planet carrier assembly member 256 . The rotating synchronizer 271 connects the sun gear member 242 to the ring gear member 254 . The sun gear member 242 rotates at the same speed as the ring gear member 254 . The planet carrier assembly members 246 , 256 rotate at the same speed as the output shaft 19 . The ring gear member 244 rotates at the same speed as the input shaft 17 . The planet carrier assembly member 246 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the ring gear member 244 , the speed of the sun gear member 242 and the ring gear/sun gear tooth ratio of the planetary gear set 240 . The sun gear member 252 does not rotate. The planet carrier assembly member 256 rotates at a speed determined from the speed of the ring gear member 254 and the ring gear/sun gear tooth ratio of the planetary gear set 250 . The numerical value of the fourth forward speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 240 , 250 .
[0106] The fifth forward speed ratio is established with the engagement of the input clutch 262 , the braking synchronizer 264 and the rotating synchronizer 268 . The input clutch 262 and the rotating synchronizer 268 connect the planet carrier assembly member 236 to the input shaft 17 . The braking synchronizer 264 connects the ring gear member 224 to the transmission housing 280 . The ring gear member 224 and the sun gear member 232 do not rotate. The planet carrier assembly members 226 , 236 rotate at the same speed as the input shaft 17 . The ring gear member 234 and the planet carrier assembly member 246 rotate at the same speed as the output shaft 19 . The ring gear member 234 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the planet carrier assembly member 236 and the ring gear/sun gear tooth ratio of the planetary gear set 230 . The numerical value of the fifth forward speed ratio is determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 230 .
[0107] The sixth forward speed ratio is established with the engagement of the input clutch 263 and the rotating synchronizers 271 , 272 . The input clutch 263 connects the ring gear member 244 to the input shaft 17 . The rotating synchronizer 271 connects the sun gear member 242 to the ring gear member 254 . The rotating synchronizer 272 connects the sun gear member 242 to the planet carrier assembly member 256 . The sun gear member 242 and the planetary gear set 250 do not rotate. The planet carrier assembly member 246 rotates at the same speed as the output shaft 19 . The ring gear member 244 rotates at the same speed as the input shaft 17 . The planet carrier assembly member 246 , and therefore the output shaft 19 , rotates at a speed determined from the speed of the ring gear member 244 and the ring gear/sun gear tooth ratio of the planetary gear set 240 . The numerical value of the sixth forward speed ratio is determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 240 .
[0108] As previously set forth, the truth table of FIG. 3 b describes the combinations of engagements utilized for six forward speed ratios and one reverse speed ratio. The truth table also provides an example of speed ratios that are available with the family member described above. These examples of speed ratios are determined the tooth ratios given in FIG. 3 b . The R1/S1 value is the tooth ratio of the planetary gear set 220 ; the R2/S2 value is the tooth ratio of the planetary gear set 230 ; the R3/S3 value is the tooth ratio of the planetary gear set 240 ; and the R4/S4 value is the tooth ratio of the planetary gear set 250 . Also depicted in FIG. 3 b is a chart representing the ratio steps between adjacent forward speed ratios and the reverse speed ratio. For example, the first to second ratio interchange has a step of 2.00.
[0109] A powertrain 310 , shown in FIG. 4 a , includes the engine 12 , a planetary transmission 314 , and the final drive mechanism 16 . The planetary transmission 314 includes an input shaft 17 continuously connected with the engine 12 , a planetary gear arrangement 318 , and an output shaft 19 continuously connected with the final drive mechanism 16 . The planetary gear arrangement 318 includes four planetary gear sets 320 , 330 , 340 and 350 .
[0110] The planetary gear set 320 includes a sun gear member 322 , a ring gear member 324 , and a planet carrier assembly member 326 . The planet carrier assembly member 326 includes a plurality of pinion gears 327 rotatably mounted on a carrier member 329 and disposed in meshing relationship with both the sun gear member 322 and the ring gear member 324 .
[0111] The planetary gear set 330 includes a sun gear member 332 , a ring gear member 334 , and a planet carrier assembly member 336 . The planet carrier assembly member 336 includes a plurality of pinion gears 337 rotatably mounted on a carrier member 339 and disposed in meshing relationship with both the sun gear member 332 and the ring gear member 334 .
[0112] The planetary gear set 340 includes a sun gear member 342 , a ring gear member 344 , and a planet carrier assembly member 346 . The planet carrier assembly member 346 includes a plurality of intermeshing pinion gears 347 , 348 rotatably mounted on a carrier member 349 and disposed in meshing relationship with the ring gear member 344 and the sun gear member 342 , respectively.
[0113] The planetary gear set 350 includes a sun gear member 352 , a ring gear member 354 , and a planet carrier assembly member 356 . The planet carrier assembly member 356 includes a plurality of intermeshing pinion gears 357 , 358 rotatably mounted on a carrier member 359 and disposed in meshing relationship with the ring gear member 354 and the sun gear member 352 , respectively.
[0114] As a result of the dual clutch arrangement of the invention, the four planetary gear sets 320 , 330 , 340 and 350 are divided into first and second transmission subsets 360 , 361 which are alternatively engaged to provide odd number and even number speed ranges, respectively. Transmission subset 360 includes planetary gear sets 320 and 330 , and transmission subset 361 includes planetary gear sets 340 and 350 . The output shaft 19 is continuously connected with members of both subsets 360 and 361 .
[0115] As mentioned above, the first and second input clutches 362 , 363 are alternatively engaged for transmitting power from the input shaft 17 to transmission subset 360 or transmission subset 361 . The first and second input clutches 362 , 363 are controlled electronically, and the disengaged input clutch is gradually engaged while the engaged input clutch is gradually disengaged to facilitate transfer of power from one transmission subset to another. In this manner, shift quality is maintained, as in an automatic transmission, while providing better fuel economy because no torque converter is required, and hydraulics associated with “wet” clutching are eliminated. All speed ratios are preselected within the transmission subsets 360 , 361 prior to engaging the respective input clutches 362 , 363 . The preselection is achieved by means of electronically controlled synchronizers. As shown, the planetary gear arrangement includes nine torque transmitting mechanisms 364 , 365 , 366 , 367 , 368 , 369 , 370 , 371 and 372 . The torque transmitting mechanisms 364 and 365 comprise braking synchronizers, and the torque transmitting mechanisms 366 , 367 , 368 , 369 , 370 , 371 and 372 comprise rotating synchronizers.
[0116] Accordingly, the input shaft 17 is alternately connected with the first and second transmission subsets 360 , 361 (i.e. through the clutch 362 to the synchronizers 366 , 367 , 368 and through the clutch 363 to the ring gear member 344 ). The ring gear member 324 is continuously connected with the sun gear member 332 through the interconnecting member 374 . The planet carrier assembly member 326 is continuously connected with the planet carrier assembly member 336 through the interconnecting member 376 . The planet carrier assembly member 346 is continuously connected with the ring gear member 334 and the output shaft 19 through the interconnecting member 378 . The planet carrier assembly member 356 is continuously connected with the transmission housing 380 .
[0117] The ring gear member 324 is selectively connectable with the transmission housing 380 through the braking synchronizer 364 . The planet carrier assembly member 336 is selectively connectable with the transmission housing 380 through the braking synchronizer 365 . The ring gear member 324 is selectively connectable with the input shaft 17 through the input clutch 362 and the rotating synchronizer 366 . The sun gear member 322 is selectively connectable with the input shaft 17 through the input clutch 362 and the rotating synchronizer 367 . The planet carrier assembly member 326 is selectively connectable with the input shaft 17 through the input clutch 362 and the rotating synchronizer 368 . The planet carrier assembly member 346 is selectively connectable with the ring gear member 354 through the rotating synchronizer 369 . The planet carrier assembly member 346 is selectively connectable with the sun gear member 352 through the rotating synchronizer 370 . The sun gear member 342 is selectively connectable with the ring gear member 354 through the rotating synchronizer 371 . The sun gear member 342 is selectively connectable with the sun gear member 352 through the rotating synchronizer 372 .
[0118] The truth tables given in FIGS. 4 b , 5 b , 6 b , 7 b , 8 b , 9 b , 10 b and 11 b show the engagement sequences for the torque transmitting mechanisms to provide at least five forward speed ratios and one reverse speed ratio. As shown and described above for the configurations in FIGS. 1 a , 2 a and 3 a , those skilled in the art will understand from the respective truth tables how the speed ratios are established through the planetary gear sets identified in the written description.
[0119] The truth table shown in FIG. 4 b describes the engagement combination and engagement sequence necessary to provide the reverse drive ratio and six forward speed ratios. A sample of the numerical values for the ratios is also provided in the truth table of FIG. 4 b . These values are determined utilizing the ring gear/sun gear tooth ratios also given in FIG. 4 b . The R1/S1 value is the tooth ratio for the planetary gear set 320 ; the R2/S2 value is the tooth ratio for the planetary gear set 330 ; the R3/S3 value is the tooth ratio for the planetary gear set 340 ; and the R4/S4 value is the tooth ratio for the planetary gear set 350 . Also given in FIG. 4 b is a chart describing the step ratios between the adjacent forward speed ratios and the reverse to first forward speed ratio. For example, the first to second forward speed ratio step is 2.07.
[0120] Those skilled in the art will recognize that the numerical values of the reverse and fifth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 330 . The numerical value of the first forward speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 320 , 330 . The numerical values of the second and fourth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 340 , 350 . The numerical value of the third forward speed ratio is 1. The numerical value of the sixth forward speed ratio is determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 340 .
[0121] A powertrain 410 shown in FIG. 5 a includes a conventional engine 12 , a planetary transmission 414 , and a conventional final drive mechanism 16 . The planetary transmission 414 includes an input shaft 17 connected with the engine 12 , a planetary gear arrangement 418 , and an output shaft 19 continuously connected with the final drive mechanism 16 . The planetary gear arrangement 418 includes four planetary gear sets 420 , 430 , 440 and 450 .
[0122] The planetary gear set 420 includes a sun gear member 422 , a ring gear member 424 , and a planet carrier assembly member 426 . The planet carrier assembly member 426 includes a plurality of intermeshing pinion gears 427 , 428 rotatably mounted on a carrier member 429 and disposed in meshing relationship with the ring gear member 424 and the sun gear member 422 , respectively.
[0123] The planetary gear set 430 includes a sun gear member 432 , a ring gear member 434 , and a planet carrier assembly member 436 . The planet carrier assembly member 436 includes a plurality of pinion gears 437 rotatably mounted on a carrier member 439 and disposed in meshing relationship with both the sun gear member 432 and the ring gear member 434 .
[0124] The planetary gear set 440 includes a sun gear member 442 , a ring gear member 444 , and a planet carrier assembly member 446 . The planet carrier assembly member 446 includes a plurality of intermeshing pinion gears 447 , 448 rotatably mounted on a carrier member 449 and disposed in meshing relationship with the ring gear member 444 and the sun gear member 442 , respectively.
[0125] The planetary gear set 450 includes a sun gear member 452 , a ring gear member 454 , and a planet carrier assembly member 456 . The planet carrier assembly member 456 includes a plurality of pinion gears 457 rotatably mounted on a carrier member 459 and disposed in meshing relationship with both the sun gear member 452 and the ring gear member 454 .
[0126] As a result of the dual clutch arrangement of the invention, the four planetary gear sets 420 , 430 , 440 and 450 are divided into first and second transmission subsets 460 , 461 which are alternatively engaged to provide odd number and even number speed ranges, respectively. Transmission subset 460 includes planetary gear sets 420 and 430 , and transmission subset 461 includes planetary gear sets 440 and 450 . The output shaft 19 is continuously connected with members of both subsets 460 and 461 .
[0127] As mentioned above, the first and second input clutches 462 , 463 are alternatively engaged for transmitting power from the input shaft 17 to transmission subset 460 or transmission subset 461 . The first and second input clutches 462 , 463 are controlled electronically, and the disengaged input clutch is gradually engaged while the engaged input clutch is gradually disengaged to facilitate transfer of power from one transmission subset to another. In this manner, shift quality is maintained, as in an automatic transmission, while providing better fuel economy because no torque converter is required, and hydraulics associated with “wet” clutching are eliminated. All speed ratios are preselected within the transmission subsets 460 , 461 prior to engaging the respective input clutches 462 , 463 . The preselection is achieved by means of electronically controlled synchronizers. As shown, the planetary gear arrangement includes nine torque transmitting mechanisms 464 , 465 , 466 , 467 , 468 , 469 , 470 , 471 and 472 . The torque transmitting mechanisms 464 , 465 and 466 comprise braking synchronizers, and the torque transmitting mechanisms 467 , 468 , 469 , 470 , 471 and 472 comprise rotating synchronizers.
[0128] Accordingly, the input shaft 17 is alternately connected with the first and second transmission subsets 460 , 461 (i.e. through the clutch 462 to the synchronizers 467 , 468 and through the clutch 463 to the ring gear member 444 ). The sun gear member 422 is continuously connected with the ring gear member 434 through the interconnecting member 474 . The planet carrier assembly member 426 is continuously connected with the sun gear member 432 through the interconnecting member 476 . The planet carrier assembly member 446 is continuously connected with the planet carrier assembly member 436 and the output shaft 19 through the interconnecting member 478 . The ring gear member 454 is continuously connected with the transmission housing 480 .
[0129] The ring gear member 424 is selectively connectable with the transmission housing 480 through the braking synchronizer 464 . The ring gear member 434 is selectively connectable with the transmission housing 480 through the braking synchronizer 465 . The planet carrier assembly member 426 is selectively connectable with the transmission housing 480 through the braking synchronizer 466 . The ring gear member 424 is selectively connectable with the input shaft 17 through the input clutch 462 and the rotating synchronizer 467 . The sun gear member 432 is selectively connectable with the input shaft 17 through the input clutch 462 and the rotating synchronizer 468 . The planet carrier assembly member 446 is selectively connectable with the planet carrier assembly member 456 through the rotating synchronizer 469 . The planet carrier assembly member 446 is selectively connectable with the sun gear member 452 through the rotating synchronizer 470 . The sun gear member 442 is selectively connectable with the planet carrier assembly member 456 through the rotating synchronizer 471 . The sun gear member 442 is selectively connectable with the sun gear member 452 through the rotating synchronizer 472 .
[0130] As shown in FIG. 5 b , and in particular the truth table disclosed therein, the input clutches and torque transmitting mechanisms are selectively engaged in combinations of three to provide six forward speed ratios and a reverse speed ratio.
[0131] [0131]FIG. 5 b also provides a chart of the ratio steps between adjacent forward ratios and between the reverse and first ratio. For example, the ratio step between the first and second forward ratios is 1.58. Those skilled in the art will recognize that the numerical values of the reverse, third and fifth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 420 , 430 . The numerical value of the first forward speed ratio is determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 430 . The numerical values of the second and sixth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 440 , 450 . The numerical value of the fourth forward speed ratio is 1.
[0132] A powertrain 510 , shown in FIG. 6 a , includes a conventional engine 12 , a powertrain 514 , and a conventional final drive mechanism 16 . The powertrain 514 includes an input shaft 17 connected with the engine 12 , a planetary gear arrangement 518 , and an output shaft 19 continuously connected with the final drive mechanism 16 . The planetary gear arrangement 518 includes four planetary gear sets 520 , 530 , 540 and 550 .
[0133] The planetary gear set 520 includes a sun gear member 522 , a ring gear member 524 , and a planet carrier assembly member 526 . The planet carrier assembly member 526 includes a plurality of pinion gears 527 rotatably mounted on a carrier member 529 and disposed in meshing relationship with both the sun gear member 522 and the ring gear member 524 .
[0134] The planetary gear set 530 includes a sun gear member 532 , a ring gear member 534 , and a planet carrier assembly member 536 . The planet carrier assembly member 536 includes a plurality of pinion gears 537 rotatably mounted on a carrier member 539 and disposed in meshing relationship with both the sun gear member 532 and the ring gear member 534 .
[0135] The planetary gear set 540 includes a sun gear member 542 , a ring gear member 544 , and a planet carrier assembly member 546 . The planet carrier assembly member 546 includes a plurality of intermeshing pinion gears 547 , 548 rotatably mounted on a carrier member 549 and disposed in meshing relationship with the ring gear member 544 and the sun gear member 542 , respectively.
[0136] The planetary gear set 550 includes a sun gear member 552 , a ring gear member 554 , and a planet carrier assembly member 556 . The planet carrier assembly member 556 includes a plurality of intermeshing pinion gears 557 , 558 rotatably mounted on a carrier member 559 and disposed in meshing relationship with the ring gear member 554 and the sun gear member 552 , respectively.
[0137] As a result of the dual clutch arrangement of the invention, the four planetary gear sets 520 , 530 , 540 and 550 are divided into first and second transmission subsets 560 , 561 which are alternatively engaged to provide odd number and even number speed ranges, respectively. Transmission subset 560 includes planetary gear sets 520 and 530 , and transmission subset 561 includes planetary gear sets 540 and 550 . The output shaft 19 is continuously connected with members of both subsets 560 and 561 .
[0138] As mentioned above, the first and second input clutches 562 , 563 are alternatively engaged for transmitting power from the input shaft 17 to transmission subset 560 or transmission subset 561 . The first and second input clutches 562 , 563 are controlled electronically, and the disengaged input clutch is gradually engaged while the engaged input clutch is gradually disengaged to facilitate transfer of power from one transmission subset to another. In this manner, shift quality is maintained, as in an automatic transmission, while providing better fuel economy because no torque converter is required, and hydraulics associated with “wet” clutching are eliminated. All speed ratios are preselected within the transmission subsets 560 , 561 prior to engaging the respective input clutches 562 , 563 . The preselection is achieved by means of electronically controlled synchronizers. As shown, the planetary gear arrangement includes nine torque transmitting mechanisms 564 , 565 , 566 , 567 , 568 , 569 , 570 , 571 and 572 . The torque transmitting mechanisms 564 and 565 comprise braking synchronizers, and the torque transmitting mechanisms 566 , 567 , 568 , 569 , 570 , 571 and 572 comprise rotating synchronizers.
[0139] Accordingly, the input shaft 17 is alternately connected with the first and second transmission subsets 560 , 561 (i.e. through the clutch 562 to the synchronizers 566 , 567 , 568 and through the clutch 563 to the ring gear member 544 ). The planet carrier assembly member 526 is continuously connected with the ring gear member 534 through the interconnecting member 574 . The ring gear member 524 is continuously connected with the sun gear member 532 through the interconnecting member 576 . The planet carrier assembly member 546 is continuously connected with the planet carrier assembly member 536 and the output shaft 19 through the interconnecting member 578 . The planet carrier assembly member 556 is continuously connected with the transmission housing 580 .
[0140] The sun gear member 522 is selectively connectable with the transmission housing 580 through the braking synchronizer 564 . The planet carrier assembly member 526 is selectively connectable with the transmission housing 580 through the braking synchronizer 565 . The sun gear member 522 is selectively connectable with the input shaft 17 through the input clutch 562 and the rotating synchronizer 566 . The sun gear member 532 is selectively connectable with the input shaft 17 through the input clutch 562 and the rotating synchronizer 567 . The planet carrier assembly member 526 is selectively connectable with the input shaft 17 through the input clutch 562 and the rotating synchronizer 568 . The planet carrier assembly member 546 is selectively connectable with the ring gear member 554 through the rotating synchronizer 569 . The planet carrier assembly member 546 is selectively connectable with the sun gear member 552 through the rotating synchronizer 570 . The sun gear member 542 is selectively connectable with the ring gear member 554 through the rotating synchronizer 571 . The sun gear member 542 is selectively connectable with the sun gear member 552 through the rotating synchronizer 572 .
[0141] As shown in FIG. 6 b , and in particular the truth table disclosed therein, the input clutches and torque transmitting mechanisms are selectively engaged in combinations of three to provide six forward speed ratios and a reverse speed ratio. The chart of FIG. 6 b describes the ratio steps between adjacent forward speed ratios and the ratio step between the reverse and first forward speed ratio.
[0142] Those skilled in the art, upon reviewing the truth table and the schematic representation of FIG. 6 a can determine that the numerical values of the reverse, third and fifth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 520 , 530 . The numerical value of the first forward speed ratio is determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 530 . The numerical values of the second and sixth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratios of the planetary gear set 540 , 550 . The numerical value of the fourth forward speed ratio is 1.
[0143] The sample speed ratios given in the truth table are determined utilizing the tooth ratio values also given in FIG. 6 b . R1/S1 value is the tooth ratio of the planetary gear set 520 ; the R2/S2 value is the tooth ratio of the planetary gear set 530 ; the R3/S3 value is the tooth ratio of the planetary gear set 540 ; and the R4/S4 value is the tooth ratio of the planetary gear set 550 .
[0144] [0144]FIGS. 7 a and 7 b illustrate a transmission wherein one of the torque transmitting mechanisms from a previously described configuration is eliminated to realize five forward speed ratios and a reverse speed ratio. Specifically, the powertrain 610 , shown in FIG. 7 a is identical to that shown in FIG. 5 a , except that the rotating synchronizer 470 of FIG. 5 a has been eliminated.
[0145] Referring to FIG. 7 a , a powertrain 610 is shown having a conventional engine 12 , a planetary transmission 614 , and a conventional final drive mechanism 16 . The planetary transmission 614 includes an input shaft 17 connected with the engine 12 , a planetary gear arrangement 618 , and an output shaft 19 continuously connected with the final drive mechanism 16 . The planetary gear arrangement 618 includes four planetary gear sets 620 , 630 , 640 and 650 .
[0146] The planetary gear set 620 includes a sun gear member 622 , a ring gear member 624 , and a planet carrier assembly member 626 . The planet carrier assembly member 626 includes a plurality of intermeshing pinion gears 627 , 628 rotatably mounted on a carrier member 629 and disposed in meshing relationship with the ring gear member 624 and the sun gear member 622 , respectively.
[0147] The planetary gear set 630 includes a sun gear member 632 , a ring gear member 634 , and a planet carrier assembly member 636 . The planet carrier assembly member 636 includes a plurality of pinion gears 637 rotatably mounted on a carrier member 639 and disposed in meshing relationship with both the sun gear member 632 and the ring gear member 634 .
[0148] The planetary gear set 640 includes a sun gear member 642 , a ring gear member 644 , and a planet carrier assembly member 646 . The planet carrier assembly member 646 includes a plurality of intermeshing pinion gears 647 , 648 rotatably mounted on a carrier member 649 and disposed in meshing relationship with the ring gear member 644 and the sun gear member 642 , respectively.
[0149] The planetary gear set 650 includes a sun gear member 652 , a ring gear member 654 , and a planet carrier assembly member 656 . The planet carrier assembly member 656 includes a plurality of pinion gears 657 rotatably mounted on a carrier member 659 and disposed in meshing relationship with both the sun gear member 652 and the ring gear member 654 .
[0150] As a result of the dual clutch arrangement of the invention, the four planetary gear sets 620 , 630 , 640 and 650 are divided into first and second transmission subsets 660 , 661 which are alternatively engaged to provide odd number and even number speed ranges, respectively. Transmission subset 660 includes planetary gear sets 620 and 630 , and transmission subset 661 includes planetary gear sets 640 and 650 . The output shaft 19 is continuously connected with members of both subsets 660 and 661 .
[0151] As mentioned above, the first and second input clutches 662 , 663 are alternatively engaged for transmitting power from the input shaft 17 to transmission subset 660 or transmission subset 661 . The first and second input clutches 662 , 663 are controlled electronically, and the disengaged input clutch is gradually engaged while the engaged input clutch is gradually disengaged to facilitate transfer of power from one transmission subset to another. In this manner, shift quality is maintained, as in an automatic transmission, while providing better fuel economy because no torque converter is required, and hydraulics associated with “wet” clutching are eliminated. All speed ratios are preselected within the transmission subsets 660 , 661 prior to engaging the respective input clutches 662 , 663 . The preselection is achieved by means of electronically controlled synchronizers. As shown, the planetary gear arrangement includes eight torque transmitting mechanisms 664 , 665 , 666 , 667 , 668 , 669 , 671 and 672 . The torque transmitting mechanisms 664 , 665 and 666 comprise braking synchronizers, and the torque transmitting mechanisms 667 , 668 , 669 , 671 and 672 comprise rotating synchronizers.
[0152] Accordingly, the input shaft 17 is alternately connected with the first and second transmission subsets 660 , 661 (i.e. through the clutch 662 to the synchronizers 667 , 668 and through the clutch 663 to the ring gear member 644 ). The sun gear member 622 is continuously connected with the ring gear member 634 through the interconnecting member 674 . The planet carrier assembly member 626 is continuously connected with the sun gear member 632 through the interconnecting member 676 . The planet carrier assembly member 646 is continuously connected with the planet carrier assembly member 636 and the output shaft 19 through the interconnecting member 678 . The ring gear member 654 is continuously connected with the transmission housing 680 .
[0153] The ring gear member 624 is selectively connectable with the transmission housing 680 through the braking synchronizer 664 . The ring gear member 634 is selectively connectable with the transmission housing 680 through the braking synchronizer 665 . The planet carrier assembly member 626 is selectively connectable with the transmission housing 680 through the braking synchronizer 666 . The ring gear member 624 is selectively connectable with the input shaft 17 through the input clutch 662 and the rotating synchronizer 667 . The sun gear member 632 is selectively connectable with the input shaft 17 through the input clutch 662 and the rotating synchronizer 668 . The planet carrier assembly member 646 is selectively connectable with the planet carrier assembly member 656 through the rotating synchronizer 669 . The sun gear member 642 is selectively connectable with the planet carrier assembly member 656 through the rotating synchronizer 671 . The planet carrier assembly member 642 is selectively connectable with the planet carrier assembly member 652 through the rotating synchronizer 672 .
[0154] As shown in FIG. 7 b , and in particular the truth table disclosed therein, the input clutches and torque transmitting mechanisms are selectively engaged in combinations of three to provide five forward speed ratios and a reverse speed ratio. The truth table also provides a set of examples for the numerical values for each of the reverse and forward speed ratios. These numerical values have been determined utilizing the ring gear/sun gear tooth ratios given in FIG. 7 b . The R1/S1 value is the tooth ratio of the planetary gear set 620 ; the R2/S2 value is the tooth ratio of the planetary gear set 630 ; the R3/S3 value is the tooth ratio of the planetary gear set 640 ; and the R4/S4 value is the tooth ratio of the planetary gear set 650 .
[0155] Those skilled in the art, upon reviewing the engagement combinations, will recognize that the numerical values of the reverse, third and fifth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 620 , 630 . The numerical value of the first forward speed ratio is determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 630 . The numerical value of the second forward speed ratio is determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 640 , 650 . The numerical value of the fourth forward speed ratio is 1.
[0156] A powertrain 710 , shown in FIG. 8 a , has the conventional engine 12 , a planetary transmission 714 , and the conventional final drive mechanism 16 . The engine 12 is continuously connected with the input shaft 17 . The planetary transmission 714 is drivingly connected with the final drive mechanism 16 through the output shaft 19 . The planetary transmission 714 includes a planetary gear arrangement 718 that has a first planetary gear set 720 , a second planetary gear set 730 , a third planetary gear set 740 , and a fourth planetary gear set 750 .
[0157] The planetary gear set 720 includes a sun gear member 722 , a ring gear member 724 , and a planet carrier assembly member 726 . The planet carrier assembly member 726 includes a plurality of pinion gears 727 rotatably mounted on a carrier member 729 and disposed in meshing relationship with both the sun gear member 722 and the ring gear member 724 .
[0158] The planetary gear set 730 includes a sun gear member 732 , a ring gear member 734 , and a planet carrier assembly member 736 . The planet carrier assembly member 736 includes a plurality of intermeshing pinion gears 737 , 738 rotatably mounted on a carrier member 739 and disposed in meshing relationship with the ring gear member 734 and the sun gear member 732 , respectively.
[0159] The planetary gear set 740 includes a sun gear member 742 , a ring gear member 744 , and a planet carrier assembly member 746 . The planet carrier assembly member 746 includes a plurality of intermeshing pinion gears 747 , 748 rotatably mounted on a carrier member 749 and disposed in meshing relationship with the ring gear member 744 and the sun gear member 742 , respectively.
[0160] The planetary gear set 750 includes a sun gear member 752 , a ring gear member 754 , and a planet carrier assembly member 756 . The planet carrier assembly member 756 includes a plurality of intermeshing pinion gears 757 , 758 rotatably mounted on a carrier member 759 and disposed in meshing relationship with the ring gear member 754 and the sun gear member 752 , respectively.
[0161] As a result of the dual clutch arrangement of the invention, the four planetary gear sets 720 , 730 , 740 and 750 are divided into first and second transmission subsets 760 , 761 which are alternatively engaged to provide odd number and even number speed ranges, respectively. Transmission subset 760 includes planetary gear sets 720 and 730 , and transmission subset 761 includes planetary gear sets 740 and 750 . The output shaft 19 is continuously connected with members of both subsets 760 and 761 .
[0162] As mentioned above, the first and second input clutches 762 , 763 are alternatively engaged for transmitting power from the input shaft 17 to transmission subset 760 or transmission subset 761 . The first and second input clutches 762 , 763 are controlled electronically, and the disengaged input clutch is gradually engaged while the engaged input clutch is gradually disengaged to facilitate transfer of power from one transmission subset to another. In this manner, shift quality is maintained, as in an automatic transmission, while providing better fuel economy because no torque converter is required, and hydraulics associated with “wet” clutching are eliminated. All speed ratios are preselected within the transmission subsets 760 , 761 prior to engaging the respective input clutches 762 , 763 . The preselection is achieved by means of electronically controlled synchronizers. As shown, the planetary gear arrangement includes nine torque transmitting mechanisms 764 , 765 , 766 , 767 , 768 , 769 , 770 , 771 and 772 . The torque transmitting mechanisms 764 , 765 and 766 comprise braking synchronizers, and the torque transmitting mechanisms 767 , 768 , 769 , 770 , 771 and 772 comprise rotating synchronizers.
[0163] Accordingly, the input shaft 17 is alternately connected with the first and second transmission subsets 760 , 761 (i.e. through the clutch 762 to the synchronizers 767 , 768 and through the clutch 763 to the ring gear member 744 ). The sun gear member 722 is continuously connected with the planet carrier assembly member 736 through the interconnecting member 774 . The ring gear member 724 is continuously connected with the sun gear member 732 through the interconnecting member 776 . The planet carrier assembly member 746 is continuously connected with the planet carrier assembly member 726 and the output shaft 19 through the interconnecting member 778 . The sun gear member 752 is continuously connected with the transmission housing 780 .
[0164] The ring gear member 734 is selectively connectable with the transmission housing 780 through the braking synchronizer 764 . The sun gear member 732 is selectively connectable with the transmission housing 780 through the braking synchronizer 765 . The planet carrier assembly member 736 is selectively connectable with the transmission housing 780 through the braking synchronizer 766 . The ring gear member 734 is selectively connectable with the input shaft 17 through the input clutch 762 and the rotating synchronizer 767 . The sun gear member 722 is selectively connectable with the input shaft 17 through the input clutch 762 and the rotating synchronizer 768 . The planet carrier assembly member 746 is selectively connectable with the ring gear member 754 through the rotating synchronizer 769 . The planet carrier assembly member 746 is selectively connectable with the planet carrier assembly member 756 through the rotating synchronizer 770 . The sun gear member 742 is selectively connectable with the ring gear member 754 through the rotating synchronizer 771 . The sun gear member 742 is selectively connectable with the planet carrier assembly member 756 through the rotating synchronizer 772 .
[0165] As shown in FIG. 8 b , and in particular the truth table disclosed therein, the input clutches and torque transmitting mechanisms are selectively engaged in combinations of three to provide six forward speed ratios and a reverse speed ratio. Also given in the truth table is a set of numerical values that are attainable with the present invention utilizing the ring gear/sun gear tooth ratios given in FIG. 8 b . The R1/S1 value is the tooth ratio of the planetary gear set 720 ; the R2/S2 value is the tooth ratio of the planetary gear set 730 ; the R3/S3 value is the tooth ratio of the planetary gear set 740 ; and the R4/S4 value is the tooth ratio of the planetary gear set 750 .
[0166] [0166]FIG. 8 b also provides a chart of the ratio steps between adjacent forward ratios and between the reverse and first forward ratio. For example, the ratio step between the first and second forward ratios is 1.96.
[0167] Those skilled in the art will recognize that the numerical values of the reverse and fifth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 720 , 730 . The numerical value of the first forward speed ratio is determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 730 . The numerical values of the second and fourth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 740 , 750 . The numerical value of the third forward speed ratio is 1. The numerical value of the sixth forward speed ratio is determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 740 .
[0168] A powertrain 810 , shown in FIG. 9 a , has the conventional engine 12 , a planetary transmission 814 , and the final drive mechanism 16 . The engine 12 is continuously connected with the input shaft 17 . The planetary transmission 814 is drivingly connected with final drive mechanism 16 through output shaft 19 . The planetary transmission 814 includes a planetary gear arrangement 818 that has a first planetary gear set 820 , a second planetary gear set 830 , a third planetary gear set 840 , and fourth planetary gear set 850 .
[0169] The planetary gear set 820 includes a sun gear member 822 , a ring gear member 824 , and a planet carrier assembly member 826 . The planet carrier assembly member 826 includes a plurality of intermeshing pinion gears 827 , 828 rotatably mounted on a carrier member 829 and disposed in meshing relationship with the ring gear member 824 and the sun gear member 822 , respectively.
[0170] The planetary gear set 830 includes a sun gear member 832 , a ring gear member 834 , and a planet carrier assembly member 836 . The planet carrier assembly member 836 includes a plurality of pinion gears 837 rotatably mounted on a carrier member 839 and disposed in meshing relationship with both the sun gear member 832 and the ring gear member 834 .
[0171] The planetary gear set 840 includes a sun gear member 842 , a ring gear member 844 , and a planet carrier assembly member 846 . The planet carrier assembly member 846 includes a plurality of intermeshing pinion gears 847 , 848 rotatably mounted on a carrier member 849 and disposed in meshing relationship with the ring gear member 844 and the sun gear member 842 , respectively.
[0172] The planetary gear set 850 includes a sun gear member 852 , a ring gear member 854 , and a planet carrier assembly member 856 . The planet carrier assembly member 856 includes a plurality of intermeshing pinion gears 857 , 858 rotatably mounted on a carrier member 859 and disposed in meshing relationship with the ring gear member 854 and the sun gear member 852 , respectively.
[0173] As a result of the dual clutch arrangement of the invention, the four planetary gear sets 820 , 830 , 840 and 850 are divided into first and second transmission subsets 860 , 861 which are alternatively engaged to provide odd number and even number speed ranges, respectively. Transmission subset 860 includes planetary gear sets 820 and 830 , and transmission subset 861 includes planetary gear sets 840 and 850 . The output shaft 19 is continuously connected with members of both subsets 860 and 861 .
[0174] As mentioned above, the first and second input clutches 862 , 863 are alternatively engaged for transmitting power from the input shaft 17 to transmission subset 860 or transmission subset 861 . The first and second input clutches 862 , 863 are controlled electronically, and the disengaged input clutch is gradually engaged while the engaged input clutch is gradually disengaged to facilitate transfer of power from one transmission subset to another. In this manner, shift quality is maintained, as in an automatic transmission, while providing better fuel economy because no torque converter is required, and hydraulics associated with “wet” clutching are eliminated. All speed ratio selection is preselected within the transmission subsets 860 , 861 prior to engaging the respective input clutches 862 , 863 . The preselection is achieved by means of electronically controlled synchronizers. As shown, the planetary gear arrangement includes nine torque transmitting mechanisms 864 , 865 , 866 , 867 , 868 , 869 , 870 , 871 and 872 . The torque transmitting mechanisms 864 , 865 and 866 comprise braking synchronizers, and the torque transmitting mechanisms 867 , 868 , 869 , 870 , 871 and 872 comprise rotating synchronizers.
[0175] Accordingly, the input shaft 17 is alternately connected with the first and second transmission subsets 860 , 861 (i.e. through the clutch 862 to the synchronizers 867 , 868 and through the clutch 863 to the ring gear member 844 ). The sun gear member 822 is continuously connected with the ring gear member 834 through the interconnecting member 874 . The planet carrier assembly member 826 is continuously connected with the sun gear member 832 through the interconnecting member 876 . The planet carrier assembly member 846 is continuously connected with the planet carrier assembly member 836 and the output shaft 19 through the interconnecting member 878 . The planet carrier assembly member 856 is continuously connected with the transmission housing 880 .
[0176] The ring gear member 824 is selectively connectable with the transmission housing 880 through the braking synchronizer 864 . The ring gear member 834 is selectively connectable with transmission housing 880 through the braking synchronizer 865 . The planet carrier assembly member 826 is selectively connectable with the transmission housing 880 through the braking synchronizer 866 . The ring gear member 824 is selectively connectable with the input shaft 17 through the input clutch 862 and the rotating synchronizer 867 . The sun gear member 832 is selectively connectable with the input shaft 17 through the input clutch 862 and the rotating synchronizer 868 . The planet carrier assembly member 846 is selectively connectable with the ring gear member 854 through the rotating synchronizer 869 . The planet carrier assembly member 846 is selectively connectable with the sun gear member 852 through the rotating synchronizer 870 . The sun gear member 842 is selectively connectable with the ring gear member 854 through the rotating synchronizer 871 . The sun gear member 842 is selectively connectable with the sun gear member 852 through the rotating synchronizer 872 .
[0177] As shown in FIG. 9 b , and in particular the truth table disclosed therein, the input clutches and torque transmitting mechanisms are selectively engaged in combinations of three to provide six forward speed ratios and a reverse speed ratio. A sample of numerical values for the individual ratios is also given in the truth table of FIG. 9 b . These numerical values have been calculated using the ring gear/sun gear tooth ratios also given by way of example in FIG. 9 b . The R1/S1 value is the tooth ratio of the planetary gear set 820 ; the R2/S2 value is the tooth ratio of planetary gear set 830 ; the R3/S3 value is the tooth ratio of the planetary gear set 840 ; and the R4/S4 value is the tooth ratio of the planetary gear set 850 . FIG. 9 b also describes the ratio steps between adjacent forward ratios and between the reverse and first forward ratio. For example, the ratio step between the first and second forward ratios is 1.59.
[0178] Those skilled in the art will recognize that the numerical values of the reverse, third and fifth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 820 , 830 . The numerical value of the first forward speed ratio is determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 830 . The numerical values of the second and sixth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 840 , 850 . The numerical value of the fourth forward speed ratio is 1.
[0179] Referring to FIG. 10 a , a powertrain 910 is shown having a conventional engine 12 , a planetary transmission 914 , and a conventional final drive mechanism 16 . The planetary transmission 914 includes an input shaft 17 connected with the engine 12 , a planetary gear arrangement 918 , and an output shaft 19 continuously connected with the final drive mechanism 16 . The planetary gear arrangement 918 includes four planetary gear sets 920 , 930 , 940 and 950 .
[0180] The planetary gear set 920 includes a sun gear member 922 , a ring gear member 924 , and a planet carrier assembly member 926 . The planet carrier assembly member 926 includes a plurality of pinion gears 927 rotatably mounted on a carrier member 929 and disposed in meshing relationship with both the sun gear member 922 and the ring gear member 924 .
[0181] The planetary gear set 930 includes a sun gear member 932 , a ring gear member 934 , and a planet carrier assembly member 936 . The planet carrier assembly member 936 includes a plurality of pinion gears 937 rotatably mounted on a carrier member 939 and disposed in meshing relationship with both the sun gear member 932 and the ring gear member 934 .
[0182] The planetary gear set 940 includes a sun gear member 942 , a ring gear member 944 , and a planet carrier assembly member 946 . The planet carrier assembly member 946 includes a plurality of intermeshing pinion gears 947 , 948 rotatably mounted on a carrier member 949 and disposed in meshing relationship with the ring gear member 944 and the sun gear member 942 , respectively.
[0183] The planetary gear set 950 includes a sun gear member 952 , a ring gear member 954 , and a planet carrier assembly member 956 . The planet carrier assembly member 956 includes a plurality of intermeshing pinion gears 957 , 958 rotatably mounted on a carrier member 959 and disposed in meshing relationship with the ring gear member 954 and the sun gear member 952 , respectively.
[0184] As a result of the dual clutch arrangement of the invention, the four planetary gear sets 920 , 930 , 940 and 950 are divided into first and second transmission subsets 960 , 961 which are alternatively engaged to provide odd number and even number speed ranges, respectively. Transmission subset 960 includes planetary gear sets 920 and 930 , and transmission subset 961 includes planetary gear sets 940 and 950 . The output shaft 19 is continuously connected with members of both subsets 960 and 961 .
[0185] In this family member, rather than having two input clutches alternatively engaged for transmitting power from the input shaft 17 to transmission subset 960 or transmission subset 961 , the first input clutch is operatively replaced by the synchronizers 964 , 965 as described below. The input clutch 963 and synchronizers 964 , 965 are controlled electronically, and the disengaged input clutch or synchronizer is gradually disengaged to facilitate transfer of power from one transmission subset to another. In this manner, shift quality is maintained, as in an automatic transmission, while providing better fuel economy because no torque converter is required, and hydraulics associated with “wet” clutching are eliminated. All speed ratios are preselected within the transmission subsets 960 , 961 prior to engaging the respective input clutch 963 or synchronizers 964 , 965 . The preselection is achieved by means of electronically controlled synchronizers. As shown, the planetary gear arrangement includes nine torque transmitting mechanisms 964 , 965 , 966 , 967 , 968 , 969 , 970 , 971 and 972 . The torque transmitting mechanisms 964 and 965 comprise braking synchronizers, and the torque transmitting mechanisms 966 , 967 , 968 , 969 , 970 , 971 and 972 comprise rotating synchronizers.
[0186] Accordingly, the input shaft 17 is alternately connected with the first and second transmission subsets 960 , 961 (i.e. through the clutch 962 to the synchronizers 966 , 967 , 968 and through the clutch 963 to the ring gear member 944 ). The planet carrier assembly member 926 is continuously connected with the ring gear member 934 through the interconnecting member 974 . The ring gear member 924 is continuously connected with the sun gear member 932 through the interconnecting member 976 . The planet carrier assembly member 946 is continuously connected with the planet carrier assembly member 936 and the output shaft 19 through the interconnecting member 978 . The sun gear member 952 is continuously connected with the transmission housing 980 .
[0187] The sun gear member 922 is selectively connectable with the transmission housing 980 through the braking synchronizer 964 . The planet carrier assembly member 926 is selectively connectable with the transmission housing 980 through the braking synchronizer 965 . The sun gear member 922 is selectively connectable with the input shaft 17 through the input clutch 962 and the rotating synchronizer 966 . The sun gear member 932 is selectively connectable with the input shaft 17 through the input clutch 962 and the rotating synchronizer 967 . The planet carrier assembly member 926 is selectively connectable with the input shaft 17 through the input clutch 962 and the rotating synchronizer 968 . The planet carrier assembly member 946 is selectively connectable with the ring gear member 954 through the rotating synchronizer 969 . The planet carrier assembly member 946 is selectively connectable with the planet carrier assembly member 956 through the rotating synchronizer 970 . The sun gear member 942 is selectively connectable with the ring gear member 954 through the rotating synchronizer 971 . The sun gear member 942 is selectively connectable with the planet carrier assembly member 956 through the rotating synchronizer 972 .
[0188] As shown in FIG. 10 b , and in particular the truth table disclosed therein, the input clutches and torque transmitting mechanisms are selectively engaged in combinations of three to provide six forward speed ratios and a reverse speed ratio. The truth table also provides a set of examples for the numerical values for each of the reverse and forward speed ratios. These numerical values have been determined utilizing the ring gear/sun gear tooth ratios given in FIG. 10 b . The R1/S1 value is the tooth ratio of the planetary gear set 920 ; the R2/S2 value is the tooth ratio of the planetary gear set 930 ; the R3/S3 value is the tooth ratio of the planetary gear set 940 ; and the R4/S4 value is the tooth ratio of the planetary gear set 950 .
[0189] Those skilled in the art, upon reviewing the engagement combinations, will recognize that the numerical values of the reverse, third and fifth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 920 , 930 . The numerical value of the first forward speed ratio is determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 930 . The numerical values of the second and sixth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 940 , 950 . The numerical value of the fourth forward speed ratio is 1.
[0190] Referring to FIG. 11 a , a powertrain 1010 is shown having a conventional engine 12 , a planetary transmission 1014 , and a conventional final drive mechanism 16 . The planetary transmission 1014 includes an input shaft 17 connected with the engine 12 , a planetary gear arrangement 1018 , and an output shaft 19 continuously connected with the final drive mechanism 16 . The planetary gear arrangement 1018 includes four planetary gear sets 1020 , 1030 , 1040 and 1050 .
[0191] The planetary gear set 1020 includes a sun gear member 1022 , a ring gear member 1024 , and a planet carrier assembly member 1026 . The planet carrier assembly member 1026 includes a plurality of pinion gears 1027 rotatably mounted on a carrier member 1029 and disposed in meshing relationship with both the sun gear member 1022 and the ring gear member 1024 .
[0192] The planetary gear set 1030 includes a sun gear member 1032 , a ring gear member 1034 , and a planet carrier assembly member 1036 . The planet carrier assembly member 1036 includes a plurality of pinion gears 1037 rotatably mounted on a carrier member 1039 and disposed in meshing relationship with both the sun gear member 1032 and the ring gear member 1034 .
[0193] The planetary gear set 1040 includes a sun gear member 1042 , a ring gear member 1044 , and a planet carrier assembly member 1046 . The planet carrier assembly member 1046 includes a plurality of intermeshing pinion gears 1047 , 1048 rotatably mounted on a carrier member 1049 and disposed in meshing relationship with the ring gear member 1044 and the sun gear member 1042 , respectively.
[0194] The planetary gear set 1050 includes a sun gear member 1052 , a ring gear member 1054 , and a planet carrier assembly member 1056 . The planet carrier assembly member 1056 includes a plurality of intermeshing pinion gears 1057 , 1058 rotatably mounted on a carrier member 1059 and disposed in meshing relationship with the ring gear member 1054 and the sun gear member 1052 , respectively.
[0195] As a result of the dual clutch arrangement of the invention, the four planetary gear sets 1020 , 1030 , 1040 and 1050 are divided into first and second transmission subsets 1060 , 1061 which are alternatively engaged to provide odd number and even number speed ranges, respectively. Transmission subset 1060 includes planetary gear sets 1020 and 1030 , and transmission subset 1061 includes planetary gear sets 1040 and 1050 . The output shaft 19 is continuously connected with members of both subsets 1060 and 1061 .
[0196] In this family member, which is a derivative of the family member shown in FIG. 10 a , rather than having two input clutches and nine synchronizers, four input clutches and six synchronizers are utilized to achieve reduced content. The first input clutch and first, second and third synchronizers in FIG. 10 a are here operatively replaced by a first, second and third input clutch 1066 , 1067 and 1068 and the second input clutch in FIG. 10 a remains here as a fourth input clutch 1063 . The input clutches 1063 , 1066 , 1067 and 1068 are controlled electronically, and the disengaged input clutch is gradually engaged while the engaged input clutch is gradually disengaged to facilitate transfer of power from one transmission subset to another. In this manner, shift quality is maintained, as in an automatic transmission, while providing better fuel economy because no torque converter is required, and hydraulics associated with “wet” clutching are eliminated. All speed ratios are preselected within the transmission subsets 1060 , 1061 prior to engaging the respective input clutch 1063 , 1066 , 1067 or 1068 . The preselection is achieved by means of electronically controlled synchronizers. As shown, the planetary gear arrangement includes six torque transmitting mechanisms 1064 , 1065 , 1066 , 1069 , 1070 , 1071 and 1072 . The torque transmitting mechanisms 1064 and 1065 comprise braking synchronizers, and the torque transmitting mechanisms 1069 , 1070 , 1071 and 1072 comprise rotating synchronizers.
[0197] Accordingly, the input shaft 17 is alternately connected with the first and second transmission subsets 1060 , 1061 (i.e. through the clutch 1066 to the sun gear member 1022 , through the clutch 1067 to the sun gear member 1032 , through the clutch 1068 to the planet carrier assembly member 1026 and through the clutch 1063 to the ring gear member 1044 ). The planet carrier assembly member 1026 is continuously connected with the ring gear member 1034 through the interconnecting member 1074 . The ring gear member 1024 is continuously connected with the sun gear member 1032 through the interconnecting member 1076 . The planet carrier assembly member 1046 is continuously connected with the planet carrier assembly member 1036 and the output shaft 19 through the interconnecting member 1078 . The sun gear member 1052 is continuously connected with the transmission housing 1080 .
[0198] The sun gear member 1022 is selectively connectable with the transmission housing 1080 through the braking synchronizer 1064 . The planet carrier assembly member 1026 is selectively connectable with the transmission housing 1080 through the braking synchronizer 1065 . The sun gear member 1022 is selectively connectable with the input shaft 17 through the rotating synchronizer 1066 . The sun gear member 1032 is selectively connectable with the input shaft 17 through the rotating synchronizer 1067 . The planet carrier assembly member 1026 is selectively connectable with the input shaft 17 through the rotating synchronizer 1068 . The planet carrier assembly member 1046 is selectively connectable with the ring gear member 1054 through the rotating synchronizer 1069 . The planet carrier assembly member 1046 is selectively connectable with the planet carrier assembly member 1056 through the rotating synchronizer 1070 . The sun gear member 1042 is selectively connectable with the ring gear member 1054 through the rotating synchronizer 1071 . The sun gear member 1042 is selectively connectable with the planet carrier assembly member 1056 through the rotating synchronizer 1072 .
[0199] As shown in FIG. 11 b , and in particular the truth table disclosed therein, the input clutches and torque transmitting mechanisms are selectively engaged in combinations of at least two to provide six forward speed ratios and a reverse speed ratio. The truth table also provides a set of examples for the numerical values for each of the reverse and forward speed ratios. These numerical values have been determined utilizing the ring gear/sun gear tooth ratios given in FIG. 11 b . The R1/S1 value is the tooth ratio of the planetary gear set 1020 ; the R2/S2 value is the tooth ratio of the planetary gear set 1030 ; the R3/S3 value is the tooth ratio of the planetary gear set 1040 ; and the R4/S4 value is the tooth ratio of the planetary gear set 1050 .
[0200] Those skilled in the art, upon reviewing the engagement combinations, will recognize that the numerical values of the reverse, third and fifth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 1020 , 1030 . The numerical value of the first forward speed ratio is determined utilizing the ring gear/sun gear tooth ratio of the planetary gear set 1030 . The numerical values of the second and sixth forward speed ratios are determined utilizing the ring gear/sun gear tooth ratios of the planetary gear sets 1040 , 1050 . The numerical value of the fourth forward speed ratio is 1.
[0201] While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims. | The family of transmissions has a plurality of members that can be utilized in powertrains to provide at least six forward speed ratios and one reverse speed ratio. The transmission family members include four planetary gear sets, two input clutches, eight or nine torque transmitting mechanisms, three fixed interconnections, and one grounded planetary gear member. The invention provides a low content multi-speed dual clutch transmission mechanism wherein the two input clutches alternately connect the engine to realize odd and even speed ratio changes. The torque transmitting mechanisms provide connections between various gear members, the fixed interconnections, the input clutches, the output shaft, and the transmission housing, and are operated in combinations of three to establish at least five forward speed ratios and at least one reverse speed ratio. | 5 |
[0001] This application claims the benefit under 35 USC §119 (e) of U.S. provisional application Ser. No. 61/373,023 filed on Aug. 12, 2010, incorporated herein by reference in its entirety.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates generally to the packaging of ophthalmic contact lenses and, more specifically, to promoting good sealing of the contact lens package.
[0004] 2. Description of the Related Art
[0005] As shown in FIGS. 1-2 , hydrophilic ophthalmic contact lenses are commonly packaged in individual packages 10 , generally known as “blister packages” or “blister packs.” A blister pack generally consists of a plastic (e.g., polypropylene) shell 12 having a bowl-shaped depression or cavity 13 in which a lens (not shown) is disposed immersed in a sterile aqueous solution (not shown) and sealed with a laminate foil cover 14 . A flat rim 16 surrounds the cavity 13 . (Shells 12 may include additional features to aid use and handling, but they are not shown for purposes of clarity.) As shown in FIG. 2 , blister packages are generally manufactured in strips comprising a number, such as five, of adjoining blister packages that a user can easily separate by snapping them apart from one another. Such packaging keeps the lens in a hydrated and sterile state before being opened and worn by a user. Often, a lens is contained within a blister package for a significant amount of time while the lens is being shipped and held in storage before use. Therefore, it is important that the aqueous solution be hermetically sealed therein, to ensure that the solution cannot leak out and to prevent contaminants from entering the lens containment area. In one method of hermetically sealing the laminate foil to the plastic shell, a heating element or heated seal plate presses the laminate foil against the rim 16 to heat-seal the foil cover 14 to the shell.
[0006] Undesirable conditions during sealing can sometimes give rise to a poor, i.e., non-hermetic, seal between the foil cover 14 and the plastic shell 12 . For example, droplets or moisture between the cover and seal area can create wrinkles in the foil cover and/or prevent the foil cover from properly adhering to the shell. These conditions can create undesired channels or pathways between the foil and bowl that can permit the aqueous solution to leak out of the blister package or contaminants to infiltrate the lens area.
[0007] Accordingly, needs exist for improvements to contact lens packaging systems that promote good, i.e., hermetic, seals between the cover and plastic shell of a blister package. The present invention is directed to these needs and others in the manner described below.
SUMMARY
[0008] The present invention relates to a system and method for absorbently removing (such as by absorbent blotting) of extraneous liquid from the rim or sealing area of a contact lens package prior to sealing it, so as to promote adhesion of the foil cover to the rim when the package is sealed. In some embodiments of the invention, an absorbent blotter may be moved into contact with the rim of a contact lens package. In other embodiments, the contact lens package may be moved into contact with an absorbent blotter. In still other embodiments, both the contact lens package and absorbent blotter can move. For example, a conveyor can advance the contact lens packages toward a blotting position. In coordination with the advancement of a contact lens package into the blotting position, an actuator can extend the absorbent blotter into contact with the rim.
[0009] In some embodiments, the system can include a liquid-detecting sub-system for detecting moisture or a droplet on the rim and trigger the blotting or absorbent removing of liquid to occur only when such liquid is detected.
[0010] In some embodiments, the system can include a dryer subsystem for removing liquid from the absorbent blotter. The dryer can include a vacuum for removing liquid by suction. Alternatively or in addition, heating, wiping, squeezing, or other means for removing liquid from the absorbent blotter can be employed.
[0011] These and other aspects, features and advantages of the invention will be understood with reference to the drawing figures and detailed description herein, and will be realized by means of the various elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following brief description of the drawings and detailed description of embodiments of the invention are exemplary and explanatory only, and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a side elevation view of a blister pack in accordance with the prior art, showing the foil cover over the rim of the shell.
[0013] FIG. 2 is a top view of a strip of blister pack shells in accordance with the prior art.
[0014] FIG. 3 is a side elevation view of an absorbent system for blotting or wicking extraneous liquid from contact lens packages, such as the blister pack shells of FIG. 1 , prior to sealing the package, showing the system in a first position, in accordance with one exemplary embodiment of the invention.
[0015] FIG. 4 is similar to FIG. 3 and shows the system in a second position, as it blots contact lens packages.
[0016] FIG. 5 is a side elevation view of another absorbent system for blotting or wicking or otherwise absorbently removing extraneous liquid from a contact lens package prior to sealing the package, in accordance with another exemplary embodiment of the invention.
[0017] FIG. 6 is a side elevation view of a portion of FIG. 5 , enlarged to show the ribbon-shaped absorbent blotter in contact with contact lens packages.
[0018] FIG. 7 is a side elevation view of a portion of an absorbent blotter, showing an exemplary layered construction.
[0019] FIG. 8 is a side elevation view of still another absorbent system for blotting or wicking or otherwise absorbently removing extraneous liquid from a contact lens package prior to sealing the package, showing the system in a first position, in accordance with still another exemplary embodiment of the invention.
[0020] FIG. 9 is similar to FIG. 8 and shows the system in a second position, as it blots a contact lens package.
[0021] FIG. 10 is a flow diagram, illustrating a method for blotting or wicking or otherwise absorbently removing extraneous liquid from a contact lens package prior to sealing it.
[0022] FIG. 11 is a flow diagram, illustrating sub-steps of the method of FIG. 10 .
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0023] The present invention may be understood more readily by reference to the following detailed description of the invention taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention.
[0024] Also, as used in this specification (“herein”) including the appended claims, the singular forms “a,” “an”, and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. With regard to specific combinations of elements described herein, such elements can alternatively be combined in any other suitable manner with each other or with still other elements, and some elements can be omitted, or portions of the elements combined together with portions of other elements to form elements that differ from those specifically described. With regard to specific method steps described herein, unless otherwise stated, the steps can alternatively be performed in sequences other than those specifically described, and some steps can be omitted, or portions of the steps combined together to form steps that differ from those specifically described. Persons skilled in the art to which the invention relates will appreciate that the invention encompasses such alternatives.
[0025] As illustrated in FIG. 3 , a conveyor has a moving portion 18 (e.g., a belt) that carries contact lens package shells 12 in a direction, indicated by an axis 20 and corresponding arrows, toward a position where successive shells 12 are blotted as described below. Shells 12 are carried in a carrier tray 22 on conveyor moving portion 18 . Carrier tray 22 can be of any suitable design, such as the conventional type commonly used in contact lens manufacturing to carry such shells 12 from one machine or process station to another. For example, such conveyors are commonly used to move a shell 12 from a station at which the lens is placed in the bowl-shaped depression or cavity 13 ( FIG. 1 ) to a station at which the cavity 13 is filled with the aqueous solution, etc. Each carrier tray 22 carries, for example, a conventional strip of five shells 12 (see FIG. 2 ). The cavities 13 of shells 12 that arrive at the system of FIG. 3 from such previous stations in the manufacturing process have been filled with a contact lens and the aqueous solution at previous stations (not shown for purposes of clarity). Accordingly, it is possible that during the filling step some of the solution may have splashed upon or otherwise undesirably become disposed upon the rim or area immediately surrounding cavity 13 (sometimes also referred to in the art as the sealing area, as it is this area to which foil cover 14 ( FIG. 1 ) is to be adhered).
[0026] In the embodiment illustrated in FIG. 3 , an actuator subsystem 24 , which can operate electrically, pneumatically or in any other suitable manner, has a piston-like member 26 with a pad-shaped absorbent blotter 28 attached to its distal end. The term “blotter” is used herein to mean a piece of absorbent material of a suitable size and shape to absorb or wick (e.g., through capillary action) moisture, droplets or other liquid from the rim or sealing area of shell 12 . The term “blotting” is used herein to mean the absorbent or wicking action of a piece of absorbent material to remove liquid. As illustrated in FIG. 4 , when actuator subsystem 24 is activated, it causes member 26 to extend downwardly, i.e., perpendicularly to axis 20 , (or, alternatively, in other embodiments it could extend in another suitable direction) in a piston-like manner until absorbent blotter 28 contacts the rim of the shell 12 that the conveyor has positioned beneath absorbent blotter 28 , or at least until the blotter contacts a droplet in the sealing area to wick the droplet off of the shell (at the “blotting position”). The contact between absorbent blotter 28 and the rim causes liquid on the rim to be drawn into absorbent blotter 28 by absorption or capillary action. Desirably most or substantially all of such liquid is drawn into the absorbent blotter 28 . After this blotting has been performed, actuator subsystem 24 lifts member 26 or otherwise causes it to retract. The conveyor then advances the next shell 12 to be blotted into the blotting position, and advances the shell 12 that has just been blotted out of the blotting position, in the direction indicated by the arrows and axis 20 in FIGS. 3-4 . Persons skilled in the art to which the invention relates will appreciate that the actuator mechanism of subsystem 24 can operate in any suitable manner known in the art. For example, in other embodiments it can passively allow gravity to drop absorbent blotter 28 and then actively retract it after blotting. Also, although in the illustrated embodiment, the actuator mechanism moves in a linear manner, in other embodiments it can move in any other suitable manner, such as by rotating an absorbent blotter or portion thereof into contact with a shell 12 in a rotary manner.
[0027] Actuator subsystem 24 optionally includes suitable control electronics that control its activation, and/or can be linked to the operation of other components of the production system. For example, it can activate each time the conveyor advances another shell 12 into the blotting position. Alternatively, it can activate only in response to detection of liquid on the rim of the shell 12 . The liquid detector can comprise a suitable camera system 30 and associated electronic image processing circuitry in subsystem 24 . When the liquid detector detects liquid on the rim of a shell 12 , it signals the actuator to blot that shell 12 in the manner described above.
[0028] A dryer subsystem 32 can also be included for removing liquid from absorbent blotter 28 . Dryer subsystem 32 can comprise, for example, a vacuum or suction pump (not separately shown) that draws liquid by suction from absorbent blotter 28 and deposits the liquid in a collection vessel for disposal. In such an embodiment, the distal portion of member 26 can be a hollow cylinder or have an internal passage, such that the distal end of the cylinder acts as a suction nozzle against the absorbent blotter 28 attached to it. A suitable hose 34 or other conduit can couple the vacuum pump in dryer subsystem 32 to the member interior or passage. Dryer subsystem 32 can include suitable control electronics, in electronic communication with actuator subsystem 24 , to control when the vacuum is activated. For example, it can be activated each time a shell 12 is blotted. Alternatively, it could be activated on a timed basis, such as every few minutes, or on any other suitable basis. It can be activated while a shell 12 is being blotted or, alternatively, between blotting one shell 12 and the next. In other embodiments, the dryer can use means for removing liquid other than or in addition to suction (vacuum), such as heat and/or a fan or blower.
[0029] As illustrated in FIG. 5 , in another exemplary embodiment, the moving portion 36 of a conveyor like that described above with regard to FIGS. 3-4 carries shells 12 in carrier trays 38 in the direction indicated by an axis 40 and corresponding arrows, toward a blotting position where shells 12 are blotted by a ribbon-like absorbent blotter 42 . Absorbent blotter 42 is wound about two reels 44 and 46 and guided by suitable guide rollers 48 toward the blotting position. Reel 44 is a supply reel on which a supply of absorbent blotter ribbon 42 is wound in preparation for operation. Reel 46 is a take-up reel that accepts absorbent blotter 42 after having been used in blotting. A suitable actuator 50 drives take-up reel 46 or otherwise causes absorbent blotter 42 to unwind from supply reel 44 , move through the blotting position between reels 44 and 46 , and become wound about take-up reel 46 . Successive shells 12 , carried on trays 38 (e.g., five to a tray), move in coordination with this movement of absorbent blotter 42 such that they successively come into contact with absorbent blotter 42 in an essentially continuous blotting process. The blotter ribbon may be advanced with each successive shell, after blotting a set number of shells, after reaching a predetermined level of moisture saturation, or according to some other protocol. After blotting, shells 12 similarly continue moving in the same direction (e.g., toward another station or process step, as described further below). Note that, alternatively, actuator 50 could be omitted in an embodiment in which absorbent blotter 42 is passively driven by the frictional contact with the rims of shells 12 . In the depicted embodiment, the blotter ribbon advances in a direction parallel to the conveyor direction. In alternate embodiments, the blotter ribbon advances crosswise or perpendicular to the conveyor direction, or obliquely thereto.
[0030] A dryer subsystem 52 , like that described above with regard to FIGS. 3-4 , can also be included in the embodiment shown in FIG. 5 for removing liquid from absorbent blotter 42 . Accordingly, a nozzle or similar portion 54 abuts absorbent blotter 42 and is coupled via a suitable hose 56 or other conduit to the vacuum pump (not separately shown) in dryer subsystem 52 . Although portion 54 is shown as abutting absorbent blotter 42 outside of the blotting position, alternatively, it could be disposed inside the blotting position, abutting the surface of absorbent blotter 42 opposite that which contacts shells 12 . In alternate embodiments, the blotter ribbon forms a continuous loop, with successive portions being dried between blotting sequences.
[0031] A portion of the blotting position described above with regard to FIG. 5 is shown in enlarged form in FIG. 6 (with carrier tray 38 shown in dashed line for clarity), showing how absorbent blotter 42 contacts a number of the rims of successive shells 12 to blot them of liquid. The blotting position and blotting action for the embodiment shown in FIGS. 3-4 are essentially the same as in this embodiment ( FIGS. 5-6 ), but the blotting position covers only a single shell 12 in FIGS. 3-4 whereas the blotting position may cover several shells 12 in this embodiment. Note that features of carrier trays 38 , which can be of any suitable conventional design, such as indexing pins and receptacles for seating shells 12 , are not shown in any figure for purposes of clarity.
[0032] Absorbent blotter 42 is shown in further detail in FIG. 7 . Note that it can comprise more than one layer, such as an upper layer 58 of non-woven polyester fiber matting bonded to a lower layer 60 (i.e., the layer that contacts shells 12 ) of non-woven ultra-high molecular weight (UHMW) super-absorbent polyester fiber matting. These materials and layered structure are intended only to be exemplary, and persons skilled in the art to which the invention relates will recognize many other suitable materials and arrangements of one or more layers, in view of the teachings herein. Absorbent blotters included in the other embodiments described herein can similarly have any such suitable structure.
[0033] As illustrated in FIGS. 8-9 , another embodiment can be similar to that described above with regard to FIG. 5 but which, rather than continuously blotting successive shells 12 as they pass through a multi-shell blotting position, blots shells 12 individually at a single-shell blotting position. The moving portion 62 of a conveyor like that described above with regard to FIGS. 3-5 carries shells 12 in trays 64 in the direction indicated by an axis 66 and corresponding arrows, toward a blotting position where shells 12 are blotted by a ribbon-like absorbent blotter 68 . Absorbent blotter 68 is wound about supply and take-up reels 70 and 72 and guided by suitable guide rollers 74 in the same manner as described above with regard to FIG. 5 . A suitable actuator 76 drives take-up reel 72 or otherwise causes absorbent blotter 42 to unwind from supply reel 70 , move through the blotting position, and become wound about take-up reel 72 .
[0034] In some embodiments, movement of the conveyor is indexed, and blotting occurs only when the conveyor halts movement of shells 12 , with a shell 12 in the blotting position. In other embodiments, movement of the conveyor is continuous, and the blotting actuation is timed to the conveyor movement. As in the embodiment of FIGS. 3-4 , an actuator subsystem 78 , which can operate electrically, pneumatically or in any other suitable manner, has a piston-like member 80 . Note in FIG. 8 that absorbent blotter 68 is spaced from (and held taut above) the rims of shells 12 before blotting. Then, as illustrated in FIG. 9 , when actuator subsystem 78 is activated, it causes member 80 to extend downwardly, i.e., perpendicularly to axis 66 , (or, alternatively, in other embodiments it could extend in another suitable direction) in a piston-like manner, and urge a portion of absorbent blotter 68 into contact with the rim of the shell 12 that the conveyor has positioned beneath member 80 at the blotting position, or at least into wicking contact with any droplets thereon. The contact between absorbent blotter 68 and the rim or droplets thereon causes any liquid on the rim to be drawn into absorbent blotter 68 by absorption or capillary (wicking) action. After this blotting has been performed, actuator subsystem 78 lifts member 80 or otherwise cause it to retract. The conveyor then advances the next shell 12 to be blotted into the blotting position, and advances the shell 12 that has just been blotted out of the blotting position.
[0035] Actuator subsystem 78 includes suitable control electronics that control when it activates. For example, it can activate each time the conveyor advances another shell into the blotting position. Alternatively, it can activate only in response to detection of liquid on the rim of the shell 12 . The liquid detector can comprise a suitable camera system 82 and associated electronic image processing circuitry in actuator subsystem 78 . When the liquid detector detects liquid on the rim of the shell 12 then in the blotting position, it signals the actuator to blot the shell 12 in the manner described above. Following blotting, the actuator 76 that drives take-up reel 72 can be signaled to advance absorbent blotter 68 by a suitable amount, such as the length of a single shell 12 (“shell spacing”). Actuators 76 and 78 can thus operate to advance both shells 12 and absorbent blotter 68 in such a coordinated or synchronized manner.
[0036] A dryer subsystem 84 , like that described above with regard to FIGS. 3-5 , can also be included in the embodiment shown in FIGS. 8-9 for removing liquid from absorbent blotter 68 . Accordingly, a nozzle or similar portion 86 abuts absorbent blotter 68 at a suitable position along its length and is coupled via a suitable hose 88 or other conduit to the vacuum pump (not separately shown) in dryer subsystem 84 .
[0037] Although only single-conveyor systems are described above for purposes of clarity, it should be understood that the system can include multiple conveyors and blotting systems operating in parallel.
[0038] As illustrated in FIGS. 10-11 , an exemplary method for removing extraneous liquid using the systems described above can be performed in conjunction with one or more of the process steps or stations of a conventional contact lens manufacturing process line. As these steps are performed, shells 12 are carried in the carrier trays in the manner described above, or otherwise conveyed through the stations or machines at which the process steps are performed. First, the conventional steps 90 and 92 of placing a contact lens (not shown) into a shell cavity and filling the cavity with aqueous solution, respectively, are performed. The steps can be performed continuously, such that successive shells 12 are filled as they pass through the lens placement and solution-filling stations (not shown). At step 94 , the filled shells 12 are optionally conveyed into a station (not shown) that uses ultrasonic vibration to remove any bubbles in the solution, as such bubbles could interfere with optical inspection of the lenses at a subsequent station. Although the ultrasonic bubble remover station is conventional, it is contemplated that the blotting station can be integrated with this station in a suitable manner. Thus, at step 96 , the shells 12 can optionally be blotted in the manner described above in conjunction with vibrational bubble removal.
[0039] As described above, and with further reference to FIG. 11 , the blotting step 96 can comprise sub-steps 98 , 100 , and 102 of, respectively: detecting whether there is any liquid on the rim of a shell; bringing the shell and a portion of the absorbent blotter into contact with one another if liquid is detected; and applying a vacuum or otherwise drying a portion of the absorbent blotter to remove some of the liquid. As noted above, the steps can be performed in any suitable order and at any suitable time with respect to each other and other steps.
[0040] Following bubble removal, the conventional step 104 of optically inspecting each lens by imaging the lens through the cavity area of shell 12 using a camera and image-processing equipment (not shown) can be performed.
[0041] At step 106 , shells 12 arrive at a station (not shown) that places the above-described foil covers 14 (see FIG. 1 ) on them and, at step 108 , seals each cover to the rim in a conventional manner, such as by applying a heat-sealing plate (not shown). The likelihood that a good seal will result is increased because the extraneous liquid is removed, as are contaminants or debris that may have become disposed upon the rims during the filling or other steps described above.
[0042] While the invention has been described with reference to preferred and example embodiments, it will be understood by those skilled in the art that a variety of modifications, additions and deletions are within the scope of the invention, as defined by the following claims. With regard to the claims, no claim is intended to invoke the sixth paragraph of 35 U.S.C. Section 112 unless it includes the term “means for” followed by a participle. | Extraneous liquid is absorbently removed from the rim or sealing area of a contact lens package prior to sealing it, so as to promote good adhesion of the foil cover to the rim when the package is sealed. As the package moves through the system, the package rim and an absorbent blotter are moved into contact with one another. The blotter absorbs any extraneous liquid on the rim. A vacuum or other dryer can be included to further remove the absorbed liquid from the blotter. | 1 |
BACKGROUND AND SUMMARY OF THE INVENTION
[0001] This invention relates to a transfer switch and, more particularly, to a separately-derived transfer switch having a lockout sequencing arrangement that sequences manual switching of a load between power supplies to prevent open neutral transients during the switching.
[0002] In an electrical supply system, there are occasions when an alternate source of electric power is necessary or desirable. For example, the capability of switching from utility power to emergency generator power is important for businesses, hospitals and industries, and is also employed in residential applications.
[0003] It is desirable for separate electrical circuits, or separate groups of electrical circuits, to be arranged so that when one group of circuits is switched to a conductive state, another group of circuits is switched to a non-conductive state so as to prevent power supply to the circuits from two different power sources at the same time, e.g. from both a utility power supply and a generator power supply. In an arrangement such as this, a switch is typically provided for each power source to control the supply of electrical power. Accordingly, it is important to ensure that the switches are prevented from both being in the ON position at the same time, to ensure that power is supplied to the switch from only one power source.
[0004] To this end, switch interlocks have been developed that are designed to prevent simultaneous connection of circuits to two different power sources, such as described in U.S. Pat. No. 6,096,986, the disclosure of which is incorporated herein and assigned to the assignee of the present application. For some transfer switches, providing linkages that prevent the inadvertent switching of circuits to two power supplies is sufficient. However, for some types of transfer switches, more than an interlock is needed. For instance, if a separately-derived transfer switch is not properly switched, open neutral switching transients may be introduced.
[0005] The present invention is directed to a sequencing lockout arrangement for use with a separately-derived transfer switch that sequences manual switching of main and generator side switches to prevent the introduction of open neutral switching transients. A separately-derived transfer switch typically includes a utility mains switch or breaker and a utility mains neutral switch as well as a generator mains switch or breaker and a generator mains neutral switch. In one embodiment of the present invention, two slidable lockout sequencers together with a rocker lockout functions to sequence switching of a load from one power source to another power source. In this embodiment, seven separate operations must be performed to switch the load between power sources. In another embodiment, the utility mains neutral and generator mains neutral switches are linked together such that switching of the utility mains neutral to a conductive position automatically switches the generator mains neutral switch to a non-conductive position, and vice-versa. In this embodiment, five separate operations are required to switch a load between power sources.
[0006] The slidable lockout sequencers together with the rocker lockout in the first-mentioned embodiment allow only one of the utility mains breaker, the utility mains neutral switch, the generator mains breaker, and the generator mains neutral switch to be switched at a time. Moreover, the lockout sequencers and the rocker lockout cooperate such that a pre-defined order or sequence of the one-at-a-time switching must be followed to switch a load from one power source to another. The slidable lockout sequencers similarly define the sequence of switching with the interlinked neutral switches of the second-mentioned embodiment. Thus, in both embodiments, the slidable lockout sequencers provide limited and ordered switching of the utility and generator switches.
[0007] Thus, it is one object of the present invention to provide a lockout arrangement for use with a separately-derived transfer switch that is operable to prevent open neutral switching transients.
[0008] It is another object of the present invention to provide a separately-derived transfer switch having a pair of slidable members that restrict movement of switch handles such that a load is switched from one power source to another in a pre-defined, unalterable sequence.
[0009] In accordance with one aspect of the present invention, these and other objects are achieved with a lockout arrangement for use with a separately-derived transfer switch having a mains switch, a generator switch, a mains neutral switch, and a generator neutral switch. The lockout arrangement includes a neutral interlock associated with the mains neutral switch and the generator neutral switch, and configured to prevent both neutral switches from being in a conductive position simultaneously. The neutral interlock includes a first bracket engaged with the mains neutral switch and a second bracket engaged with the generator neutral switch. The brackets are adapted to move in response to movement of a neutral switch. The lockout arrangement further includes a first interlock configured to engage the first bracket to prevent movement of the first bracket, and a second interlock configured engage the second bracket to prevent movement of the second bracket. The first and second interlocks are arranged such that the interlocks cannot be engaged with their respective brackets simultaneously.
[0010] In accordance with another aspect, the invention is directed to a separately-derived transfer switch having a first mains switch associated with a first power supply and a second mains switch associated with a second power supply. The transfer switch further includes a first neutral switch and a second mains neutral switch associated with the first and the second power supplies, respectively. A lockout sequencing arrangement has a first lockout that restricts simultaneous switching of the first and the second neutral switch and further includes a second lockout configured to engage the first lockout to restrict movement of the first lockout when the first main switch is a conductive position, and a third lockout configured to engage the first lockout to restrict movement of the first lockout when the second main switch is in a conductive position.
[0011] The present invention may also be embodied in a method of disconnecting a load from a utility power supply and connecting the load to a generator. The method includes switching a mains switch from an ON position to an OFF position. The method continues with disengaging a mains side lockout from engagement with a neutral switch assembly lockout to allow movement of a mains neutral switch and a generator neutral switch. The method further includes switching, in tandem, the mains neutral switch from an ON position to an OFF position and the generator neutral switch from an OFF position to an ON position. In addition, the method includes engaging a generator side lockout with the neutral switch assembly lockout to prevent switching of the mains neutral switch and the generator neutral switch, and switching a generator switch from an OFF position to an ON position The above series of steps may be performed in a reverse order to disconnect the load from the generator and to connect the load to the utility power supply.
[0012] Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The drawings illustrate the best mode presently contemplated of carrying out the invention.
[0014] In the drawings:
[0015] FIG. 1 is a front elevation view of a transfer panel containing a utility mains breaker, a utility mains neutral switch, a generator mains breaker, and a generator mains neutral switch together with a lockout arrangement containing two slidable lockout sequencers and a rocker lockout according to one embodiment of the present invention and shown with the utility mains breaker and the mains neutral switch in an ON position and the generator mains breaker and the generator mains neutral switch in an OFF position;
[0016] FIG. 2 is an enlarged view of the transfer panel of FIG. 1 showing the utility mains breaker and the utility mains neutral switch in the ON position and the generator mains breaker and the generator mains neutral switch in the OFF position;
[0017] FIG. 3 is a front elevation view of the transfer panel shown in FIG. 2 with the utility mains breaker switched to an OFF position;
[0018] FIG. 4 is a front elevation view of the transfer panel shown in FIG. 2 with a mains side lockout sequencer having been slid to free the utility mains neutral switch;
[0019] FIG. 5 is a front elevation view of the transfer panel shown in FIG. 2 with the utility mains breaker and the utility mains neutral switch switched to the OFF position and positioned within a recess formed in the mains side lockout sequencer;
[0020] FIG. 6 is a front elevation view of the transfer panel shown in FIG. 2 with the rocker lockout pivoted upward to block the utility mains neutral switch from being switched to the ON position and to free the generator mains neutral switch;
[0021] FIG. 7 is a front elevation view of the transfer panel shown in FIG. 2 with the generator mains neutral switch shown switched from an OFF position defined within a recess of a generator side lockout sequencer to an ON position;
[0022] FIG. 8 is a front elevation view of the transfer panel shown in FIG. 2 with the generator side lockout sequencer having been slid to free the generator mains breaker;
[0023] FIG. 9 is a front elevation view of the transfer panel shown in FIG. 2 with the generator mains breaker switch moved to the ON position thereby resulting in connection of a load to the generator power supply;
[0024] FIG. 10 is a front enlarged elevation view of a transfer panel similar to that shown in FIG. 2 according to another embodiment of the present invention containing a utility mains breaker, a generator mains breaker, and an interlinked utility mains neutral switch and generator mains neutral switch together with a lockout arrangement containing two slidable lockout sequencers and shown with the utility mains breaker and the mains neutral switch in an ON position and the generator mains breaker and the generator mains neutral switch in an OFF position;
[0025] FIG. 11 is a front elevation view of the transfer panel shown in FIG. 10 with the utility mains breaker switched to an OFF position;
[0026] FIG. 12 is a front elevation view of the transfer panel shown in FIG. 10 with a mains side lockout sequencer having been slid to free the utility mains neutral switch;
[0027] FIG. 13 is a front elevation view of the transfer panel shown in FIG. 10 with the utility mains breaker and the utility mains neutral switch switched to the OFF position and positioned within a recess formed in the mains side lockout sequencer and the generator mains neutral switch switched from the OFF position to the ON position;
[0028] FIG. 14 is a front elevation view of the transfer panel shown in FIG. 10 with the generator side lockout sequencer having been slid to free the generator mains breaker;
[0029] FIG. 15 is a front elevation view of the transfer panel shown in FIG. 10 with the generator mains breaker switch moved to the ON position thereby resulting in connection of a load to the generator power supply;
[0030] FIG. 16 is an isometric view of a lockout assembly according to another aspect of the invention and shown with a portion of an electrical panel having a utility mains breaker switch, a generator mains breaker switch, a utility neutral switch, and a generator neutral switch;
[0031] FIG. 17 is an exploded view of the lockout assembly of FIG. 16 ;
[0032] FIG. 18 is a front elevation view of the lockout assembly of FIG. 16 with the utility mains breaker and the utility neutral switch in conductive ON positions and the generator mains breaker and the generator neutral switch in non-conductive OFF positions;
[0033] FIG. 19 is a front elevation view of the lockout assembly of FIG. 16 with the utility mains breaker in a non-conductive OFF position, the utility neutral switch in the conductive ON position, and the generator mains breaker and the generator neutral switch in non-conductive OFF positions;
[0034] FIG. 20 is a front elevation view of the lockout assembly of FIG. 16 with a first movable interlock moved to clear switching of the neutral switches;
[0035] FIG. 21 is a front elevation view of the lockout assembly of FIG. 16 with the utility mains breaker and the utility neutral switch in non-conductive OFF positions, the generator neutral switch in a conductive ON position, and the generator mains breaker in a non-conductive OFF position;
[0036] FIG. 22 is a front elevation view of the lockout assembly of FIG. 16 with a second movable interlock moved to clear switching of the generator mains breaker; and
[0037] FIG. 23 is a front elevation view of the lockout assembly of FIG. 16 with the utility mains breaker and utility neutral switch in non-conductive OFF positions and the generator mains breaker and the generator neutral switch in conductive ON positions.
DETAILED DESCRIPTION OF THE INVENTION
[0038] FIG. 1 shows a load center assembly 10 according to one embodiment of the present invention, which is configured to supply power to a series of electrical circuits from one of at least two power sources. Representatively, load center assembly 10 controls the supply of power to the electrical circuits from a primary power source, such as utility power, and an alternate or secondary power source, such as an electric generator, which is adapted to supply power in the event power from the primary power source is unavailable. Typically, the alternate or secondary power source is an electric generator, although it is understood that any other source of secondary or alternate power may be employed. The following description utilizes terminology which makes reference in various instances to a generator, and it is understood that such terminology is used for the sake of convenience and that the term “generator” is meant to encompass any secondary or alternate power source, and is not limited to a generator as the alternate power source. Similarly, it is understood that use of the term “utility” is meant to encompass any primary power source, and is not limited to power provided through a utility company power grid.
[0039] Load center assembly 10 includes a cover 12 adapted to be mounted to wall 13 and having a door 14 pivotably connected thereto. Cover 12 includes a series of knockouts constructed to be removed as load breakers 16 are added. In the illustrated embodiment, each of the knockouts has been removed and loaded with breakers 16 . Further, in the illustrated embodiment, the knockouts, and thus breakers 16 , are arranged in two columns, but it is understood that other layouts are possible. A utility mains switch or breaker 18 is constructed to be connected to a utility power input. A generator mains neutral switch 20 , generator mains breaker 22 , and a utility mains neutral switch 24 are constructed to be electrically connected to the respective power sources, as known in the art. The load center assembly 10 further has an interlock assembly 26 that prevents the inadvertent connection of the utility power input via utility mains breaker 18 and generator power input via generator mains breaker 22 from being concurrently connected to the load terminals of the load center assembly 10 . As will be explained, the interlock assembly 26 also controls movement of the neutral switches 20 , 24 to ensure that the breakers and switches are actuated in a predefined sequence.
[0040] Referring now to FIG. 2 , the interlock assembly 26 includes a pair of slidable lockouts 28 , 30 and a centrally positioned rocker lockout 32 . Lockout 28 is associated with the utility mains breaker 18 and the utility mains neutral switch 24 , and thus will be referred to as “utility side lockout” whereas lockout 30 is associated with the generator mains breaker 22 and the generator mains neutral switch 20 , and thus will be referred to as “generator side lockout”.
[0041] The utility side lockout 28 includes a header 34 , a shorted base 36 , a first leg 38 , and a second shortened leg 40 . It is understood that the lockout 28 may fabricated as a single unitary body or the header 34 , base 36 , and legs 38 , 40 may be fastened together using conventional fasteners. The first leg 38 includes first and second slots 42 , 44 that are vertically spaced from and aligned with one another. Respective alignment pins 46 , 48 extend through the openings and define a range of motion for the utility side lockout 28 . The arrangement of the header 34 , shortened base 36 , leg 38 , and shortened leg 40 collectively define a recess 50 sized to receive the handles 52 and 54 of the utility mains breaker 18 and the utility mains neutral switch 24 , respectively.
[0042] The generator side lockout 30 is similar in construction to the utility side lockout 28 . The generator side lockout 30 includes a header 56 , a shorted base 58 , a first leg 60 , and a second shortened leg 62 . It is understood that the lockout 30 may also be fabricated as a single unitary body or the header 56 , base 58 , and legs 60 , 62 may be fastened together using conventional fasteners. The first leg 60 includes first and second slots 64 , 66 that are vertically spaced from and aligned with one another. Respective alignment pins 68 , 70 extend through the openings and define a range of motion for the utility side lockout 30 . In addition, the alignment pins 68 and 70 are aligned with pins 46 and 48 , respectively. The lockout 30 also includes a recess 72 sized to receive the handles 74 and 76 of the generator mains breaker 22 and the generator mains neutral switch 20 , respectively.
[0043] The rocker lockout 32 includes a rocker body 78 that is positioned generally between utility mains neutral switch 24 and the generator mains neutral switch 20 . The rocker body 78 is coupled to a pivot pin 80 in a manner that allows the rocker body to be pivoted. Ears 82 , 84 extend from the rocker body 78 and as will be explained limit the range of motion of the rocker lockout 32 . The ears 82 , 84 may be integrally formed with the rocker body 78 or may be separate components that are fastened to the rocker body 78 in a conventional manner.
[0044] In FIG. 2 , the utility mains breaker switch handle 52 and the utility mains neutral switch handle 54 are both in the ON position and the generator mains breaker handle 74 and the generator mains neutral switch handle 76 are in the OFF position. When the breakers and switches are in this position, the load circuits of the load center assembly 10 are electrically connected to the utility power source. The interlock arrangement 26 is constructed and associated with the breakers and switch handles such that generator side handles 74 , 76 cannot be moved to their ON positions when the utility side handles 52 , 54 are in the ON position. Moreover, the utility mains neutral switch handle 54 is blocked from being moved to the OFF position by the shortened base 36 of the generator side lockout 28 . For the utility mains neutral switch handle 54 to be in the ON position shown in FIG. 2 , the rocker lockout 32 must be pivoted counterclockwise. This movement is only possible if the generator mains neutral switch handle 76 is in the OFF position. In addition, once the rocker lockout 32 is pivoted to the position shown in FIG. 2 , the generator mains neutral switch handle 76 cannot be switched from the OFF position to the ON position.
[0045] The interlock assembly 26 forces an operator to complete a seven step sequence to manually disconnect the load center from one power source and connect it to the other power source. The seven step sequence for disconnecting the load center from the utility power source and connecting it to the generator is shown in FIGS. 3 through 10 .
[0046] In the first step, shown in FIG. 3 , the utility mains breaker handle 52 is moved outwardly in the direction of arrow 86 from the ON position to the OFF position. As a result of this outward movement, the switch handle 52 is moved to a position within recess 50 of the utility side lockout 28 . Additionally, as a result of this movement, the switch handle 52 no longer blocks downward movement of the lockout 28 . More specifically, when the switch handle 52 is in the ON position, FIG. 2 , the shorted leg 40 of the lockout 28 is generally adjacent the switch handle 52 . As a result, the lockout 28 cannot be slid downward along arrow 88 , shown in FIG. 4 .
[0047] In step 2 , downward movement of the generator side lockout 28 causes the shorted leg 40 to move adjacent the utility mains breaker handle 52 , as shown in FIG. 4 . In this position, the switch handle 52 cannot be moved back to its ON position until the lockout 28 is slid upward. In addition, as shown in FIG. 4 , the shortened base 36 of the lockout 28 also slides downward to a position below that of the utility mains neutral switch handle 54 thereby freeing the switch handle 54 to be moved to the OFF position.
[0048] Thus, at step 3 , the utility mains neutral switch handle 54 can be moved outwardly along arrow 90 , as shown in FIG. 5 . In this position, both of the utility side switches 52 , 54 are in the OFF position as are the generator side switch handles 74 , 76 . As such, the electrical loads are not being fed power from either power source.
[0049] In step 4 , shown in FIG. 6 , the rocker lockout 32 must be pivoted clockwise, represented by arrow 92 , to free the generator mains neutral switch handle 76 . This clockwise movement also causes the body 78 of the rocker lockout 32 to move adjacent to the utility mains neutral switch handle 54 , which effectively impedes switching back of the switch handle 54 to its ON position. Additionally, ear 82 of the rocker lockout 32 abuts the lower surface of the shortened leg 40 of the utility side lockout 28 when the rocker lockout is fully pivoted to the position shown in FIG. 6 . This abutment limits further pivoting of the rocker lockout 32 past the desired position.
[0050] With the generator mains neutral switch 76 free by clockwise movement of the rocker lockout 32 , in step 5 , the operator may then move the generator mains neutral switch handle 76 from the OFF position in the direction of arrow 94 to the ON position, as shown in FIG. 7 . As further shown in FIG. 7 , when the generator mains neutral switch handle 74 is moved to the ON position, the generator side lockout 30 is free to slide upwardly. More particularly, when the generator mains neutral switch handle 74 is in the OFF position, the switch handle 74 is adjacent the base 58 of the generator side lockout 30 and therefore impedes upward movement of the lockout 30 .
[0051] In step 6 , the generator side lockout 30 is slid upward in the direction of arrow 96 , as shown in FIG. 8 . As a result of this upward movement, the shorted leg 62 of the lockout 30 that previously was adjacent the generator mains breaker handle 74 is also moved upward away from the switch handle 74 . Similarly, the base 58 of the lockout 30 slides upward to sit adjacent the generator mains neutral switch handle 76 . In this position, the base 58 blocks the switch handle 76 from being moved back to its OFF position.
[0052] In step 7 , shown in FIG. 9 , the generator mains breaker handle 74 is switched from the OFF position to the ON position in the direction of arrow 98 . When the generator mains breaker handle 74 is switched to the ON position, the load center is then electrically connected to the generator power source.
[0053] One skilled in the art will appreciate that the interlock assembly 26 forces an operator to first switch OFF the utility mains breaker, then switch OFF the utility mains neutral switch, then switch ON the generator mains neutral switch, and then switch ON the generator mains breaker to disconnect the load center 10 from the utility power supply and connect it to the generator power supply. The mechanical configuration of the interlock assembly 26 does not allow the sequence to be adjusted by the operator. In addition, one skilled in the art will appreciate that the steps described above are carried out in reverse to disconnect the load center from the generator power source and connect it to the utility power source.
[0054] Referring now to FIG. 10 , an interlock assembly 100 according to another representative embodiment of the present invention is shown. Interlock assembly 100 sequences an operator through five steps to disconnect the load center 10 from one power source and connect it to another power source.
[0055] The interlock assembly 100 includes a pair of slidable lockouts 102 , 104 . Lockout 102 is associated with the utility mains breaker 18 and the utility mains neutral switch 24 , and thus will be referred to as “utility side lockout” whereas lockout 104 is associated with the generator mains breaker 22 and the generator mains neutral switch 20 , and thus will be referred to as “generator side lockout”.
[0056] The utility side lockout 102 includes a header 106 , a shorted base 108 , a first leg 110 , and a second shortened leg 112 . It is understood that the lockout 102 may fabricated as a single unitary body or the header 106 , base 108 , and legs 110 , 112 may be fastened together using conventional fasteners. The first leg 110 includes first and second slots 114 , 116 that are vertically spaced from and aligned with one another. Respective alignment pins 118 , 120 extend through the openings and define a range of motion for the utility side lockout 102 . Further, the arrangement of the header 106 , shortened base 108 , leg 110 , and shortened leg 112 collectively define a recess 122 sized to receive the handles 52 and 54 of the utility mains breaker 18 and the utility mains neutral switch 24 , respectively.
[0057] The generator side lockout 104 is similar in construction to the utility side lockout 102 . The generator side lockout 104 includes a header 124 , a shorted base 126 , a first leg 128 , and a second shortened leg 130 . It is understood that the lockout 104 may also be fabricated as a single unitary body or the header 124 , base 126 , and legs 128 , 130 may be fastened together using conventional fasteners. The first leg 128 includes first and second slots 132 , 134 that are vertically spaced from and aligned with one another. Respective alignment pins 136 , 138 extend through the openings and define a range of motion for the utility side lockout 104 . In addition, the alignment pins 136 and 138 are aligned with pins 118 and 120 , respectively. Further, the lockout 104 also includes a recess 140 sized to receive the handles 74 and 76 of the generator mains breaker 22 and the generator mains neutral switch 20 , respectively.
[0058] The interlock assembly 100 further has an interlinking bar 142 that is connected to the utility mains neutral switch handle 54 and the generator mains neutral switch handle 76 . This interlinking of handles 54 and 76 causes the switch handles to be moved simultaneously. Thus, when handle 54 is switched to the OFF position, switch handle 76 is switched to the ON position, and vice-versa. The interlinking bar 142 represents one known means of interconnecting handles 54 and 75 . It is understood that other types of interlinking configurations may be used and are considered within the scope of the present invention. One such in-line interlinking configuration is shown in U.S. Pat. No. 6,031,193, the disclosure of which is incorporated herein by reference. Another representative interlinking configuration is described in U.S. Pat. No. 6,927,349, the disclosure of which is incorporated herein by reference.
[0059] In general, the interlock assembly 100 is similar to the interlock assembly 26 shown in FIGS. 1 through 9 , with the exception that the rocker lockout has been removed and replaced with the interlinking bar 142 . By interlinking the neutral switch handles 54 , 76 , the number of steps to disconnect the load center from one power source and connect it to another power source, relative to the sequence shown in FIGS. 3 through 9 is reduced by two steps. A five-step sequence for disconnecting the load center 10 from the utility power source to the generator power source will be described with respect to FIGS. 11 through 15 .
[0060] In the first step, shown in FIG. 11 , the utility mains breaker handle 52 is moved outwardly in the direction of arrow 144 from the ON position to the OFF position. As a result of this outward movement, the switch handle 52 is moved to a position within recess 122 of the utility side lockout 102 . Additionally, as a result of this movement, the switch handle 52 no longer blocks downward movement of the lockout 102 . More specifically, when the switch handle 52 is in the ON position, FIG. 10 , the shorted leg 112 of the lockout 102 is generally adjacent the switch handle 52 . As a result, the lockout 102 cannot be slid downward along arrow 146 , shown in FIG. 12 .
[0061] In step 2 , downward movement of the generator side lockout 102 causes the shorted leg 112 to move adjacent the utility mains breaker handle 52 , as shown in FIG. 12 . In this position, the switch handle 52 cannot be moved back to its ON position until the lockout 102 is slid upward. In addition, as shown in FIG. 12 , the shortened base 108 of the lockout 102 also slides downward to a position below that of the utility mains neutral switch handle 54 thereby freeing the switch handle 54 to be moved to the OFF position.
[0062] Thus, at step 3 , the utility mains neutral switch handle 54 is moved outwardly along arrow 148 , as shown in FIG. 13 . In this position, both of the utility side switches 52 , 54 are in the OFF position as are the generator side switch handles 74 , 76 . As such, the electrical loads are not being fed power from either power source. Further, because the utility mains neutral switch handle 54 is interlinked with the generator mains neutral switch handle 76 , movement of the utility neutral switch handle 54 in the direction of arrow 148 automatically causes the generator mains neutral switch handle to move in the direct of arrow 150 from the OFF position, shown in FIG. 10 , to the ON position.
[0063] When the generator mains neutral switch handle 74 is in the ON position, the generator side lockout 104 is freed to slide upwardly. More particularly, when the generator mains neutral switch handle 74 is in the OFF position, the switch handle 74 is adjacent the base 126 of the generator side lockout 104 and therefore impedes upward movement of the lockout 104 .
[0064] In step 4 , the generator side lockout 104 is slid upward in the direction of arrow 152 , as shown in FIG. 14 . As a result of this upward movement, the shorted leg 130 of the lockout 104 that previously was adjacent the generator mains breaker handle 74 is also moved upward away from the switch handle 74 . Similarly, the base 126 of the lockout 104 slides upward and is positioned adjacent the generator mains neutral switch handle 76 . In this position, the base 126 blocks the switch handle 76 from being moved back to its OFF position, which because of the interlinking of the neutral switches 54 and 76 , also prevents the utility mains neutral switch 54 from being switched to the ON position.
[0065] In step 5 , shown in FIG. 15 , the generator mains breaker handle 74 is switched from the OFF position to the ON position in the direction of arrow 154 . When the generator mains breaker handle 74 is switched to the ON position, the load center is then electrically connected to the generator power source.
[0066] One skilled in the art will appreciate that the interlock assembly 100 forces an operator to first switch OFF the utility mains breaker, then switch OFF the utility mains neutral switch, which causes the generator mains neutral switch to be switched to the ON position, and then switch ON the generator mains breaker to disconnect the load center 10 from the utility power supply and connect it to the generator power supply. The mechanical configuration of the interlock assembly 100 does not allow the sequence to be adjusted by the operator. In addition, one skilled in the art will appreciate that the steps described above are carried out in reverse to disconnect the load center from the generator power source and connect it to the utility power source.
[0067] FIG. 16 shows a lockout assembly 162 according to another embodiment of the invention. Similar to the lockout assemblies described previously, lockout assembly 162 sequences switching of a separately-derived transfer switch in a pre-defined and fixed order to electrically disconnect an electrical panel from a primary power source and electrically connect the electrical panel to an alternate or secondary power source, such as an electric generator, and vice-versa. The lockout assembly 162 will be described with respect to a transfer switch apparatus 164 consisting of a utility mains breaker or switch 166 having a switch handle 167 , and a generator mains breaker or switch 168 having a switch handle 169 , that are generally aligned with one another such that a breaker is in a conductive ON position when switched toward the other breaker. Conversely, a breaker is in a non-conductive OFF position when switched away from the other breaker. The utility mains breaker 166 and the generator mains breaker 168 are each double-pole breakers and, as such, each includes a pair of switch members tied together in a manner that is known. The transfer switch apparatus 164 also includes a utility neutral switch 170 having a switch handle 171 , and a generator neutral switch 172 having a switch handle 173 , that are interlinked together so that the switches switch in tandem, as will be described in greater detail below.
[0068] With additional reference to FIG. 17 , the lockout assembly 162 is generally comprised of three separate lockout members 174 , 176 , and 178 that are arranged to define the order by which the transfer switch apparatus can be switched between power sources. Lockout member 174 interlinks the neutral switch 170 , 172 and generally includes brackets 180 and 182 that interface with neutral switches 170 and 172 , respectively. The brackets 180 , 182 have a generally U-shape defined by a generally planar base 184 , 186 and respective pairs of upturned walls 188 , 190 and 192 , 194 . Openings 196 , 198 are formed in planar bases 184 , 186 and are sized to receive the switch handles of neutral switches 170 and 172 , respectively. Additionally, openings 200 , 202 are defined in upturned walls 190 and 194 of brackets 180 and 182 , respectively. A bridging plate 204 is fastened to the planar bases 184 , 186 so as to interlink the two bases. Each switch handle 171 , 173 is configured to receive a pin or dowel 206 , 208 to prevent the planar bases 184 , 186 and the bridging plate 204 from being removed from engagement with the neutral switches 170 , 172 . In addition to interlinking planar bases 184 , 186 , the bridging plate 204 is also used as an actuator. The bridging plate 204 has a depth that is sufficient to engage the switch handles when the neutral switches 170 , 172 are being manually switched. More particularly, when one neutral switch is being switched to the ON position, the switch handle will press against the bridging plate 204 which will then push against the opposite switch thereby causing the other switch to follow the movement of the first-mentioned switch. When a neutral switch is being switched to an OFF position, the bridging plate will pull the bracket for the other neutral switch in the same direction thereby causing the other switch to switch in the same direction, e.g., to its ON position. The bridging plate 204 is fastened to the brackets 180 and 182 by a pair of fasteners 209 .
[0069] As further shown in FIG. 17 , a support bar 210 is located in a channel 211 that extends between the utility mains and the generator mains breaker switch handles as well as the neutral switch handles. In this regard, the support bar 210 is located beneath brackets 180 and 182 of the neutral interlock 174 and does not interfere with operation of the neutral interlock 174 or the neutral switches 170 , 172 . A pair of posts 212 , 214 extend upwardly from the support bar 210 and are generally aligned with one another. A base bar 216 is oriented transversely to the support bar 210 and sits atop the support bar 210 so as to pass through gaps 218 and 220 formed between the tied-together switch handles of the utility mains breaker 166 and the generator mains breaker 168 , respectively.
[0070] An alignment plate 222 having a pair of holes 224 , 226 is positioned atop the base bar 216 and the support bar 210 with the posts 212 , 214 received by holes 224 and 226 , respectively. A screw 228 , or suitable fastener, interconnects the support bar 210 , base bar 216 , and the alignment plate 222 . Lockout member 176 , which includes a slide 230 , is positioned atop the alignment plate 222 and lockout member 178 , which includes a slide 232 , is positioned atop slide 230 . Slide 230 includes an elongated channel 234 that receives posts 212 and 214 and, similarly, slide 232 has an elongated channel 236 that also receives posts 212 and 214 . In this regard, channels 234 and 236 are generally aligned with one another when the lockout assembly 162 is assembled. A retention plate 238 is used to secure the slides 230 and 232 in place, but does so in a manner that allows longitudinal displacement of the slides but prevents lateral displacement of the slides, as will be described. Plate 238 has a pair of holes 240 and 242 that are within the footprint of channels 234 and 236 and align with posts 212 and 214 , respectively. A pair of fasteners 244 and 246 may then be used to secure the retention plate 238 to the posts 212 and 214 without impacting the slidability of the slides 230 and 232 .
[0071] Slides 230 and 232 each have a protruding tab 248 and 250 , respectively, that is designed to be received in a respective one of the openings 200 , 202 of brackets 180 , 182 . When a slide is moved such that its tab is inserted into and received by one of the aforementioned openings, the neutral switches cannot be switched. That is, the slides are permitted to slide longitudinally about posts 212 , 214 but cannot move laterally. In this regard, the slides prevent lateral movement of the brackets 180 , 182 when engaged therewith by tabs 248 , 250 . Each slide 230 , 232 also includes a leg 252 and 254 , respectively. The legs 252 , 254 extend along axes that are perpendicular to that of the tabs and are designed to block switching of the utility mains breaker 166 and the generator mains breaker 168 , respectively, as will be described.
[0072] With reference now to FIGS. 18 through 23 , the aforedescribed lockout assembly 162 and its lockout members 174 , 176 , and 178 , sequences manual switching of the neutral switches and the mains breakers. More particularly, the lockout assembly 162 is designed and the lockouts 174 , 176 , and 178 are arranged such that the loads on the transfer switch may be disconnected from one power source and connected to another power source in five separate and unalterable steps or sequences.
[0073] In FIG. 18 , the utility mains breaker switch handle 167 and the utility neutral switch handle 171 are in the conductive or ON position whereas the generator mains breaker switch handle 169 and the generator neutral switch handle 173 are in the non-conductive or OFF positions. With the switch handles in these positions, the tab 250 of slide 178 is received in opening 200 formed in the upturned wall 190 of bracket 180 . When the opening 200 is aligned with tab 250 so that tab 250 may be received in the opening 200 , opening 202 formed in the upturned wall 194 of bracket 182 is positioned out of alignment with tab 248 of slide 176 . Moreover, the tab 248 is aligned with a solid portion of the upturned wall 194 adjacent the opening 202 . As a result, tab 248 cannot be slid upward. Since the tab 248 cannot be slid upward, the leg 252 of slide 176 cannot be moved to clear switch handle 169 . As such, the leg 252 blocks switching of switch handle 169 to the ON position. Additionally, with the tab 250 received within opening 200 , the neutral switch handles 171 and 173 cannot be switched. As noted above, the switch handles 171 , 173 are interlinked and therefore move in tandem during a switching action. It will thus be appreciated that with the lockout members 174 , 176 , and 178 positioned in the orientations shown in FIG. 18 , the only permitted switch movement is switching of utility mains breaker 166 and, more particularly, switching of switch handle 167 away from switch handle 169 in the direction represented by arrow 256 to the OFF position, as shown in FIG. 19 .
[0074] As shown in FIG. 19 , when the utility mains breaker 166 is switched to the OFF position (step 1 ), the leg 254 of slide 178 is no longer blocked by the switch handle 167 and, as such, the slide 178 may be slid downward in the direction of arrow 258 to withdraw tab 250 from opening 200 (step 2 ), as shown in FIG. 20 . With the slide 178 slid downward to withdraw tab 250 from opening 200 , movement of the brackets 180 , 182 , and thus neutral switches 170 , 172 , is no longer prevented by slide 178 . As such, the neutral switch handle 171 may be moved in the direction of arrow 260 to the OFF position (step 3 ). Since the neutral switch handles 171 , 173 are interlinked by the aforedescribed lockout 174 , switch handle 173 follows movement of switch handle 171 in the direction of arrow 260 to the ON position, as shown in FIG. 21 . Preferably, the neutral switches and the neutral lockout are constructed such that when a switch handle is moved to the OFF position, the opposite switch handle moves to the ON position in tandem but is placed in the ON position slightly after the switch handle is in the OFF position. In this regard, a neutral switch handle is not placed in the ON position until after the opposite neutral switch handle is in the OFF position.
[0075] As a result of the switching of the mains neutral switch handle 171 to the OFF position and the generator neutral switch handle 173 to the ON position, opening 202 of bracket 182 will align with tab 248 of slide 176 . As such, slide 176 may be slid upward in the direction of arrow 262 (step 4 ) to insert tab 248 into opening 202 , as shown in FIG. 22 . When the tab 248 is inserted into the opening 202 , the neutral switches 170 , 172 cannot be moved. Movement of the slide 176 upward also moves its leg 252 upward to free the generator mains breaker 168 so that its switch handle 169 can be moved in the direction of arrow 264 from the OFF position to the ON position (step 5 ) as shown in FIG. 23 .
[0076] One skilled in the art will appreciate that the interlock assembly 162 forces an operator to first switch OFF the utility mains breaker, then switch OFF the utility mains neutral switch, which causes the generator mains neutral switch to be switched to the ON position, and then switch ON the generator mains breaker to disconnect the load center 10 from the utility power supply and connect it to the generator power supply. The mechanical configuration of the interlock assembly 162 does not allow the sequence to be adjusted by the operator. In addition, one skilled in the art will appreciate that the steps described above are carried out in reverse to disconnect the load center from the generator power source and connect it to the utility power source.
[0077] While the embodiments of the invention have been shown and described in connection with manual movement of the various components, it should also be understood that movement of some or all of the components may be accomplished using conventional actuating devices.
[0078] Various alternatives and embodiments are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter regarded as the invention. | An interlock arrangement operatively associated with utility and generator side switches of an electrical panel including a first main switch associated with the first power supply and a second main switch associated with the second power supply. The interlock arrangement includes a first neutral switch associated with the first power supply, and a second neutral switch associated with the second power supply. A lockout sequencer arrangement has a first lockout that restricts simultaneous switching of the first and the second neutral switch, a second lockout configured to engage the first lockout to restrict movement of the first lockout when the first main switch is a conductive position, and a third lockout configured to engage the first lockout to restrict movement of the first lockout when the second main switch is in a conductive position. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to hearing optimization device and hearing optimization method, which are hearing optimization technologies adjustable to hearing characteristic of an individual and his/her hearing situation (including sound environment such as noises), the technologies being designed to be adjustable to hearing of the individual who may be a person with impaired hearing or one with normal hearing, whereby he/she can enjoy clear, comfortable and smooth conversation (including telephone conversation) in any kind of situation.
BACKGROUND OF THE INVENTION
[0002] A various conventional hearing aids, designed for hearing impaired persons, have been proposed. However, hearing differs greatly between individuals, and also it is affected from time to time by other factors such as physical condition of a user and his/her sound environment.
[0003] Solutions have been addressed to aid hearing impairment in such a way that hearing characteristic of an individual hearing impaired user is measured at specific frequency ranges using an audiometer or the like for example, the result being used to calculate preferable correction and output characteristic for a hearing aid, so that the hearing impaired user can select a hearing aid which provides preferable characteristic (by controlling output for specific frequency ranges) to him/her, or he/she can adjust characteristic on the hearing aid. However, such methods have their own limits because of the difficulty to measure hearing impairment condition or such precisely by using a measuring instrument.
[0004] For example, in Japanese published unexamined application No. 2000-165483, because of the possible audible difficulty for a hearing impaired user, a digital phone adjusts its audio output comprising steps including: a step wherein a user parameter, which represents haring spectrum of an individual user, is obtained; a step wherein digital input signal, which represents information heard by a user, is received; a step wherein, in order to generate hearing-adjusted digital signal, digital input signal is adjusted according to the user parameter; and a step wherein analog output signal is generated based on the hearing-adjusted digital signal. However, a special place and highly complicated processes are required in order to obtain hearing characteristic of impaired persons.
[0005] Moreover, individual hearing impaired persons would go to various places in their daily lives, which situation requires correction adjustment over output characteristic of a hearing aid, corresponding to sound environment of the place where the user is in, because hearing characteristic is subject to the present sound environment. However, the fact is that there was no such device which can be easily adjusted to the aforementioned situation.
[0006] Also, hearing is affected by physical condition of an individual and so on, so that correction over the similar output characteristic to that of the last time may not necessarily work out the best even if the sound environment is the same as before.
[0007] Further issue is that hearing is of human aesthesia, so that it is only understood by a hearer and difficult to explain verbally to other people including doctors and specialists. However, in order to measure the hearer's hearing characteristic, his/her personal perception, which cannot be shared with anyone else, needs to be taken out, which is very difficult to do.
[0008] An ideal but not realistic solution is a hearing aid being provided with an equalizer, which can adjust input audio corresponding to each user, place, and time, for each user to adjust at the place and time of use of the device. Very possibly this issue would also suffer persons with normal hearing that in noisy environment voice of other people as well as other sounds are hard to hear, resulting in unsmooth conversation, including telephone conversation.
[0009] Also one of other demands, in audio field including music listening for example, is for preferable acoustic characteristic which can be adjusted by means of adjusting frequency continuously over various frequency ranges of sound source, corresponding to hearing characteristic of an individual, a place or other factors.
[0010] Patent Document1: Japanese published unexamined application No. 2000-165483
DISCLOSURE OF THE INVENTION
Problems to be Solved by the Invention
[0011] There has been a demand for hearing optimization device and method which can be adjusted easily by an individual user corresponding to his/her hearing characteristic of the day, his/her sound environment, and so on. Conventional hearing aids for hearing impaired persons are designed to measure hearing characteristic by using a special measuring device or the like, to adjust output characteristic suited for the hearer. However, as aforementioned, hearing of an individual is not only being accurately understood by the hearer alone but also differs according to his/her physical condition and the place he/she is in. Therefore, conventional technologies have not necessarily been satisfactory.
[0012] Likewise, even persons with normal hearing have sometimes suffered from insufficient voice output of a person on the other side of a mobile phone, or the like, which is used in various outdoor situations, of which usability can be greatly improved if optimized voice output can be heard according to factors such as the place where it is used. Specifically, in noisy environment such as airport or railway station, by easy adjustment to hearing characteristic of the mobile phone user in accordance with his/her sound environment, conversation over mobile phone can be easy in a bad sound environment.
[0013] Particularly, hearing (how a sound is heard) is a perceptive matter, and is neither easy to explain verbally to other people nor measurable without limitation by an equipment, therefore a hearer needs some kind of means he can easily adjust. Such an adjustable means is what easily adjusts a difference between individuals and/or sound environments.
[0014] Moreover, for audio equipment and the like, if there is a continuous adjustment mechanism, more corresponding adjustment to human hearing than before becomes available.
Means of Solving the Problems
[0015] The present invention, in view of the aforementioned conventional drawbacks, provides hearing optimization device and hearing optimization method such as hearing aid and mobile phone, wherein optimization and correction can be easily done corresponding to hearing of each high frequency range and low frequency range without changing output loudness (perceptive sound volume) of audio signal, and further wherein being combined with a user-adjustable technology whereby a hearer can adjust by him/herself while hearing or listening.
[0016] In order to solve the aforementioned issues, the inventors of this present invention have adopted the following means after keen examination. That is, in order for separate gain control of input audio signal according to frequency, the present invention is preliminarily provided with a high boost (high frequency boosting) frequency characteristic reference line (DEFINITION: reference line according to which increase and decrease amount of gain of the original audio signal according to frequency range is determined) for high frequency range enhancement and a low boost (low frequency boosting) frequency characteristic reference line for low frequency range enhancement.
[0017] The present invention is also provided with an audio signal processing and generating means (DEFINITION: means by which, a single frequency is dual distributed, one for high frequency enhancement and the other for low frequency enhancement, each of which references its corresponding frequency characteristic reference line, and generates the original audio signals), whereby the input audio signal is dual distributed, and the two audio signal processings are carried out for the high boost (high frequency boosting) audio signal to enhance a high frequency range according to the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) audio signal to enhance a low frequency range according to the low boost (low frequency boosting) frequency characteristic reference line.
[0018] The present invention is further provided with: the synthesized audio signal output means, wherein the two input audio signals are generated by the audio signal processing and generating means to be used as an audio signal output; and a synchronous adjustment means for the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) frequency characteristic reference line to synchronously adjust the two characteristic reference lines—namely the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) frequency characteristic reference line—by a pair of adjustment means. The high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) frequency characteristic reference lines are crossed at a memorized frequency.
[0019] Synchronous enhancement is carried out by changing inclinations of the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) frequency characteristic reference line, the crossing point being a rotation center. A memorized crossing frequency range for the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) frequency characteristic reference line is between 500 Hz and 2 kHz.
[0020] As aforementioned, the adjustment means, which synchronously adjusts the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) frequency characteristic reference line with each other, adjusts said high boost (high frequency boosting) frequency characteristic reference line and said low boost (low frequency boosting) frequency characteristic reference line in symmetrical inclination to each other, the crossing point being a center where the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) characteristic reference line are crossed with each other at a memorized frequency. In this way, easy simultaneous enhancement is possible by a pair of adjustment means for the high frequency range and the low frequency range.
[0021] Described hereinafter is a method on how to make automatic adjustment. The present invention is provided with: an input audio signal analysis and memory means, whereby the input audio signal is analyzed and input audio situation is memorized; a memory means for input audio situation and inclinations of high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines, which memorizes inclinations of high boost (high frequency boosting) frequency characteristic reference line and low boost (low frequency boosting) frequency characteristic reference line, adjusted by a user using the adjustment means, simultaneously with the input audio signal analysis and memory means; and an automatic adjustment means for inclinations of high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines, whereby the input audio signal is analyzed, and whereby an audio situation pattern similar to that of corresponding input audio situation is selected from the memory means for input audio situation and inclinations of high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines, and whereby inclinations of the high and low boost (high and low frequency boosting) frequency characteristic reference lines are determined without any user adjustment.
[0022] In this way, a user can obtain clear and comfortable audio signal output without any adjustment when he/she is in the same sound environment.
[0023] The automatic inclination adjustment means for the high boost (high frequency boosting) and low boost (low frequency boosting) frequencies reference lines is provided with a learning function, so that optimized inclinations for high boost (high frequency boosting) and low boost (low frequency boosting) characteristic reference lines can be obtained more easily and automatically as memories are accumulated for places where the user is likely to go to. The analysis means to analyze the input audio signal is a frequency analysis means.
[0024] Or possibly, the present invention is provided with: an input audio signal analysis means to analyze the input audio signal and to recognize the input audio situation; and/or a memory means for inclinations of the high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines corresponding to memorized input audio situation, wherein inclinations of the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) characteristic reference line are preliminarily memorized. In this case, inclinations of high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines are memorized, using preliminarily gathered data from average persons with normal hearing, suitable for each memorized sound environment. The analysis means to analyze the audio signal is a frequency analysis means.
[0025] Described hereinbefore is a method on how to simultaneously adjust two frequency characteristic reference lines (high boost (high frequency boosting) and low boost (low frequency boosting)), each for high frequency range and low frequency range. Described hereinafter is about a method on how to enhance core voice frequencies in human conversations.
[0026] The present invention is preliminary provided with: frequency characteristic reference lines in order to gain control an input audio signal according to frequency; and an audio signal processing and generating means to gain control the input audio signal according to the frequency characteristic reference lines.
[0027] The frequency characteristic reference lines are provided with an adjustment means which adjusts inclinations of frequency characteristic reference lines, wherein a reference frequency is a rotation center. The reference frequency range of the rotation center is between 500 Hz and 2 kHz.
[0028] The aforementioned description is about the method on how to automatically adjust a high frequency range and a low frequency range, i.e. the two frequency characteristic reference lines (high boost (high frequency boosting) and low boost (low frequency boosting)), simultaneously.
[0029] Described hereinafter is a method on how to automatically adjust single frequency characteristic reference line. The present invention is provided with: the input audio signal analysis and memory means to analyze the input audio signal and memorize the input audio situation; a memory means for input audio situation and inclinations of frequency characteristic reference lines, whereby inclinations of frequency characteristic reference lines adjusted by a user using the adjustment means are memorized simultaneously with aforementioned input audio signal analysis and memory means; and an automatic adjustment means for inclinations, whereby input audio signal is analyzed, corresponding input audio situation is selected from the memory means for input audio situation and inclinations, and whereby inclinations of the frequency characteristic reference lines are determined without any user adjustment.
[0030] The automatic inclination adjustment means for frequency characteristic reference line is more useful by providing a learning function. The analysis means to analyze the input audio signal is a frequency analysis.
[0031] Or possibly, the present invention is provided with: an input audio signal analysis means to analyze the input audio signal and to recognize input audio situation; and a memory means for inclinations of frequency characteristic reference lines corresponding to input audio situation, whereby inclinations of frequency characteristic reference lines, corresponding to the memorized audio situation, are preliminarily memorized. Just like the aforementioned case of two frequency characteristic reference lines, inclinations of high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines are memorized, using preliminarily gathered data from average persons with normal hearing, suitable for each memorized sound environment. Further likewise, the analysis means to analyze the input audio signal is a frequency analysis means.
[0032] Described hereinafter is a method on how to apply the aforementioned method to hearing aid. This method is applicable to both the former case of two frequency characteristic reference lines (high boost (high frequency boosting) and low boost (low frequency boosting)) and the latter case of single frequency characteristic reference line. The hearing optimization device and the hearing optimization method are applied to hearing aids.
[0033] Also, the adjustment means is controllable independently from an audio signal output adjustment means, wherein the audio signal output adjustment means and the adjustment means are adjusted by the same mechanical adjustment device, and further wherein the mechanical adjustment device is provided with either one of the audio signal output adjustment means, a volume control which selects the adjustment means, or the mechanical adjustment and selection means which controls and selects frequency.
[0034] The hearing aid has a unified construction attached to/in an ear, wherein the adjustment means is provided within the unified construction. Or possibly, the hearing aid is composed of a hearing aid remote control unit and an ear attachment unit, each of the hearing aid remote control unit and the ear attachment unit is provided with a communication means to communicate with each other either by wired or short-range radio communication, the adjustment means being provided within the hearing aid remote control unit.
[0035] Described hereinbefore is an application method to hearing aid.
[0036] Described hereinafter is an application method to communication device including mobile phone. This method is applicable to both the former case of two frequency characteristic reference lines (high boost (high frequency boosting) and low boost (low frequency boosting)) and the latter case of single frequency characteristic reference line. The aforementioned hearing optimization device and the hearing optimization method are applied to a telecommunication means. The telecommunication means is a telephone such as mobile phone and land line, or further can be site-specific telephone equipment such as intercommunication system.
[0037] The hearing optimization device and the telecommunication means are of unified construction, wherein the adjustment means is provided within the unified construction. Or possibly, the hearing optimization device is independent from the telecommunication means, and the hearing optimization device and the telecommunication means are interfaced with a wired or short-range radio communication means.
[0038] Described hereinafter is a further application for use in noisy environments. This method is applicable to both the former case of two frequency characteristic reference lines (high boost (high frequency boosting) and low boost (low frequency boosting)) and the latter case of single frequency characteristic reference line.
[0039] The hearing optimization device and the hearing optimization method are provided with: a background-noise adjustment means which decreases gain of a memorized frequency range of memorized background noises; and a background noise adaptation activation means with which a user can activate the background noise adaptation means over the input audio. In this way, a user can hear in good conditions in noisy environments by using the activation means freely.
[0040] Or possibly, in order to be used in noisy environments, the hearing optimization device and the hearing optimization method is provided with: a background-noise recognition means to measure whether or not any background-noise of a memorized frequency is present; a background-noise adjustment means which decreases gain of a memorized frequency range; and an automatic background-noise muting activation means to activate the background-noise adjustment means when the background-noise recognition means recognizes that there is some noise. In this way, background-noise adaptation is possible when memorized background-noise is identified. A memorized frequency range of the background noises for the background-noise adaptation means is between 20 Hz and 500 Hz, and preferably between 20 Hz and 200 Hz.
[0041] Described hereinafter is an adjustment method, adapted to factors such as personal hearing characteristic or locations, continuously corresponding to various frequency ranges.
[0042] In order for gain control according to frequency of input audio signal, the present invention is preliminarily provided with a high boost (high frequency boosting) frequency characteristic reference line to enhance a high frequency range and a low boost (low frequency boosting) frequency characteristic reference line to enhance a low frequency range, wherein two audio signals are generated by dual distributing the input audio signal, one of the dual distributed input audio signal being used as a high boost (high frequency boosting) audio signal generated by a high boost (high frequency boosting) audio signal processing and generating means to enhance a high frequency range referring to the high boost (high frequency boosting) frequency characteristic reference line, and the other of the dual distributed input audio signal being used as a low boost (low frequency boosting) audio signal generated by a low boost (low frequency boosting) audio signal processing and generating means to enhance a low frequency range referring to the low boost (low frequency boosting) frequency characteristic reference line, and further provided with a synthesized audio signal output means, which makes an output audio signal by synthesizing two audio signals, which are: a high boost (high frequency boosting) audio signal coefficient-multiplying means which multiplies coefficient to adjust a ratio for synthesizing the high boost (high frequency boosting) audio signal with memorized two audio signals; and a low boost (low frequency boosting) audio signal coefficient-multiplying means which multiplies coefficient to adjust a ratio for synthesizing the low boost (low frequency boosting) audio signal with memorized two audio signals.
[0043] Audio signal synthesis becomes available by adjusting ratio of the high boost (high frequency boosting) audio signal and the low boost (low frequency boosting) audio signal in such a way that: the memorized coefficient for the high boost (high frequency boosting) audio signal is set by the high boost (high frequency boosting) coefficient input adjustment means; and, likewise, the memorized coefficient for the low boost (low frequency boosting) audio signal is set by the low boost (low frequency boosting) coefficient input adjustment means. Therefore, it becomes possible to output desired audio signal because the high boost (high frequency boosting) audio signal according to the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) audio signal according to the low boost (low frequency boosting) frequency characteristic reference line are adjustable at any desired ratio.
[0044] The high boost (high frequency boosting) frequency characteristic reference line is provided with an adjustment means for high boost (high frequency boosting) frequency characteristic reference line to adjust its inclination, a memorized frequency being as a rotation center, and the low boost (low frequency boosting) frequency characteristic reference line is provided with an adjustment means for low boost (low frequency boosting) frequency characteristic reference line to adjust its inclination, a memorized frequency being as a rotation center
[0045] The present invention is further provided with: the high boost (high frequency boosting) center position adjustment means to adjust a center position, its rotation center being a memorized frequency for the high boost (high frequency boosting) frequency characteristic reference line; and the low boost (low frequency boosting) center position adjustment means to adjust a center position, its rotation center being a memorized frequency for the low boost (low frequency boosting) frequency characteristic reference line.
[0046] Greater adjustment flexibility is offered if the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) frequency characteristic reference line are adjusted independently from each other. A frequency range of a rotation center of the high boost (high frequency boosting) frequency characteristic reference line is between 1000 Hz and 8000 Hz, and a frequency range of a rotation center of the low boost (low frequency boosting) frequency characteristic reference line is between 400 Hz and 1000 Hz. By arranging this plurality of adjustments, frequency hearing environment becomes adjustable in continuous fashion, which is essential for audio equipments.
[0047] Described further hereinafter is a method, particularly a method to be added to the aforementioned mechanism, to arrange optimized hearing environment corresponding to audio input situation.
[0048] The present invention is provided with: an input audio signal analysis and memory means whereby the input audio signal is analyzed and the input audio situation is memorized; a memory means for input audio situation and inclinations of high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines, whereby inclinations of the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) frequency characteristic reference line, which are adjusted by a user using the adjustment means, are memorized simultaneously with the input audio signal analysis and memory means; and further an automatic adjustment means for inclinations of the high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines, wherein the automatic adjustment means analyzes the input audio signal, and selects corresponding input audio situation from the memory means for input audio situation and inclinations of high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines, and further determines inclinations of the high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines without any user adjustment. In this way, optimized inclination information of high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines is automatically called to arrange hearing status corresponding to input audio.
[0049] The present invention is further provided with: a memory means for input audio situation and rotation center position of high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines to memorize rotation center position which is simultaneously adjusted with inclinations of the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) frequency characteristic reference line; and an automatic adjustment means for rotation center position and inclinations of the high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines, wherein the automatic adjustment means analyzes input audio signal, and selects corresponding input audio situation from the memory means for input audio situation and rotation center position and inclinations of high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines, and further determines rotation center position and inclinations of the high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines without any user adjustment.
[0050] The present invention is further provided with: an input audio signal analysis and memory means, whereby the input audio signal is analyzed and the input audio situation is memorized; a memory means for input audio situation and high boost (high frequency boosting) and low boost (low frequency boosting) coefficients to memorize high boost (high frequency boosting) coefficient and low boost (low frequency boosting) coefficient, which are adjusted by a user using the adjustment means, simultaneously with the input audio signal analysis and memory means; and an automatic adjustment means for high boost (high frequency boosting) and low boost (low frequency boosting) coefficients, whereby an input audio signal is analyzed, and a corresponding input audio situation is selected from the memory means for input audio situation and high boost (high frequency boosting) and low boost (low frequency boosting) coefficients, and the high boost (high frequency boosting) and low boost (low frequency boosting) coefficients are determined without any adjustment by a user. The analysis means to analyze the input audio signal is a frequency analysis means.
[0051] The present invention is provided with: in order for gain control according to frequency of input audio signal, a high boost (high frequency boosting) frequency characteristic reference line to enhance high frequency range and a low boost (low frequency boosting) frequency characteristic reference line to enhance low frequency range; a high boost (high frequency boosting) audio signal processing and generating means, whereby the input audio signal is dual distributed, one of the dual distributed signal refers to the high boost (high frequency boosting) frequency characteristic reference line, controls gain according to frequency, and enhances high frequency range; a low boost (low frequency boosting) audio signal processing and generating means, wherein the high boost (high frequency boosting) audio signal, generated by the aforementioned audio signal processing and generating means, and the other half of the dual distributed input audio signals is gain controlled according to frequency range, and low frequency range is enhanced referring to the aforementioned low boost (low frequency boosting) frequency characteristic reference line, wherein the low boost (low frequency boosting) audio signal generated by the low boost (low frequency boosting) audio signal processing and generating means and the aforementioned high boost (high frequency boosting) audio signal generated by the high boost (high frequency boosting) audio signal processing and generating means are generated; a high boost (high frequency boosting) audio signal coefficient-multiplying means, whereby coefficient-multiplying is carried out to adjust a ratio to synthesize two memorized audio signals with the high boost (high frequency boosting) audio signal; a low boost (low frequency boosting) audio signal coefficient-multiplying means, whereby coefficient-multiplying is carried out to adjust a ratio to synthesize two memorized audio signals with the low boost (low frequency boosting) audio signal; and a synthesized audio signal output means, whereby two audio signals generated by the high boost (high frequency boosting) audio signal coefficient-multiplying means and the low boost (low frequency boosting) acoustic coefficient-multiplying means are synthesized to be used as an audio output.
[0052] The high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) frequency characteristic reference line are provided with: an adjustment means for inclination of high boost (high frequency boosting) frequency characteristic reference line, which adjusts inclination using a memorized frequency as a rotation center; an adjustment means for inclination of low boost (low frequency boosting) frequency characteristic reference line, which adjusts inclination using a memorized frequency as a rotation center; a high boost (high frequency boosting) center position adjustment means, which adjusts center position using a memorized frequency of the high boost (high frequency boosting) frequency characteristic reference line as a rotation center; and a low boost (low frequency boosting) center position adjustment means, which adjusts center position using a memorized frequency of the low boost (low frequency boosting) frequency characteristic reference line as a rotation center.
[0053] Further, it becomes possible to generate continuous audio signal corresponding to a user's hearing, his/her sound environment, and so on by providing the present invention with at least one adjustment means selected from the followings: a high/low boost (high/low frequency boosting) rotation center position adjustment means; a high boost (high frequency boosting) coefficient input adjustment means which adjusts coefficient, to be coefficient-multiplied on the high boost (high frequency boosting) audio signal; or a low boost (low frequency boosting) coefficient input adjustment means which adjusts coefficient, to be coefficient-multiplied on the low boost (low frequency boosting) audio signal.
[0054] The high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) frequency characteristic reference line are adjusted independently from each other. The frequency range of a rotation center of the high boost (high frequency boosting) frequency characteristic reference line is between 1000 Hz and 8000 Hz, and the frequency range of a rotation center of the low boost (low frequency boosting) frequency characteristic reference line is between 400 Hz and 1000 Hz.
[0055] The frequency characteristic reference line can be single. In that case, the present invention is provided with: a frequency characteristic reference line in order for gain control according to frequency of input audio signal; and an audio signal processing and generating means whereby the input audio signal is gain controlled according to frequency referring to the frequency characteristic reference lines.
[0056] The hearing optimization device and the hearing optimization method, whereby audio signal is generated and output by the audio signal processing and generating means, wherein the a frequency range of the reference rotation center is between 500 Hz and 2 kHz, are provided with: an inclination adjustment means for the frequency characteristic reference lines to adjust its inclinations using a reference frequency as a rotation center; and a rotation center position adjustment means which adjusts the rotation center position of the reference frequency.
ADVANTAGEOUS EFFECT OF THE INVENTION
[0057] As described hereinbefore, for hearing aids designed for hearing impaired persons the present invention enables hearing correction corresponding to hearing characteristic of each user without making any complicated adjustment, and moreover, hearing correction is possible with easy adjustment in various places of various sound environments. A user can make optimized hearing correction regardless of time and place because the present invention allows him/her to adjust it easily, independent of his/her hearing condition of the day, his/her location at the moment, etc., according to his/her own hearing perception that only he/she can understand exactly.
[0058] The present invention is also beneficial for a person with normal hearing by allowing him/her clear and comfortable conversation in noisy environment or similar situation—he/she makes optimized correction with easy adjustment on his/her mobile phone etc. according to the location when he/she talks over the phone in various sound environments where various background noises are present. Further, the present invention enables easy and continuous hearing optimization corresponding to various hearings, sound environments, and locations.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0059] The drawings are described in greater detail below.
[0060] FIG. 1 is a schematic block diagram showing an embodiment of the present invention. FIG. 2 shows frequency characteristic reference lines which determine enhancement level of input audio signal according to frequency range.
[0061] In FIG. 1 , the input audio signal is dual distributed to be used for audio signal generation. High frequency enhancing signal processing method is to refer to a high boost (high frequency boosting) frequency reference line 102 , and, by a high boost (high frequency boosting) audio signal processing and generating means 101 , generates high boost (high frequency boosting) audio signal. Low frequency enhancing signal processing method is to refer to a low boost (low frequency boosting) frequency reference line 104 , and, by a low boost (low frequency boosting) audio signal processing and generating means 105 , generates low boost (low frequency boosting) audio signal. Audio signal synthesizing method is to synthesize the generated high boost (high frequency boosting) audio signal and low boost (low frequency boosting) audio signal by a synthesis means 106 for high/low boost (high/low frequency boosting) audio signal to make an audio signal output.
[0062] Adjustment of frequency characteristic reference line is explained here in some details. By using a synchronous adjustment means 103 as shown in FIG. 1 , a user synchronously adjusts the high boost (high frequency boosting) frequency characteristic reference line 102 and the low boost (low frequency boosting) frequency characteristic reference line 104 .
[0063] In an adjustment method as shown in FIG. 2 , preliminarily set high boost (high frequency boosting) frequency characteristic reference line and low boost (low frequency boosting) frequency characteristic reference line are numbered as 201 and 204 respectively.
[0064] In order to increase the inclination by the synchronous adjustment means 103 as shown in FIG. 1 , a user gradually adjusts a high boost (high frequency boosting) frequency characteristic reference line 201 and a low boost (low frequency boosting) frequency characteristic reference line 204 until they reach 202 and 206 respectively, with crossing point 210 being user-adjusted at 1000 Hz as a center point, where each frequency characteristic reference line crosses.
[0065] In order to decrease the inclination by the synchronous adjustment means 103 as shown in FIG. 1 , a user gradually adjusts the low boost (low frequency boosting) frequency characteristic reference line 201 and the low boost (low frequency boosting) frequency characteristic reference line 204 until they reach 203 and 205 respectively, with crossing point 210 being user-adjusted at 1000 Hz as a center point, where each frequency characteristic reference line crosses.
[0066] Now going into details. FIG. 3 is a flow diagram of the foregoing description. First, audio signal input is analog-to-digital converted in 301 as needed, and then the digital audio signal is dual distributed in 302 . One of the dual distributed digital audio signals is used for high boost (high frequency boosting) audio signal generation 303 in a way that high frequency is enhanced referring to high boost (high frequency boosting) frequency characteristic reference line 305 . The other is used for low boost (low frequency boosting) audio signal generation 304 in a way that low frequency is enhanced referring to a low boost (low frequency boosting) frequency characteristic reference line 306 .
[0067] A more detailed explanation is given by using FIG. 2 . Gain is controlled independently according to frequency range, more specifically; gain of digital audio signal is increased or decreased according to the user-adjusted high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines.
[0068] For the high boost (high frequency boosting) frequency characteristic reference line 201 , which enhances high frequency, gain increase will enhance high frequency referring to the high boost (high frequency boosting) characteristic reference line 201 of each frequency range. For example, in frequency range A as displayed in FIG. 2 , gain increase amount ah (between baseline 209 and point 207 on frequency characteristic reference line 201 ) is added to.
[0069] For the low boost (low frequency boosting) frequency characteristic reference line 204 , which enhances low frequency, gain decrease will enhance low frequency referring to the low boost (low frequency boosting) characteristic reference line 204 of each frequency range. For example, in frequency range A as displayed in FIG. 2 , gain decrease amount al (between baseline 209 and point 208 on frequency characteristic reference line 204 ) is decreased from.
[0070] The generated high frequency enhanced high boost (high frequency boosting) audio signal and low frequency enhanced low boost (low frequency boosting) audio signal are synthesized in 307 , digital-to-analog converted in 308 as needed, and output as an audio signal.
[0071] Explained next is a method which requires no adjustment in such a case that surrounding sound environment situation (frequency pattern) is similar to that of preliminarily memorized one. FIG. 4 displays its schematic block diagram. The input audio signal is frequency analyzed by an input audio signal analysis means 401 to be made as an input audio situation (frequency pattern) and through a control means 404 , is memorized in an input audio situation (frequency pattern) and high/low boost (high/low frequency boosting) frequency characteristic reference line inclination memory means 405 . to memorize the input audio situation (frequency pattern), being frequency analyzed by the input audio signal analysis means 401 , in input audio situation (frequency pattern) and the high/low frequency characteristic reference line inclination memory means 405 by the control means 404 .
[0072] In the above mentioned process, audio signal output is made by a high/low boost (high/low frequency boosting) audio signal processing and generating means 406 as aforementioned and as in FIG. 3 , according to inclinations of high boost (high frequency boosting) frequency characteristic reference line and low boost (low frequency boosting) frequency characteristic reference line.
[0073] While listening to the output audio, a user, through a user interface 403 , then by high/low frequency characteristic reference line adjustment means 402 , adjusts inclinations of the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) frequency characteristic reference line, then by the control means 404 , together with an input audio situation (frequency pattern) which is frequency analyzed by the aforementioned input audio signal analysis means 401 , to be memorized in input audio situation (frequency pattern) and the high/low frequency characteristic reference line inclination memory means 405 .
[0074] FIG. 5 shows a flow of memorization into input audio situation (frequency pattern) and high/low boost (high/low frequency boosting) frequency characteristic reference line inclination memory means. Input audio signal is frequency analyzed in an input audio signal analysis 501 to be output as an input audio situation (frequency pattern).
[0075] Output audio, being generated in a high/low boost (high/low frequency boosting) audio signal processing and generating means 502 , is, through a user interface 504 , then by a high/low boost (high/low frequency boosting) frequency characteristic reference line adjustment 503 , adjusting inclinations of the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) frequency characteristic reference line, then by a control means 505 , together with the aforementioned input audio situation (frequency pattern) 501 , memorized in an input audio situation (frequency pattern) and high/low boost (high/low frequency boosting) frequency characteristic reference line inclination memory 506 .
[0076] Described next is a method which makes suitable audio output adapted to the frequency pattern (surrounding sound environment situation) by calling inclinations of high/low boost (high/low frequency boosting) frequency characteristic reference lines from optimum input audio situation (frequency pattern) and high/low frequency characteristic reference line inclination memory means. Input audio signal is frequency analyzed by the input audio signal analysis means 401 in FIG. 4 , to be made as an frequency pattern, and by the control means 404 , examines whether a set of corresponding frequency pattern is being memorized in input audio situation (frequency pattern) and the high/low frequency characteristic reference line inclination memory means 405 , and if there is one, calls and sends to the high/low boost (high/low frequency boosting) audio signal processing and generating means 406 to make an audio output.
[0077] This input audio situation (frequency pattern) and high/low frequency characteristic inclination memory, by being provided with a learning function, automatically adjusts to a user's specific sound environments as he/she continues to use the adjustment function.
[0078] However, an automatically called adjustment may not necessarily fit a user's hearing characteristic. In this case, adjustment is made through the user interface 403 and by the high/low boost (high/low frequency boosting) frequency characteristic reference line adjustment means 402 . The control means 404 monitors whether there is such an adjustment and when there is one, without referring to input audio situation (frequency pattern) and the high/low boost (high/low frequency boosting) frequency characteristic reference line inclination memory means 405 , inclinations of high boost (high frequency boosting) frequency characteristic reference line and low boost (low frequency boosting) frequency characteristic reference line, being adjusted by the high/low boost (high/low frequency boosting) frequency characteristic reference line inclination adjustment means 402 , are forwarded to the high/low boost (high/low frequency boosting) audio signal processing and generating means 406 to be used as an audio signal output.
[0079] In a flow diagram as shown in FIG. 6 , a user, through a user interface 604 , monitors whether a high/low boost (high/low frequency boosting) frequency characteristic reference line adjustment 603 is being activated, and if it is, inclinations of a high boost (high frequency boosting) frequency characteristic reference line and a low boost (low frequency boosting) frequency characteristic reference line, being adjusted in the high/low boost (high/low frequency boosting) frequency characteristic line adjustment 603 , are sent to a high/low boost (high/low frequency boosting) audio signal processing and generating 602 to be used as an audio signal output.
[0080] If a control means 606 , in its monitoring, determines that the high/low boost (high/low frequency boosting) frequency characteristic reference line adjustment 603 is not being made, then input audio signal is frequency analyzed in 601 , the input audio situation (frequency pattern) by the control means 606 and in 605 , searches any corresponding data to this audio situation (frequency pattern), from user-adjusted memories of input audio situation (frequency pattern) and high/low boost (high/low frequency boosting) frequency characteristic reference line inclinations. Called inclinations, if any, of a high boost (high frequency boosting) frequency characteristic reference line and a low boost (low frequency boosting) frequency characteristic reference line are sent to the high/low boost (high/low frequency boosting) frequency audio signal processing and generating 602 to be used as an audio output.
[0081] In this way, adjusted inclinations of high boost (high frequency boosting) frequency characteristic reference line and low boost (low frequency boosting) frequency characteristic reference line for each frequency pattern are memorized, so that if an input audio is similar to any of the preliminarily memorized surrounding sound environment situation (frequency pattern), there is no need for adjustment. Inclinations of high boost (high frequency boosting) frequency characteristic reference line and low boost (low frequency boosting) frequency characteristic reference line, being memorized together with the corresponding surrounding sound environment situation (frequency pattern), are called to be used as an audio output by high/low boost (high/low frequency boosting) audio signal processing and generating means.
[0082] This embodiment requires a user to adjust according to the sound environment he/she is in. However, it is also possible to preliminarily measure and memorize inclinations of high boost (high frequency boosting) frequency characteristic reference line and low boost (low frequency boosting) frequency characteristic reference line by sound environments suited for average persons with normal hearing, and then, when needed, analyze an input audio signal to call inclinations of corresponding high boost (high frequency boosting) characteristic reference line and low boost (low frequency boosting) characteristic reference line.
[0083] Explained next is an application of this embodiment to hearing aid. FIG. 7 is a configuration example. The hearing aid in this example is composed of an ear attachment unit 701 and a hearing aid remote control unit 706 . The two units interface with each other by short range radio communication such as Bluetooth or ZigBee. Communication portions may be wired instead of wireless.
[0084] The ear attachment unit 701 is provided with an audio signal input portion 702 , a processing portion 705 wherein the aforementioned audio signal processing is performed, a communication portion 704 to radio communicate with the remote control unit, and an audio signal output portion 703 . The hearing aid remote control Unit 706 is provided with an adjustment portion 708 to perform adjustment, and a communication portion 707 to communicate with the ear attachment unit. An example of the adjustment portion of a hearing aid is shown in FIG. 8 , which is provided with a function button 801 displayed as F, an up button 802 displayed as UP, and a down button 803 displayed as DWN. Volume is adjustable by UP and DWN buttons.
[0085] The aforementioned frequency adjustment is performed in such ways that holding down the F button and pressing the UP button will increase inclination of frequency characteristic reference line, and holding down the F button and pressing the DWN will decrease inclination of frequency characteristic reference line. FIG. 9 displays a flow of how different functions of the UP and DWN buttons can be activated. Cognition whether the F button is being held down is made in 901 : when it is being held down, the UP and DWN buttons will adjust inclinations of frequency characteristic reference lines to adjust frequency characteristic according to a user's hearing characteristic; and when it is not being held down, the UP and DWN buttons will adjust volume.
[0086] This embodiment provides the audio signal input portion within the ear attachment unit and the adjustment portion within the remote control unit of the hearing aid. However, other configurations of embodiment are possible. For example, all functions may be housed in the ear attachment unit. Any combination may be used unless it is against the spirit of the present invention.
[0087] Explained next is an embodiment for mobile phone, of which configuration is displayed in FIG. 10 . An audio signal from telephone voice output unit 1001 is processed by the aforementioned method. An adjustment portion 1002 adjusts inclination of the frequency characteristic reference lines, adjusts frequency characteristic of a user's hearing characteristic, a processing portion 1003 processes audio signal, and an audio signal output portion 1004 outputs audio signal. Since mobile phones are preinstalled with user input interface, their existing control portions can be assigned with individual adjustment function. As shown in FIG. 11 , the audio signal output is adjusted by volume increase/decrease and/or inclination increase/decrease of high/low boost (high/low frequency boosting) frequency characteristic reference lines. This embodiment is further provided with a noise compression function, which significantly decreases gain of a specific frequency range in order to make human voice frequency range more clearly hearable when the user is in a noisy environment.
[0088] Explained next is a method for noise compression. When a user is on the mobile phone, some environmental background noises may mask the voice of a person who is on the other side of the phone. By compressing these noises the voice of the other party becomes more hearable. FIG. 12 shows about background noise compression, wherein graph (a) displays an audio situation 1201 before background noise compression, whereas graph (b) displays an audio situation after background noise compression, wherein gain of a frequency range between 20 Hz and 300 Hz is decreased to a level numbered as 1202 , the frequency range being where human voice masking noises are on.
[0089] This embodiment activates background noise compression manually by a user, however, it is also available to have it done automatically, i.e., the specific frequency range (between 20 Hz and 300 Hz in this graph) is monitored to activate the compression function automatically when sound pressure exceeds a certain level.
[0090] This embodiment is about the background noise compression for a mobile phone. However, the embodiment is not limited to this particular application but is also applicable to a hearing aid. Further, this embodiment houses an adjustment portion and a processing portion within a mobile phone unit. However, the embodiment is not limited to this particular configuration but is also possible to house the adjustment portion and the processing portion within a headset, or within a set of a microphone and an earphone, for communication with a mobile phone. Or other telephone call applications than a mobile phone, such as a personal computer or the like being connected to an IP phone or other kinds of communication lines, are possible. Any combination may be used unless it is against the spirit of the present invention.
[0091] Explained next is about another embodiment of the present invention. FIG. 13 is a schematic block diagram showing another embodiment of the present invention. FIG. 14 is a graph showing frequency characteristic reference lines in accordance which enhancement level of input audio signal is determined according to a frequency range. As shown in FIG. 13 , signal processing method of input audio signal is to refer to a frequency characteristic reference line 1302 , and then, by a frequency-adjusted audio signal processing and generating means 1301 , to generate audio signal.
[0092] Now explaining about frequency characteristic reference line adjustment, a frequency characteristic reference line 1302 is adjustable by a frequency characteristic reference line adjustment means 1303 as shown in FIG. 13 . As shown in FIG. 14 , a preliminarily set frequency characteristic reference line is numbered as 1401 . In order to increase the inclination by the synchronous adjustment means 1303 as shown in FIG. 13 , a user gradually adjusts the frequency characteristic reference line until it reaches 1402 , with the rotation center 1406 being user-adjusted at 1000 Hz.
[0093] Likewise, in order to decrease the inclination by the synchronous adjustment means 1303 as shown in FIG. 13 , a user adjusts the frequency characteristic reference line until it reaches 1403 , with the rotation center 1406 being user-adjusted at 1000 Hz. Going into details now with FIG. 15 which is a flow diagram of the above mentioned. Input audio is analog-to-digital converted as needed in 1501 , and then the converted digital audio signal is processed in frequency characteristic adjustment audio signal generation 1502 by referring to a frequency characteristic reference line 1504 .
[0094] A more detailed explanation is given by using FIG. 14 . Gain is controlled independently according to frequency range. More specifically, gain of digital audio signal is increased or decreased according to the user-adjusted frequency characteristic reference lines. When a frequency characteristic reference line is being adjusted at 1401 , gain is increased or decreased according to the frequency characteristic reference line 1401 . For example, in frequency range A as displayed in FIG. 14 , gain increase amount a (between baseline 1405 and point 1404 on frequency characteristic reference line 1401 ) is added to. The generated audio signal is then digital-to-analog converted in 1503 as shown in FIG. 15 , as needed, to be output as an audio.
[0095] Explained next is a method which requires no adjustment in such a case that a surrounding sound environment situation (frequency pattern) is similar to that of preliminarily memorized one. FIG. 16 displays its schematic block diagram. Here, input audio signal is frequency analyzed by an input audio signal analysis means 1601 , and an input audio situation (frequency pattern) is, through a control means 1604 , memorized in an input audio situation (frequency pattern) and frequency characteristic reference line inclination memory means 1605 .
[0096] In the above mentioned process, an audio output is made by audio signal generating means 1606 as aforementioned and as in FIG. 15 , according to inclinations of frequency characteristic reference lines.
[0097] While listening to the output audio, a user is, through a user interface 1603 , then by a frequency characteristic reference line adjustment means 1602 , adjusts inclinations of the frequency characteristic reference lines, then by control means 1604 , together with an input audio situation (frequency pattern) which is frequency analyzed by the aforementioned input audio signal analysis means 1601 , to be memorized in input audio situation (frequency pattern) and frequency characteristic reference line inclination memory means 1605 .
[0098] FIG. 17 shows a flow of memorization into input audio situation (frequency pattern) and frequency characteristic reference line inclination memory means. Input audio signal is frequency analyzed in input audio signal analysis 1701 to be output as an input audio signal. Output audio, being generated in audio signal processing and generating 1702 , is, through a user interface 1704 , then by frequency characteristic reference line adjustment 1703 , adjusting inclinations of the frequency characteristic reference lines, then by control means 1705 , together with the aforementioned input audio situation (frequency pattern) 1701 , memorized in an input audio situation (frequency pattern) and frequency characteristic reference line inclination memory means 1706 .
[0099] Described next is a method which makes suitable audio signal output adapted to the surrounding sound environment situation (frequency pattern) by calling inclinations of frequency characteristic reference lines from optimum input audio situation (frequency pattern) and frequency characteristic reference line inclination memory means according to the surrounding sound environment situation.
[0100] Audio input is frequency analyzed by the input audio signal analysis means 1601 in FIG. 16 , and an input audio situation (frequency pattern), by control means 1604 , examines whether a set of corresponding input audio situation (frequency pattern) is being memorized in input audio situation (frequency pattern) and frequency characteristic reference line inclination memory means 1605 , and if there is one, calls and sends to the audio signal processing and generating means 1606 to make an audio output.
[0101] This input audio situation (frequency pattern) and frequency characteristic inclination memory, by being provided with a learning function, automatically adjusts to a user's specific sound environment as he/she continues to use the adjustment function. However, an automatically called adjustment may not necessarily fit a user's hearing characteristic. In this case, adjustment is made through the user interface 1603 and by the frequency characteristic reference line adjustment means 1602 . Control means 1604 monitors whether there is such an adjustment, and when there is one, without referring to an input audio situation (frequency pattern) and the frequency characteristic reference line inclination memory means 1605 , inclinations of frequency characteristic reference lines, being adjusted by the frequency characteristic reference line inclination adjustment means 1602 , are forwarded directly to the audio signal processing and generating means 1606 to be used as an audio output.
[0102] In a flow diagram as shown in FIG. 18 , in a control means 1806 , a user, through a user interface 1806 , monitors whether frequency characteristic reference line adjustment 1803 is being activated, and if it is, inclinations of frequency characteristic reference lines, being adjusted in 1803 , are sent to an audio signal processing and generating means 1802 to be used as an audio output.
[0103] If the control means 1806 , in its monitoring, determines that the frequency characteristic reference line adjustment 1803 is not being made, then input audio signal is frequency analyzed in 1801 to be made as an input audio situation (frequency pattern) then by the control means 1806 and in 1805 , searches any corresponding data to this input audio situation (frequency pattern), from memories of input audio signal and frequency characteristic reference line inclinations. Called inclinations, if any, frequency characteristic reference lines are sent to the audio signal processing and generating means 1802 to be used as an audio output.
[0104] In this way, adjusted inclinations of frequency characteristic reference lines for each surrounding sound environment situation (frequency pattern) are memorized, so that if an input audio is similar to any of the preliminarily memorized surrounding sound environment situation (frequency pattern), there is not any need for adjustment. Inclinations of frequency characteristic reference line, being memorized together with the corresponding surrounding sound environment situation (frequency pattern), are called to be used as an audio output by audio signal processing and generating means.
[0105] This embodiment requires a user to adjust according to sound environment. However, it is also possible to preliminarily measure and memorize inclinations of frequency characteristic reference lines suited for sound environment of average persons with normal hearing, and then, when needed, analyze input audio signals to call inclinations of corresponding frequency characteristic reference lines.
[0106] Explained next is an application of this embodiment to hearing aid. FIG. 19 is a configuration example. The hearing aid in this example is composed of an ear attachment unit 1901 and a hearing aid remote control unit 1904 . The two units interface with each other by short range radio communication such as Bluetooth or ZigBee. The ear attachment unit 1901 is provided with a communication portion 1903 to radio communicate with the remote control unit 1904 , and an audio output portion 1902 .
[0107] The hearing aid remote control Unit 1904 is provided with an audio input portion 1906 , an adjustment portion 1907 to perform adjustment, a processing portion 1908 , and a communication portion 1905 to communicate with the ear attachment unit 1901 . This embodiment provides the audio signal input portion within the ear attachment unit, however, it may be housed in the ear attachment unit. Any combination may be used unless it is against the spirit of the present invention. An example of the adjustment portion of a hearing aid is shown in FIG. 20 , which is provided with a function button 2001 displayed as F, an up button 2002 displayed as UP, and a down button 2003 displayed as DWN. Volume is adjustable by UP and DWN buttons.
[0108] The aforementioned frequency adjustment is performed in such ways that holding down the F button and pressing the UP button will increase inclination of frequency characteristic reference line, and holding down the F button and pressing the DWN will decrease inclination of frequency characteristic reference line. FIG. 21 displays a flow of how different functions of the UP and DWN buttons can be activated. Cognition whether the F button is being held down is made in 2101 : when it is being held down, the UP and DWN buttons will adjust inclinations of frequency characteristic reference lines to adjust frequency characteristic according to a user's hearing characteristic; and when it is not being held down, the UP and DWN buttons will adjust volume.
[0109] FIG. 22 shows another embodiment of construction of a mobile phone, which comprises a mobile phone unit 2201 and a headset 2204 . The mobile phone unit 2201 comprises a telephone voice output portion 2202 , and a communication portion 2203 to communicate with the headset 2204 . The headset 2204 comprises an audio signal input portion (not indicated in the figure), a communication portion 2208 which communicates with the mobile phone unit 2201 , an adjustment portion 2205 which adjusts input frequency characteristic by adjusting inclination of frequency characteristic reference line, a processing portion 2206 which processes audio signal according to adjustment result from the processing adjustment portion, and an audio signal output portion 2207 .
[0110] Explained next is further another embodiment of a mobile phone, as shown in FIG. 23 , wherein an adjustment portion is housed within a headset unit, the adjustment portion being provided with a function button 2301 displayed as F, an up button 2302 displayed as UP, a down button 2303 displayed as DWN, and a noise compression button 2304 displayed as C. Volume is adjustable by UP and DWN buttons.
[0111] The aforementioned frequency adjustment is performed in such ways that holding down the F button and pressing the UP button will increase inclination of frequency characteristic reference line, holding down the F button and pressing the DWN will decrease inclination of frequency characteristic reference line, and pressing the C button will compress the frequency range of compress level of background noise.
[0112] Explained next is a method for noise compression. When a user is on the mobile phone, some environmental background noises may mask the voice of a person who is on the other side of the phone. By compressing these noises the voice of the other party becomes more hearable. FIG. 24 shows about background noise compression, wherein graph (a) displays an audio situation 2401 before background noise compression, whereas graph (b) displays an audio situation after background noise compression, wherein gain of a frequency range between 30 Hz and 350 Hz is decreased to a level numbered as 2402 , the frequency range being where human voice masking noises are on.
[0113] This embodiment activates background noise compression manually by a user, however, it is also available to have it done automatically, i.e., the specific frequency range (between 30 Hz and 350 Hz in this graph) is monitored to activate the compression function automatically when sound pressure exceeds a certain level.
[0114] In this embodiment, noise compression is applied to only audio signal output; however, it can also be applied to audio signal input. In this case, the voice of a user talking on the mobile phone can be transmitted to a person on the other side of the line with background noise in the voice frequency range being compressed.
[0115] This embodiment is about the background noise compression for a mobile phone. However, the embodiment is not limited to this particular application but is also applicable to a hearing aid. Further, this embodiment houses an adjustment portion and a processing portion within a mobile phone unit. However, the embodiment is not limited to this particular configuration but is also possible to house the adjustment portion and the processing portion within a headset, or a set of a microphone and an earphone, for communication with a mobile phone.
[0116] Or other telephone call applications than a mobile phone, such as a personal computer or the like being connected to an IP phone or other kinds of communication lines, are possible. Any combination may be used unless it is against the spirit of the present invention.
[0117] FIG. 25 is a schematic block diagram of further another embodiment of the present invention. FIG. 26 shows a high boost (high frequency boosting) frequency characteristic reference line, in accordance which enhancement level of input audio signal is determined to enhance a high frequency range. FIG. 27 shows a low boost (low frequency boosting) frequency characteristic reference line, in accordance which enhancement level of input audio signal is determined to enhance a low frequency range.
[0118] In FIG. 25 , the input audio signal is dual distributed to be used for audio signal generation. High frequency enhancing signal processing method is to refer to a high boost (high frequency boosting) frequency reference line 2502 , and, by a high boost (high frequency boosting) audio signal processing and generating means 2501 , generate high boost (high frequency boosting) audio signal. Low frequency enhancing signal processing method is to refer to a low boost (low frequency boosting) frequency reference line 2507 , and, by a low boost (low frequency boosting) audio signal processing and generating means 2508 , generate low boost (low frequency boosting) audio signal.
[0119] The generated high boost (high frequency boosting) audio signal is, by referring to a high boost (high frequency boosting) audio signal coefficient-multiplying adjustment means 2510 , coefficient-multiplied by a high boost (high frequency boosting) audio signal coefficient-multiplying means 2509 . The coefficient may be any numeric value between 0.01 and 10.
[0120] Likewise, the generated low boost (low frequency boosting) audio signal is, by referring to a low boost (low frequency boosting) audio signal coefficient-multiplying adjustment means 2512 , coefficient-multiplied by low boost (low frequency boosting) audio signal coefficient-multiplying means 2511 . Likewise, the coefficient may be any numeric value between 0.01 and 10. These coefficient-multiplied audio signals are synthesized by a synthesis means 2513 for high and low boost (high and low frequency boosting) coefficient-multiplied audio signal to make an audio signal output.
[0121] Explained now is about adjustment of high boost (high frequency boosting) frequency characteristic reference lines. As shown in FIG. 25 , a high boost (high frequency boosting) frequency characteristic reference line rotation center adjustment means 2503 adjusts rotation center of inclination, and a low boost (low frequency boosting) frequency characteristic reference line inclination adjustment means 2504 adjusts inclination.
[0122] FIG. 26 shows an example wherein a rotation center 2601 is set at 1000 Hz. Inclination of a user-adjusted high boost (high frequency boosting) frequency characteristic reference line 2602 may be adjusted to be as 2603 or 2604 by the inclination adjustment means. FIG. 26 also shows another example wherein a rotation center 2605 is set at 3000 Hz. Inclination of a user-adjusted high boost (high frequency boosting) frequency characteristic reference line 2606 may be adjusted to be as 2603 or 2604 by the inclination adjustment means.
[0123] The aforementioned high boost (high frequency boosting) frequency characteristic reference line inclination rotation center adjustment means is performed by the high boost (high frequency boosting) frequency characteristic reference line rotation center adjustment means 2503 as shown in FIG. 25 , and high boost (high frequency boosting) frequency characteristic reference line inclination adjustment is performed by the high boost (high frequency boosting) frequency characteristic reference line inclination adjustment means 2504 also as shown in FIG. 25 .
[0124] Explained now is about adjustment of low boost (low frequency boosting) frequency characteristic reference lines. As shown in FIG. 25 , a low boost (low frequency boosting) frequency characteristic reference line rotation center adjustment means 2505 adjusts rotation center of inclination, and a low boost (low frequency boosting) frequency characteristic reference line inclination adjustment means 2506 adjusts inclination.
[0125] FIG. 27 shows an example wherein a rotation center 2701 is set at 400 Hz. Inclination of a user-adjusted low boost (low frequency boosting) frequency characteristic reference line 2702 may be adjusted to be as 2703 or 2704 by the inclination adjustment means. FIG. 27 also shows another example wherein a rotation center 2705 is set at 800 Hz. Inclination of a user-adjusted low boost (low frequency boosting) frequency characteristic reference line 2706 may be adjusted to be as 2707 or 2708 by the inclination adjustment means.
[0126] The aforementioned low boost (low frequency boosting) frequency characteristic reference line inclination rotation center adjustment means is performed by the low boost (low frequency boosting) frequency characteristic reference line rotation center adjustment means 2505 as shown in FIG. 25 , and low boost (low frequency boosting) frequency characteristic reference line inclination adjustment is performed by the low boost (low frequency boosting) frequency characteristic reference line inclination adjustment means 2506 also as shown in FIG. 25 .
[0127] This embodiment explains that a rotation center of frequency characteristic inclination may be moved from one frequency range to another as shown in FIG. 26 and FIG. 27 . However, another possibility is that a rotation center may be on a frequency characteristic reference line as shown in FIG. 28 . If a point 2802 on a frequency characteristic reference line 2801 is used as a rotation center, the inclination may be adjusted to be as 2803 or 2804 . Likewise, if a point 2806 on a frequency characteristic reference line 2801 is used as a rotation center, the inclination may be adjusted to be as 2807 or 2808 .
[0128] Explained in more detail now of the aforementioned using a flow diagram as shown in FIG. 29 , wherein, in sequence, audio signal input is analog-to-digital converted in 2901 , the converted digital audio signal is dual distributed in 2902 to be used for audio signal generation. For the dual distributed digital audio signal, high frequency enhancing signal processing method is to refer to a high boost (high frequency boosting) frequency reference line 2905 , and, by 2903 , generates a high boost (high frequency boosting) audio signal, and a low frequency enhancing signal processing method is to refer to low boost (low frequency boosting) frequency reference line 2906 , and, by 2904 , generates a low boost (low frequency boosting) audio signal.
[0129] Gain control is made independently according to frequency range. Gain control of digital audio signal is made by increasing or decreasing according to user-adjusted high boost (high frequency boosting) and low boost (low frequency boosting) frequency characteristic reference lines, as described in the aforementioned embodiment.
[0130] Then, the generated high frequency enhanced high boost (high frequency boosting) audio signal refers to a high boost (high frequency boosting) audio signal coefficient 2909 , and generates high boost (high frequency boosting) coefficient-multiplied audio signal at 2907 . Likewise, the generated low frequency enhanced low boost (low frequency boosting) audio signal refers to a low boost (low frequency boosting) audio signal coefficient 2910 , and generates low boost (low frequency boosting) coefficient-multiplied audio signal at 2908 . And then, in 2911 , the high boost (high frequency boosting) coefficient-multiplied audio signal and the low boost (low frequency boosting) coefficient-multiplied audio signal are synthesized and, as appropriate, is digital-to-analog converted at 2912 to be output as an audio signal.
[0131] Explained next is a method which requires no adjustment in such a case that a surrounding sound environment is similar to that of a preliminarily memorized frequency pattern. FIG. 30 displays its schematic block diagram. The input audio signal is frequency analyzed by an input audio signal analysis means 3001 and, through a control means 3010 , is memorized in a memory means for input audio situation (frequency pattern), rotation center and inclinations of high/low frequency characteristic reference lines, and audio signal multiple coefficients 3008 . In the above mentioned process, in sequence, rotary canters and inclinations of high boost (high frequency boosting) frequency characteristic reference line and low boost (low frequency boosting) frequency characteristic reference line are referred to, high/low boost (high/low frequency boosting) audio signals are generated, audio signal multiple coefficient is referred to, and high/low boost (high/low frequency boosting) audio signals are coefficient-multiplied to be synthesized to make an audio signal output.
[0132] The output audio, through a user interface 3003 , and by a high/low boost (high/low frequency boosting) frequency characteristic reference line adjustment means, and a high/low boost (high/low frequency boosting) audio signal coefficient-multiplying adjustment means, adjusts high/low frequency characteristic reference lines and high/low boost (high/low frequency boosting audio signal multiple coefficient, as shown in 3002 .
[0133] 3004 in 3002 is a high boost (high frequency boosting) frequency characteristic reference line adjustment means. For drawing simplification purpose, rotation center adjustment and inclination adjustment for high boost (high frequency boosting) frequency characteristic reference line are described within a same text box. However, these are two different functions.
[0134] Likewise, 3005 in 3002 is a low boost (low frequency boosting) frequency characteristic reference line adjustment means. For drawing simplification purpose, rotation center adjustment and inclination adjustment for low boost (low frequency boosting) frequency characteristic reference line are described within a same text box. However, these are two different functions.
[0135] 3006 in 3002 is a high boost (high frequency boosting) audio signal multiple coefficient adjustment means. 3007 in 3002 is a low boost (low frequency boosting) audio signal multiple coefficient adjustment means.
[0136] Information which is processed by the high/low boost (high/low frequency boosting) frequency characteristic adjustment means and also by the high/low boost (high/low frequency boosting) audio signal multiple coefficient adjustment means in 3002 is, by a control means 3010 , together with the input audio situation (frequency pattern) which is frequency analyzed by the input audio signal analysis means 3001 , memorized in a memory means 3008 for the input audio situation (frequency pattern) and the rotation center and inclinations of high/low boost (high/low frequency boosting) frequency characteristic reference lines, and audio signal multiple coefficients.
[0137] FIG. 31 is a flow diagram, illustrating how an input audio signal is memorized in memory means for input audio signal (input frequency pattern), rotation center and inclinations of high/low boost (high/low frequency boosting) frequency characteristic reference lines and audio signal multiple coefficients. The input audio signal is frequency analyzed by an input audio signal analysis means 3101 and is output as an input audio situation (frequency pattern). A user, while listening to the output audio generated by a high/low boost (high/low frequency boosting) audio signal processing and generating means 3102 , through a user interface 3104 , by an adjustment means 3103 for high/low boost (high/low frequency boosting) frequency characteristic reference lines and an adjustment means 3105 for high/low boost (high/low frequency boosting) audio signal multiple coefficient, adjusts high/low boost (high/low frequency boosting) frequency characteristic reference line rotation center, inclinations and audio signal multiple coefficients. The high/low boost (high/low frequency boosting) frequency characteristic reference line rotation center, inclinations and audio signal multiple coefficients, adjusted by the 3103 and the 3105 , is, together with the input audio signal analysis means 3101 , memorized in a memory means 3107 for input audio situation (frequency pattern), high/low boost (high/low frequency boosting) frequency characteristic reference lines rotation centers and inclinations, and high/low boost (high/low frequency boosting) audio signals multiple coefficients.
[0138] Explained next is a method, wherein surrounding sound environment situation (frequency pattern) is memorized in most suitable input audio situation and high/low boost (high/low frequency boosting) frequency reference lines rotation center and inclinations and audio signal multiple coefficient memory means, and then call the rotation center and inclinations of the high boost (high frequency boosting) frequency characteristic reference line and the low boost (low frequency boosting) frequency characteristic reference line, and high/low boost (high/low frequency boosting) audio signal multiple coefficient, and then an audio suitable to the corresponding surrounding sound environment is output.
[0139] Input audio signal is frequency analyzed by the input audio signal analysis means 3001 in FIG. 30 , and by the control means 3010 , examines whether a set of corresponding audio situation (frequency pattern) is being memorized in a memory means 3008 for input audio situation (frequency pattern) and high/low boost (high/low frequency boosting) frequency characteristic reference lines rotation centers and inclinations and audio signal multiple coefficients, and if there is one, calls and sends to a high/low boost (high/low frequency boosting) audio signal processing and generating means 3009 to make an audio output.
[0140] This input audio situation (frequency pattern) and high/low boost (high/low frequency boosting) frequency characteristic reference line inclination memory means, by being provided with a learning function, automatically adjusts to a user's specific sound environment as he/she continues to use the adjustment function.
[0141] However, an automatically called adjustment may not necessarily fit a user's hearing characteristic. In this case, adjustment is made through the user interface 3003 and by the adjustment means 3002 . Control means 3010 monitors whether there is such an adjustment, and when there is one, without referring to the input audio situation (frequency pattern) and the high/low boost (high/low frequency boosting) frequency characteristic reference line inclination and audio signal multiple coefficient memory means 3008 , audio signal is directly output by the high/low boost (high/low frequency boosting) audio signal processing and generating means 3009 after being adjusted by the adjustment means 3002 .
[0142] In a flow diagram as shown in FIG. 32 , in a control means 3206 , a user, through a user interface 3203 , monitors whether a high/low boost (high/low frequency boosting) frequency characteristic reference line adjustment 3202 and a high/low boost (high/low frequency boosting) audio signal multiple coefficient adjustment 3204 are being activated, and if they are, refers to information adjusted by adjustment means 3202 and 3204 , controls in 3206 , and outputs an audio signal by a high/low boost (high/low frequency boosting) audio signal processing, generating and synthesis means 3207 .
[0143] If control means 3206 , in its monitoring, determines that no adjustment is being made by 3202 and/or 3204 , then audio signal being frequency analyzed in 3201 is recognized to measure input audio situation (frequency pattern) then by control means 3206 , searches any corresponding data to this input audio situation (frequency pattern), from a memory means 3205 for an input audio situation (frequency pattern) and high/low boost (high/low frequency boosting) frequency reference lines rotation center and inclinations and high/low boost (high/low frequency boosting) audio signal multiple coefficients. Called data, if any, are sent to a high/low boost (high/low frequency boosting) audio signal processing, generating and synthesis means 3207 to be used as an audio signal output.
[0144] The memory means already memorizes input audio situation (frequency pattern) and high/low boost (high/low frequency boosting) frequency reference lines rotation center and inclinations and audio signal multiple coefficients, for various surrounding sound environment situation (frequency pattern), so that if an input audio is similar to any of the preliminarily memorized surrounding sound environment situation (frequency pattern), there is no need for adjustment, input audio signal and high/low boost (high/low frequency boosting) frequency reference lines rotation center and inclinations and audio signal multiple coefficients, being memorized together with the corresponding surrounding sound environment situation (frequency pattern), are called to be used as an audio output by the high/low boost (high/low frequency boosting) audio signal processing and generating means.
[0145] This embodiment requires a user to adjust according to his/her sound environment, however, it is also possible to preliminarily measure and memorize inclinations of high boost (high frequency boosting) frequency characteristic reference line and low boost (low frequency boosting) frequency characteristic reference line of a sound environment suited for average persons with normal hearing, and then, when needed, analyze input audio signal to call inclinations of corresponding high boost (high frequency boosting) characteristic reference line and low boost (low frequency boosting) characteristic reference line.
[0146] Explained next is about a case for a single frequency characteristic reference line. FIG. 33 is a schematic block diagram of another embodiment of the present invention. FIG. 34 shows frequency characteristic reference lines in accordance which enhancement level of input audio signal is determined according to frequency ranges. In FIG. 33 , signal processing method of input audio signal is to refer to a frequency characteristic reference line 3302 , and, by an audio signal processing and generating means 3301 , generate an audio signal. FIG. 34 shows an example of frequency characteristic reference lines, wherein 3401 and 3405 are examples of rotation centers on frequency characteristic reference lines, which are adjusted by a frequency characteristic reference line rotation center adjustment means 3303 , and a frequency characteristic reference line inclination adjustment means 3304 , as shown in FIG. 33 .
[0147] For adjustment of inclination, with a rotation center 3401 in FIG. 34 , a frequency characteristic reference line 3402 may shift to 3403 by increasing the inclination, or may shift to 3404 by decreasing the inclination, likewise, with a rotation center 3406 in FIG. 34 , a frequency characteristic reference line 3406 may shift to 3407 by increasing the inclination, or may shift to 3408 by decreasing the inclination, These adjustments are performed by a frequency characteristic reference line inclination adjustment means 3304 in FIG. 33 .
[0148] Explained in more detail now of the aforementioned using a flow diagram as shown in FIG. 35 , wherein, in sequence, audio signal input is analog-to-digital converted in 3501 as needed, and the converted digital audio signal is, referring to a frequency characteristic reference line 3503 , audio signal generated in 3502 . Gain is adjusted independently according to frequency range, of which digital audio signal may be increased or decreased according to user-adjusted frequency characteristic reference line, which is shown in the aforementioned embodiment. Digital-to-analog conversion may be made in 3504 , as needed, to make an audio output.
[0149] The aforementioned embodiment shows straight frequency characteristic reference lines to make explanations simple; however, those are not limited to straight lines but may be curved ones as appropriate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0150] FIG. 1 is a schematic diagram showing an embodiment of the present invention;
[0151] FIG. 2 is a graph showing adjustments of frequency characteristic reference lines, according to the present invention;
[0152] FIG. 3 is a flow diagram, according to the present invention;
[0153] FIG. 4 is a block diagram showing adjustments corresponding to surrounding sound environments, according to the present invention;
[0154] FIG. 5 is a flow diagram showing adjustments suited to user's specific sound environments, according to the present invention;
[0155] FIG. 6 is a memory reading flow diagram showing adjustments corresponding to surrounding sound environments, according to the present invention;
[0156] FIG. 7 is a schematic diagram showing an embodiment of a hearing aid, according to the present invention;
[0157] FIG. 8 is a schematic diagram showing an example of control buttons, according to the present invention;
[0158] FIG. 9 is a flow diagram showing control button determination, according to the present invention;
[0159] FIG. 10 is a schematic block diagram showing an embodiment of a mobile phone, according to the present invention;
[0160] FIG. 11 is a schematic diagram showing control input of a mobile phone, according to the present invention;
[0161] FIG. 12 illustrates graphs showing gain control corresponding to background noises, according to the present invention;
[0162] FIG. 13 is a schematic block diagram showing another embodiment of the present invention;
[0163] FIG. 14 is a graph showing frequency characteristic reference lines, according to the present invention;
[0164] FIG. 15 is a flow diagram, according to the present invention;
[0165] FIG. 16 is a block diagram showing automatic adjustments, according to the present invention;
[0166] FIG. 17 is a block diagram showing adjustments by a user, according to the present invention;
[0167] FIG. 18 is a block diagram showing learning ability, according to the present invention;
[0168] FIG. 19 is a schematic block diagram of another embodiment of construction of a hearing aid, according to the present invention;
[0169] FIG. 20 is a schematic diagram showing an example of control buttons, according to the present invention;
[0170] FIG. 21 is a flow diagram showing control button determination, according to the present invention;
[0171] FIG. 22 is another embodiment of a mobile phone, according to the present invention;
[0172] FIG. 23 is a schematic diagram showing control input, according to the present invention;
[0173] FIG. 24 illustrates graphs showing gain control corresponding to background noises, according to the present invention;
[0174] FIG. 25 is a schematic diagram showing an embodiment which has a plurality of adjustment mechanisms, according to the present invention;
[0175] FIG. 26 is a graph showing adjustments of high boost (high frequency boosting) frequency characteristic reference lines, according to the present invention;
[0176] FIG. 27 is a graph showing adjustments of low boost (low frequency boosting) frequency characteristic reference lines, according to the present invention;
[0177] FIG. 28 is a graph showing other adjustments of low boost (low frequency boosting) frequency characteristic reference lines, according to the present invention;
[0178] FIG. 29 is a flow diagram of an embodiment which has a plurality of adjustment mechanisms, according to the present invention;
[0179] FIG. 30 is a block diagram showing adjustments corresponding to surrounding sound environments, according to the present invention;
[0180] FIG. 31 is a flow diagram showing adjustments suited to user's specific sound environments, according to the present invention;
[0181] FIG. 32 is a flow diagram showing adjustments suited to user's other specific sound environments, according to the present invention;
[0182] FIG. 33 is a schematic block diagram showing an embodiment of which frequency characteristic reference line is a single line, according to the present invention;
[0183] FIG. 34 is a graph showing adjustments of frequency characteristic reference lines, according to the present invention; and
[0184] FIG. 35 is a flow diagram showing an embodiment of which frequency characteristic reference line is a single line, according to the present invention. | A hearing optimization device and hearing optimization method having a high boost frequency characteristic reference live for high frequency range enhancement and a low boost frequency characteristic reference live for low frequency range enhancement to achieve separate gain control of input audio signal according to frequency. An audio signal processing and generating means is also included, along with synthesized audio signal output structure. | 7 |
TECHNICAL FIELD
The present invention is directed to an ink cartridge system for a pen of an ink-jet type printer.
BACKGROUND INFORMATION
One type of ink-jet printer includes a carriage that is reciprocated back and forth across a sheet of paper that is advanced through the printer. The reciprocating carriage holds a pen very close to the paper. The pen is controlled by the printer for selectively ejecting ink drops from the pen while the pen is reciprocated or scanned across the paper, thereby to produce characters or an image on the paper.
The pen has a reservoir for holding a limited amount of ink. A relatively larger supply of ink is provided in a replaceable stationary container that is mounted to the printer. A tube may be connected between the supply container and the pen, thereby to conduct the flow of ink from the supply container to the pen for replenishing the pen reservoir as needed.
An efficient and easy-to-use printer will include mechanisms that permit rapid replacement of a depleted collapsible container without ink leakage from either the depleted cartridge or full cartridge that is used as a replacement.
SUMMARY OF THE INVENTION
The present invention is directed to a system that provides a replaceable cartridge for storing ink, in conjunction with a station for securing the cartridge to the printer to facilitate rapid and leak-free replacement of the cartridges.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a collapsible ink cartridge in accordance with one aspect of the invention.
FIG. 2 is a top plan view of the collapsible ink cartridge showing the ink cartridge in a collapsed configuration.
FIG. 3 is a side elevation view of the collapsible ink cartridge.
FIG. 4 is a side elevation view of a collapsible ink cartridge showing the ink cartridge in an empty, collapsed configuration.
FIG. 5 is a cross-sectional view of a collapsible ink cartridge taken along line 5--5 of FIG. 1.
FIG. 6 is a cross-sectional view taken along line 6--6 of FIG. 1 showing the fitment that is carried by the cartridge for facilitating coupling of the cartridge with a member for removing ink from the cartridge.
FIG. 7 is a perspective view of a cartridge and printer station made in accordance with the present invention.
FIG. 8 is a cross-sectional view of the system taken along line 8--8 in FIG. 7.
FIG. 9 is a cross-sectional view similar to FIG. 8, except taken when the cartridge is disconnected from the coupling station.
FIG. 10 is a section view taken along line 10--10 of FIG. 9.
FIG. 11 is a cross-sectional view of an alternative embodiment of a cartridge fitment.
FIG. 12 is a cross-sectional view of another alternative embodiment of the cartridge fitment.
DESCRIPTION OF PREFERRED EMBODIMENTS
An ink cartridge system in accordance with a preferred embodiment of the present invention includes a collapsible cartridge, as designated in FIG. 1 with reference numeral 10. The ink cartridge 10 includes a body 12 with two substantially identical opposing upper and lower wall panel assemblies 14a, 14b (see FIG. 3). The opposing wall panel assemblies 14a, 14b have opposed inner surfaces 15 (see FIG. 5). As shown in FIGS. 1 and 2, each of the panel assemblies 14a, 14b has a relatively large, square-shaped planar panel 16a, 16b. The square panels 16a, 16b respectively define the top and bottom of the cartridge 10. The panel assemblies 14a, 14b are joined at a square-shaped frame 18 and are, therefore, symmetrical about a central plane defined by the frame 18.
The cartridge 10 in FIGS. 1 and 3 is shown in a maximum volume or full configuration. In the full configuration, the upper and lower panel assemblies 14a, 14b extend respectively upward and downward from the frame 18 to define a cavity 19 within the body 12 for the storage of ink (see FIG. 5). The body 12 is collapsible to an empty configuration wherein the upper and lower panel assemblies 14a, 14b collapse flat against each other within a plane defined by the frame 18 (see FIGS. 2 and 4).
Given the symmetry of the cartridge 10, the following description of the upper panel assembly 14a applies equally as well to the lower panel assembly 14b.
The upper square panel 16a has four identical straight edges 20. The frame 18 has four substantially identical frame side members 22. The square panel 16a is positioned with respect to the frame 18 so that the square panel edges 20 align with the frame side members 22. Accordingly, the upper panel assembly 14a and the frame 18 have four sides of substantially common construction. One side of common construction is designated by reference numeral 23 and isolated for description purposes by the phantom line of FIGS. 1 and 2. The following description of this side 23 applies equally as well to the other three sides of common construction between the upper panel assembly 14a and frame 18.
An elongate rectangular edge panel 24 interconnects the square panel 16a and an intermediate portion 26 of the frame side member 22. The rectangular edge panel 24 has inner and outer longitudinal edges 28, 30 and end edges 34. The edge panel longitudinal edges 28, 30 are substantially equal in length to the square panel edge 20. The edge panel inner edge 28 is hinged to the square panel edge 20 at a square panel hinge 35. The edge panel outer edge 30 is hinged to the frame intermediate portion 26 at a double hinge 36. As is described below, the edge panels 24 of the symmetrical upper and lower panel assemblies 14a, 14b attach to the frame intermediate portion 26 at the double hinge 36 (see FIG. 5).
The edge panel 24 is oriented to extend diagonally between the upper square panel 16a and the frame 18 when the cartridge 10 is in the full configuration (see FIG. 3). The edge panel 24 lays flat with the square panel 16a within the plane defined by the frame 18 when the cartridge 10 is in the empty configuration (see FIG. 4).
As shown in FIG. 2, a triangular-shaped (corner) panel 39 is attached to each edge panel end edge 34 at an end hinge 40. To facilitate the description of the triangular panels 39, reference is made to FIG. 2, which shows the panels of the first common side construction 23 flat, in the empty configuration. So viewed, the triangular panel 39 has one 45° angle, one obtuse angle, and one acute angle of less than 45°. The shortest (first) edge 42 of the triangle is defined between the 45° and obtuse angles. The longest (second) edge 44 of the triangle is defined between the 45° and acute angles. A third edge 46 of the triangle is defined between the acute and obtuse angles.
The triangular panel first edge 42 is substantially equal in length to the edge panel end edge 34, and attaches thereto at end hinge 40. The second edge 44 of the triangular panel 39 extends radially outward from the corner of the upper square panel 16a. In other words, the line defined by the second triangular panel edge 44 diagonally bisects the upper square panel 16a. The diagonally bisecting lines defined by both triangular panel second edges 44 of the common side of construction 23 are mutually perpendicular so that the common side of construction 23 forms a 90° "slice" from the upper panel assembly 14a.
The triangular panel third edge 46 extends outward from the edge panel outer edge 30. The third edge 46 is hinged to a frame corner portion 50 at a corner double hinge 52. The frame corner portion 50 is set apart from the frame intermediate portion 26 by an outwardly opening frame side notch 54 that aligns with the end hinge 40. The corner double hinge 52 is substantially identical in construction to frame double hinge 36. The corner double hinge 52 connects the symmetric triangular panels 39 of both the upper and lower panel assemblies 14a, 14b to the frame corner portion 50.
The common side of construction 23 is integrally attached to adjacent common sides of construction at corner hinges 48. One corner hinge 48 hinges each triangular panel 39 of the common side of construction 23 to an identical triangular panel 39 of an adjacent common side of construction. Each hinged pair of triangular panels 39 attach to the corner hinge 48 at their second edges 44 and extend symmetrically therefrom.
Referring to the entire upper panel assembly 14a and frame 18 shown in FIG. 2, pairs of hinged triangular panels 39 are positioned at each corner of the upper panel assembly 14a. The pairs of triangular panels 39 project beyond the lines formed by the edge panel outer edges 30. The projection of the pairs of triangular panels 39 permits the edge panel outer edges 30 and the triangular panel third edges 46 to remain within the plane defined by the frame 18 in the full and the empty configurations (see FIGS. 1 and 4).
The frame corner portions 50 of adjacent common sides of construction intersect at a corner notch 55. Thus, the corner hinges 48 extend radially from the corners of the upper wall panel 16a to the corner notches 55 at the corners of the frame 18.
In the full configuration, as shown in FIGS. 1 and 3, the edge panels 24 are oriented to extend diagonally at an angle of about 35° from the plane of the frame 18. The corner hinges 48 extend upwardly from the corners of the frame corner portions 50 to the corners of the upper square panels 16a. The triangular panels 39 of adjacent common sides of construction 23 angle downwardly on either side of the corner hinges 48 to the end hinges 40 and the double corner hinges 52.
The material defining the frame side and corner notches 54, 55 is resilient. The resilient material permits the frame 18 at the notches 54, 55 to resiliently flex during the collapse of the body 12 from the full configuration (FIG. 1) to the empty configuration (FIG. 2).
As will now be described, the hinges 35, 40, 48 and double hinges 36, 52 flex to permit the inner surfaces 15 of the body 12 (see FIG. 5) to lie flat and smooth against each other in the collapsed, empty configuration.
FIG. 5 shows a cross-section of double hinge 36. The frame intermediate portion 26 and the edge panel outer edge 30 have opposing bevels that form an upper framing groove 59. An identical symmetric lower framing groove 60 is formed between the edge panel 24 of the lower panel assembly 14b and the frame intermediate portion 26. A bridge of the frame's resilient material separates the bottoms of the grooves 59, 60. The resilient material flexes to permit the edge panels 24 of the upper and lower panel assemblies 14a, 14b to pivot together about the frame double hinge 36. The corner double hinge 52 is of similar construction to permit the triangular panels 39 of the upper and lower panel assemblies 14a, 14b to pivot together.
The hinges 35, 40, 48 between the panels of the common side of construction 23 permit the upper panel assembly 14a to collapse flat. FIG. 5 shows a cross-section of an exemplary square panel hinge 35. The hinge 35 includes opposing bevels on the square panel edge 20 and the edge panel inner edge 38 to form a V-shaped hinge groove 56 on the exterior of the panel assembly 14a. A narrow bridge of resilient material remains between the bottom of the hinge groove 56 and the inner surface 15 of the panel assembly 14a. The panel assembly inner surface 15 is unbroken across the square panel hinge 35.
The edge and corner hinges 40, 48 are of substantially identical construction. Thus, the panel assembly inner surface 15 is completely smooth and flat in the empty configuration. The hinges 35, 40, 48 are identical to the corresponding hinges of the symmetric lower panel assembly 14b. Thus, the inner surfaces 15 of both the upper and lower panel assemblies 14a, 14b are smooth and lie flat against each other in the empty configuration (see phantom in FIG. 5).
The cartridge 10 is filled with ink in the full configuration. One frame intermediate portion 26 is shaped to define a fitment 61 through which ink may be conducted in and out of the cartridge (see FIG. 1). Preferably, the cartridge 10 is molded in the full configuration so that a collapsed cartridge tends to resile toward the full configuration to provide advantages as described below.
With particular reference to FIGS. 1 and 6, the fitment 61 includes a cylindrically shaped sleeve 100 that is bonded, as by heat welding, into a correspondingly shaped opening that is molded into one of the side members 22 of the frame 18. In this regard, the frame member is essentially bifurcated into a top part 22a and a bottom part 22b. The top part 22a wraps around the top half of the sleeve 100 and the bottom part 22b wraps around the bottom half of the sleeve. In a preferred embodiment, the portion of the frame parts 22a and 22b facing the sleeve have formed within them a rabbet groove 102 into which fits an annular tongue 104 protruding from the sleeve 100. As noted, the sleeve 100 and frame parts 22a, 22b are joined by heat welding or, for example, by an adhesive. The outer end 106 of the sleeve is flanged at the edge of the frame parts 22a, 22b. The interior of that end 106 is chamfered 108 to facilitate mating of the fitment with a coupler, as described below.
The inner end 110 of the sleeve 100 is shaped to define a spout 112 that extends along the axis of the sleeve and protrudes from the inner end 110 to a location inside the outer end 106 of the sleeve. The spout 112 has an inner passage 114 that is open to fluid communication with the cavity 19 of the cartridge 10. Near the outer end 118 of the spout the passage 114 is occluded by a pierceable septum 120 that remains in place until pierced by the coupler as explained below. Accordingly, until the filled cartridge is coupled to the station in the printer, the ink within the cavity 19 is sealed from ambient.
An annular chamber 122 is defined by the fitment to surround the spout 112 inside the sleeve. The chamber extends along the substantial length of the spout (FIG. 6).
With reference to FIGS. 7-9, a cartridge 10 is placed by the user into a station 150 that is carried in the printer. The station 150 includes means for supporting the cartridge 10, coupling the fitment of the cartridge with a tube that conducts the ink from the cartridge to an ink-jet pen, and applying pressure to the cartridge for moving ink from the cartridge through the tube.
More particularly, a preferred embodiment of the station 150 includes a bottom wall 152 onto which may rest the square-shaped panel 16a or 16b of a cartridge 10. The cartridge 10 fits between two upwardly protruding side walls 154, 156 with the fitment 61 of the cartridge facing an end wall 158 of the station. The end wall 158 has mounted to it the above-mentioned coupler 160.
As shown in FIGS. 7-10, the coupler 160 includes an annular mounting ring 162 that is fastened across the edge of an aperture 164 formed in the end wall 158 of the station. A generally tubular connector 166 protrudes inwardly into the station, centered along an axis 168 that is spaced from the bottom wall 152 by a distance corresponding to half the thickness of a full cartridge 10. A resilient sealing ring 170 is mounted, such as by swaging with a metal channel member 172, to the innermost end of the connector 166. The resilient sealing ring 170 has an inside diameter slightly less than the outside diameter of the spout 112, thereby to seal the connector interior space 174 to the spout during the time the cartridge 10 is joined to the coupler 160 (FIG. 8).
The coupler 160 is shaped to define a hollow needle 180 that protrudes from the mounting ring 162 inwardly, inside connector 166, for a distance about halfway through the interior space 174 of the connector. The needle 180 includes an orifice 182 formed through its outermost end. The outside diameter of the needle 180 is less than the inside diameter of the passage 114 so that the needle fits inside of the passage. Moreover, when the cartridge fitment is first moved against the coupler, the needle pierces through the septum 120 so that fluid communication is provided between the passage 114 and the interior 184 of the needle, through the orifice 182.
The interior 184 of the needle is contiguous with that of a tube fitting 186 that protrudes outwardly from the mounting ring 162. A flexible tube 190 has one end attached to the tube fitting 186. The other end of the tube 190 may be connectable to the reservoir of an ink-jet pen (not shown) that is reciprocated by a carriage and controlled for directing ink drops onto paper that is advanced through the printer.
In view of the foregoing, it will be appreciated that whenever the cartridge fitment 61 is pushed against the coupler 160, the sealing ring 170 will engage the exterior surface of the spout 112. Preferably, the outermost end 118 of the spout surface is chamfered to facilitate the movement of the sealing ring over the spout. As the spout 112 fits into the interior space 174, the needle 180 is inserted into the spout to pierce through the septum 120, thereby to permit ink to flow from the cartridge cavity 19, through the needle orifice 182, through the needle interior 184, and into the tube 190.
It is noteworthy that the innermost end (that is, to the left in FIG. 9) of the needle 180 is spaced from the sealing ring 170 so that the sealing ring seals against the outer surface of the spout 112 before the needle pierces the septum 120. As a result, any ink that may move from the cartridge to the space between the needle and the interior wall of the spout will be sealed between the spout and the tubular connector 166, and not leak within the station 150.
As explained more fully below, forces tending to push ink from the cartridge 10 are removed whenever the cartridge is removed from the coupler so that the tendency of the cartridge to resile toward its full configuration will create a slight back pressure inside the cartridge, which back pressure will draw into the cartridge any ink that is trapped inside the space 174.
Preferably, the annular space 174 between the needle and the interior wall of the connector 166 is sufficiently small to trap by capillarity any residual ink that moves into that space, so that the ink will not leak from the coupler.
A spring-loaded pressure bar 200 is carried by the station 150 for forcing together the top and bottom of the cartridge to move ink out therefrom. More particularly, the pressure bar 200 is a generally U-shaped member with its base 202 extending across the station between the side walls 154, 156. The legs 204, 206 of the bar extend from opposite ends of the base 202. The ends of the legs 204, 206 each join a spring hinge 208. The spring hinges 208 urge the base 202 toward the bottom wall 152 of the station. The spring hinges 208 are carried by a support rod 210 that extends substantially across the width of the station near the end wall 158. Support brackets 211 are connected between the respective side walls 154, 156 and corresponding ends of the support rod 210 to secure the pressure bar 200 to the station 150.
A thin plastic flag 212 is attached to the base 202. The flag permits the user to pull upwardly against the force of the spring hinges 208 so that a cartridge 10 may be inserted through the space between the bar 202 and the bottom wall 152 of the station. Once the cartridge is in place within the station (that is, with the needle 180 of the coupler 160 engaging the spout 112 as shown in FIG. 8), the flag 212 is released and the bar 202 provides a force tending to push the top wall 16a of the cartridge toward the bottom wall 16b so that the bag will collapse as ink is depleted by the pen.
In a preferred embodiment, the downward force of the bar is automatically removed whenever the pen is not being filled; that is, when there is no requirement for forcing ink through the tube 190 to the pen. As noted earlier, removal of the force permits the resilient ink cartridge 10 to move toward the full configuration, thereby establishing a slight back pressure for preventing ink from leaking through the cartridge or through the attached tube 190. Accordingly, lever 220 is attached to extend from one hinge 208 near leg 206 of the bar 202 to protrude generally horizontally across the station end wall 158. A conventional solenoid-type actuator 222 is mounted to the end wall 158 so that the associated extendable and retractable actuator rod 224 is pivotally coupled to the end of the lever 220. A suitable control signal is provided to the actuator 220 whenever the pen requires filling with ink so that the actuator rod 224 will extend upwardly in FIG. 8, thereby releasing the spring hinges 208 to exert the pressure applied by the bar 200.
FIG. 11 depicts in cross-section an alternative embodiment of a fitment of the present invention, which fitment is useable with the above-described cartridge 10 and station 150. In this embodiment, the fitment 361 includes a sleeve 300 generally corresponding to the sleeve configuration 100 described above. The spout 312 defined by the sleeve has an outer end that curves inwardly, thereby to define a slightly smaller-diameter opening 313 than the remaining portion of the spout. This spout construction is employed for capturing inside the spout a stainless steel or polyethylene ball 314. The innermost end of the fitment 361 defines a generally cylindrical spring-retaining chamber 320.
A spring 322 is contained within the chamber 320 and normally urges the ball 314 against the outer end 313 of the spout for closing the spout. The spring includes an elongated, normally curved base part 324 and a post 326 integrally formed therewith. The post 326 extends into the spout 312. The outermost end of the spring post 326 engages the ball 314. The outermost ends of the bowed base 324 bear against the inner wall 321 of the fitment portion that defines the chamber 320. An aperture 325 is formed in that wall 321 for defining a path from the cartridge interior cavity 19 through the chamber and out of the spout 312 once the ball is displaced (that is, moved to the left in FIG. 11).
The ball 314 is displaced by the needle 180 of the coupler 160 as it passes into the spout interior. In this regard, the orifice 182 formed in the needle is, for this embodiment, located away from the long axis 168 of the spout so that the orifice will not be occluded as the needle is pushed against the spring-biased ball.
As the ball 314 is pushed from the opening 313, the bow 324 of the spring straightens to permit retraction of the post 326. When the cartridge is removed from the coupler 160, the spring 322 pushes the ball back to the outermost end of the spout thereby to close the spout when the cartridge is disconnected from the coupler.
FIG. 12 shows in cross-section another alternative embodiment of a fitment 461 wherein the spout 412 is again shaped at its outermost end to capture within the spout a stainless steel or polyethylene ball 414. In innermost end of the spout includes a bracket 428 that protrudes into the passageway of the spout. A compression spring 426 is fixed inside of the spout, one end of the spring bearing upon the bracket 428, and the other end bearing upon the ball. It will be appreciated that whenever the cartridge 10 is moved to engage the coupler 160, the needle 180 (with eccentric orifice 182) will displace the ball 414 and compress the spring 426, thereby to provide a path for ink flow from the cartridge cavity 19 through the spout 412. Removal of the cartridge from the coupler 162 will permit the spring 426 to return the ball 414 to the outermost end of the spout thereby to close the cartridge to prevent leaking.
The foregoing has been described in connection with preferred and alternative embodiments. It will be appreciated by one of ordinary skill in the art, however, that various modifications and variations may be substituted for the mechanisms and method described here while remaining defined by the appended claims and their equivalents. | The present invention is directed to a system that provides a replaceable cartridge for storing ink, in conjunction with a printer station for rapid and leak-free replacement of the cartridges. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to electrical capacitors and has particular reference to low cost, relatively small variable or adjustable capacitors.
2. Description of the Prior Art
As is well known, the capacitance value of a capacitor is proportional to the area of the conductor plates and inversely proportional to the thickness of the dielectric material therein.
Heretofore, fixed capacitors of relatively high capacitance value have been formed of a thin plastic or paper dielectric material on which a thin layer of a conductive material is bonded. Two or more such films are interleaved and wrapped in a coil to form the capacitor. In view of this form of construction, such capacitors can be made into small or miniature sizes.
On the other hand, variable capacitors have generally been constructed of conductor plates or elements which are movable relative to each other and separated to receive a suitable dielectric fluid, such as air or other gaseous or liquid substance, there-between. Since the conductor elements must be separated, they must be made rigid and accurately and precisely spaced. Also, air and other fluid dielectrics have relatively low breakdown voltage characteristics, requiring a relatively large spacing between the conductor elements. Thus, such variable capacitors are comparatively bulky, heavy and expensive to manufacture and cannot generally be made in very small or miniature sizes. Furthermore, in many cases, elaborate sealing means must be provided to prevent contamination or dilution of the gaseous or liquid dielectric by the exterior environment which could cause eventual malfunction or breakdown of the capacitor.
Various attempts have been made to overcome the above-noted disadvantages of prior variable capacitors. For example, U.S. Pat. No. 3,284,682 issued to H. E. Lippman on Nov. 8, 1966, discloses a variable capacitor in which rigid plates are spirally formed and interleaved with each other, with defined spacing therebetween to receive a dielectric gas such as air or the like. The plates are adjusted axially relative to each other to vary the capacitance. In this case, the plates and other operating parts must be made and assembled with a high degree of precision and accuracy and the conductor plates must be precisely spaced to maintain consistent results and to prevent breakdown of the dielectric which might otherwise occur if the distance between the plates is allowed to vary. Thus, the resulting capacitor tends to become relatively large and expensive to manufacture and is subject to malfunction if wear should occur in the operating parts.
SUMMARY OF THE INVENTION
I have discovered that an inexpensive, compact and reliable variable capacitor having a relatively high degree of capacitance can be formed by providing a pair of very thin interleaved flexible films of a suitable dielectric plastic or the like material having a superposed conductive layer of metal or the like on one surface. Such films are coiled in spiral form and are axially adjustable in sliding contact with and relative to each other. Because of the relatively high dielectric breakdown strength of plastic or the like films, such as polyethylene terphthalate (available commercially as Mylar, an E. I. Du Pont trademark), polycarbonate, polypropylene, etc., films, the film may be formed of a thickness considerably less than the thickness of the air gap between the conductive plates of any previously known capacitor. I have further discovered that when the interleaved films are coiled into a relatively small diameter and the coils are supported along their respective edges, they can be made extremely thin, yet rigid enough to permit relative axial sliding movement therebetween. For example, plastic films on the order of 0.005 to 0.010 of an inch thick, which are normally highly flexible and structurally limp, become sufficiently rigid, when so formed, to permit sliding interengagement and the development of a high degree of capacitance.
It is therefore a principal object of this invention to provide a variable capacitor of relatively high capacitance.
Another object is to provide a variable capacitor which is simple and inexpensive to manufacture and assemble.
Another object is to provide a variable capacitor which is not dependent upon air or other gaseous or liquid fluid as a dielectric.
A further object is to provide a variable capacitor which can be manufactured in miniature, as well as in larger sizes, and has relatively high capacitance capability.
A still further object is to provide such a variable capacitor which can be readily shielded to prevent the emanation of electromagnetic radiation therefrom and/or sealed to protect its interior from environmental contamination.
Still another object of the invention is to provide such a variable capacitor capable of precise adjustment of capacity setting through multi-turn movement of one conductor relative to the other.
BRIEF DESCRIPTION OF THE DRAWING
The manner in which the above and other objects of the invention are accomplished will be readily understood by reference to the following description considered in conjunction with the accompanying drawing, wherein:
FIG. 1 is an enlarged longitudinal sectional view of a variable capacitor embodying a preferred form of the invention.
FIG. 2 is a transverse sectional view taken substantially long line 2--2 of FIG. 1.
FIG. 3 is a greatly enlarged fragmentary sectional view taken along line 3--3 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
While this invention is susceptible to embodiment in many different forms, there is shown in the drawing and will be described herein a particular embodiment thereof, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to that embodiment. The scope of the invention will be limited only by the language of the appended claims.
Referring now to the drawing, the capacitor comprises a cylindrical housing 11 of rigid material, such as plastic, or ceramic, having an end wall 12 formed integrally therewith. A circular wall plate 13 preferably of electrically insulating material, having a circular electrically conductive plate 14 suitably secured thereto, is fitted within a counterbore 15 formed in the open end of the housing 11. The wall plate 13 may be secured in the counterbore by a suitable adhesive. Alternatively the end plate 13 can be secured to the end of housing 11 or within its inner cylindrical surface.
A bearing hub 40 is suitably secured to the wall plate 13 and forms a bearing for one end of a screw threaded shaft 16. The latter may be of electrically insulating material and has a flattened end section 17 protruding from the wall plate 13 to receive a knob (not shown) or other device for rotating the shaft. A flange 18 formed on the shaft bears against an inward projection 42 of the hub 40 to prevent outward axial movement of the shaft. The opposite end of the shaft 16 has a reduced diameter bearing journal thereon rotatably mounted in a bearing 19 formed in the end wall 12 of the housing. A sealing ring 29 of rubber or the like may be fitted in an annular groove in the bearing hub 40 in engagement with the shaft 16 to hermetically seal the interior of the housing from the exterior environment.
A threaded bearing bushing 20 is threadedly engaged with the threaded portion of the shaft 16 and has secured to it a rigid disc 21 of electrically insulating material to which is suitably secured a plate 22 of electrically conductive material.
Interleaved films or plates 23 and 24 are coiled in spiral form and located about the axis of shaft 16 in sliding contact with each other. The films are each formed of a thin dielectric base 35 (FIG. 3), such as Mylar, on one surface of which a thin layer 36 of conductive material, such as aluminum, is bonded, plated, sputtered or otherwise applied.
The right hand edges of the coils of film 24 are secured, preferably by an electrically conductive adhesive 37, to the plate 22, thus electrically connecting the layer 36 to the plate 22. Likewise, the left hand edges of the coils of film 23 are secured by a suitable conductive adhesive (not shown) to the conductor plate 14.
Although the films 23 and 24 are relatively thin, and are therefore highly flexible and may to some extent be normally limp, when coiled in interleaved fashion and arranged in sliding relation with each other they become sufficiently rigid to permit relative axial sliding movement therebetween.
An electric terminal 27 is anchored in the wall of the housing 11 and is electrically connected to the plate 14. Alternatively, the terminal 27 could be integral with plate 14 within the scope of this invention. A second terminal 28 is also anchored in the housing wall and is connected by a flexible conductor 39 to the conductor plate 22.
Means are provided to prevent turning of the plate 21 while being moved along the length of the housing 11 by rotation of the shaft 16, and for this purpose, a notch 31 is formed in the plate 21 which slidably embraces a spline 32 extending lengthwise of the housing 11 and integral therewith.
The hub 40 is preferably formed with screw threads 41 thereon for mounting in a hole in a panel or the like (not shown), with the flattened portion of the shaft extending through the panel.
According to the invention, the films 23 and 24 are preferably assembled on their respective plates by coiling the same in interleaved and snug fitting engagement on a suitable arbor (not shown), then applying a suitable conductive adhesive such as shown at 37, between the right hand edges of the coils of film 24 and conductor plate 22, and between the left hand edges of the coils of film 23 and conductor plate 14, and then holding the films in engagement with their respective conductor plates until suitably bonded. Other forms of bonding, such as heat welding, may also be used.
From the above it will be seen that the device of the present invention results in an inexpensive, lightweight capacitor which can be manufactured in miniature as well as larger sizes, is highly reliable, does not require precise and accurate manufacturing techniques, provides a large amount of capacitance and is adjustable through a wide range of capacitance values. | A variable capacitor formed of two flexible interleaved films, each having a dielectric layer and a superposed electrically conductive layer. The films are coiled about an axis in sliding contact with each other and are movable axially relative to each other to vary the capacitance. | 8 |
GOVERNMENT RIGHTS
This invention was made with United States Government support under Contract No. DE-AC04-94AL85000 awarded by the U. S. Department of Energy. The Government has certain rights in this invention.
BACKGROUND OF THE INVENTION
In the field of micromechanics, mechanical devices are fabricated which are on the scale of micrometers (i.e., approximately 1×10 -6 ). In particular, electrically powered micrometer-sized micro-motors (or "micro-engines" as they are known) exist which are designed to provide rotational motion in order to drive a mechanical load. These devices are typically electrically powered and are generally constructed using surface machining techniques, which can be generally applicable to the micro, milli and macro domains. However, a similar mechanism may be designed with LIGA technology ("Lithographie Galvanoforming Abforming", an acronym which evolved from the Karlsruhe Nuclear Research Center in Germany). This type of device, for example, is described in U.S. Pat. No. 5,631,514 to Garcia t al., titled "Microfabricated Microengine for Use as a Mechanical Drive and Power Source in the Microdomain and Fabrication Process" and is sufficient to drive a mechanical load at micrometer scale for a variety of end-use applications.
While applications using a micromachined mirror are found in the prior art (such as the article titled "Micromirrors Project Better Images", Byte magazine, July 1996), such mirrors are fabricated to remain substantially in the same plane as the plane the mirror was originally fabricated in. The invention disclosed herein differs from existing micromirror technology in several respects. First, until the present invention, micromirror technology attempted to rely on a rigid link to raise the mirror out of the plane of the wafer, but with great difficulty and varied results. Second, until the present invention, there was no practical way to mechanically move a micrometer-sized mirror up and out of the plane of the wafer, but rather, was done manually with a probe tip which typically resulted in damage to the mirror, the nearby fabricated structures or the wafer itself. Third, raising the micrometer-sized mirror manually was not a reliable procedure due to the unpredictable forces generated on the mirror structure and other nearby structures. Fourth, manually raising the mirror is impractible for almost all commercial applications. Fifth, prior art is devoid of technology which allows the mirror to be substantially raised out of the wafer's plane of fabrication. Finally, the planar structures created by surface micromachining present difficulties with developing a sufficient moment to move fabricated structures out of and into the x, y coordinate plane when actuated by those same planar structures, wherein the difficulty arises due to the short moment arms (in thickness direction of the z-coordinate axis) which are created during the fabrication process.
The present invention overcomes the prior art's deficiencies by providing an apparatus to selectively drive a specially designed output gear mechanism which, in turn through a series of linkage systems and other structures, engages a mirror to move the mirror out of and into the mirror's plane of fabrication by buckling. Similarly, the present invention allows selective operation of the mirror to any predefined angle in the x, y or z coordinate axis. The present invention is useful in certain industries (such as the defense industry) and is especially useful to redirect remotely located electromagnetic signals from an electromagnetic source such as an optical source having an optical beam diameter ranging from 100 to 400 micrometers. Consequently, the present invention may be utilized in nuclear detonation systems, conventional munitions detonation systems, optical scanners, in optical switching applications for fiberoptic communication systems, for assembly of other michromachinery and other related applications. For example, with the advent of fiber optic telecommunication systems has created the need for small, highly efficient, low-cost optical switches that are used to redirect optical signals such as provided by the present invention. Additionally, the present invention is useful in other applications requiring larger switching systems.
It is therefore an object of the present invention to provide a device for redirecting optical signals comprising a primary driver means, a linkage system attached to the primary driver means to amplify the input force from the primary driver means, a pusher rod rotatably coupled to the linkage system, a flexible link element connected to the pusher rod and adapted to buckle upon a predetermined force applied by the pusher rod and a mirror being coupled to the pusher rod.
It is a further object of the present invention to provide a micrometer-sized device adapted to redirect signals by use of a mirror structure and a flexible link adapted to buckle, both the flexible link and the mirror structure fabricated from the plane of a wafer and capable of movement into or out of the wafer's plane of fabrication.
It is also an object of the present invention to provide a device for redirecting electromagnetic signals including a driver means adapted to provide a predetermined force, a linkage system attached to the primary driver means, a pusher rod in mechanical communication with the linkage system, a flexible link element in mechanical communication with the linkage system and adapted to buckle upon the predetermined force, a pusher rod in mechanical communication with the flexible link element and a micrometer-sized mirror in mechanical communication with the pusher rod.
It is a further object of the present invention to disclose a device adapted to redirect electromagnetic signals by use of a movable, deformable micrometer mirror structure without any manual intervention.
It is an object of the present invention to provide a device fabricated on a substrate in the microdomain for redirecting signals including a flexible link element adapted to buckle upon a predetermined force applied by a pusher rod to thereby raise a micrometer fabricated mirror into a preselected position above the plane of the fabricated substrate into a third coordinate dimension without any manual intervention.
It is also an object of the present invention to provide a device for redirecting signals having a mirror structure fabricated from the plane of a wafer and capable of movement into or out of the wafer's plane of fabrication, the mirror structure including at least one support structure attached to the wafer, to thereby permit rotation of the mirror structure out of the plane of the wafer by support structure bending.
It is also an object of the present invention to provide a micrometer-sized device for redirecting signals having a mirror structure fabricated from the plane of a wafer and capable of movement into or out of the wafer's plane of fabrication, the mirror structure attached at one end to the wafer by at least one support structure, and at the other end, attached to a flexible link by a plurality of hinges, to thereby allow rotation of the mirror structure.
It is another object of the present invention to provide an apparatus for redirecting electrical signals between two substrates, the invention including a contact structure fabricated from the plane of a first wafer and in electrical communication with an electical circuit fabricated on the first wafer, the contact structure being capable of movement into or out of the first wafer's plane of fabrication so as to electrically contact a second electrical circuit fabricated on a second wafer, thereby allowing redirection of an electrical signal between two or more wafers.
It is also an object of the present invention to provide a device for redirecting electrical signals on a wafer, the invention including a contact structure fabricated from the plane of a wafer and in electrical communication with an electical circuit fabricated on the wafer, the contact structure being capable of movement within the first wafer's plane of fabrication so as to electrically contact a second electrical circuit fabricated on the wafer, thereby allowing redirection of an electrical signal between two or more electrical circuits fabricated on the same wafer.
SUMMARY OF THE INVENTION
The present invention comprises a primary driver means, a linkage system mechanically coupled to the primary driver to thereby amplify the input force provided by the primary driver, a pusher rod rotationally coupled to the linkage system, a flexible element mechanically coupled to the pusher rod and adapted to buckle upon a predetermined force, and a mirror structure coupled to the flexible rod element.
The present invention is a single degree of freedom system, which is a system where all elements of the invention move in unison. In particular, all structural elements are formed on a single crystal silicon wafer. As such, a plurality of electrostatic or magnetic circuits control the operation of the primary driver means to drive the linkage system in gear-like fashion. When the linkage system is engaged, the linkage system engages the pusher rod with a predetermined force and in approximately a single coordinate direction to thereby provide such force to the flexible link. To assist in the unidirectional axial thrust of the pusher rod, a plurality of optional guides attached to the wafer can be employed. The flexible link is adapted to buckle at the predetermined force. When buckled, the flexible link engages the mirror structure to thereby allow the mirror structure to move into or out of the wafer's plane of fabrication at any predetermined angle with respect to the wafer. Preferably, all components are fabricated in the micro domain, but may be larger as desired.
The present invention overcomes the difficulty of raising a mirror which has been fabricated in the plane of a wafer through a design that utilizes the phenomenon known as buckling to provide sufficient forces to raise a micrometer-sized mirror structure up and out of the wafer's plane of fabrication. By applying axial forces to the push rod and thereby forcing the flexible link to buckle, an internal bending moment about an axis parallel to the wafer's surface is created which can be harnessed to raise or lower the micrometer-sized mirror structure.
The novel features of the present invention will become apparent to those of ordinary skill in the art upon examination of the following detailed description of the invention or can be learned by practice of the present invention. It should be understood, however, that the detailed description of the invention and the specific examples presented, while indicating certain embodiments of the present invention, are provided for illustration purposes only because various changes and modifications within the spirit and scope of the invention will become apparent to those of ordinary skill in the art from the detailed description of the invention and claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of the present invention illustrating the present invention when not in operation;
FIG. 2 is a partial top view of the present invention;
FIG. 3a is a cross-sectional view of the flexible rod element and mirror structure of the present invention when not in operation;
FIG. 3b is a cross-sectional view of the flexible rod element and mirror structure of the present invention when engaged to raise the mirror structure to a predefined angle;
FIG. 3c is a cross-sectional view of the flexible rod element and mirror structure of the present invention when engaged to raise the mirror structure to a predefined angle;
FIG. 4 illustrates the flexible rod and the mirror structure of the present invention;
FIG. 5 is a top view of the present invention illustrating the present invention when in operation;
FIG. 6 is a graph illustrating the amount of force generated by the linkage system to actuate the flexible rod element and mirror structure of the present invention;
FIG. 7 depicts an alternate embodiment of the present invention; and
FIG. 8 illustrates another alternate embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the preferred embodiment as seen in FIG. 1, the present invention 10 comprises a micrometer-sized primary driver means 11, a linkage system 31 mechanically coupled in gear-like fashion to primary driver means 11 to thereby amplify the input force provided by primary driver means 11, a pusher rod 51 rotationally coupled to linkage system 31, a flexible rod element 71 mechanically coupled to pusher rod 51 and adapted to buckle or flex upon a predetermined force, a micrometer-sized mirror structure 91 coupled to flexible rod element 71, and a plurality of driver stops 101a, 101b, all integrally formed on the surface of wafer 9 by surface micromachining techniques, generally using polysilicon.
Primary driver means 11 is a general purpose actuator, and preferably, is a microengine having two synchronized actuators 13a, 13b as a power source which converts oscillatory motion from actuators 13a, 13b into rotational motion via direct linkage connections 15a, 15b to linkage system 31. In the preferred embodiment, primary driver means 11 is the microfabricated microengine disclosed in U.S. Pat. No. 5,631,514 to Garcia et al., the specification and teachings of which are hereby incorporated by reference. Alternatively, those of skill in the art will realize that any device adapted to drive an output gear or linkage system 31 can be employed as primary driver means 11.
As seen in FIGS. 1 and 2, linkage system 31 is mechanically coupled in gear-like fashion to primary driver means 11 through linkage connections 15a and 15b. In particular, linkage system 31 is designed to amplify the input force provided by primary driver means 11 and includes circular hub 35 mechanically connected to wafer surface 9 by segmented gear pivot 39, an outer gear 33, a plurality of spokes 37 interconnecting hub 35 to outer gear 33, and elongated curved drive link 32. Preferably, a plurality of holes 36 (or, etch release holes) are formed upon hub 35 and spokes 37 to lighten the weight of linkage system 31, and also serve in the fabrication process to assist in the elimination of oxide. The gear teeth on outer gear 33 are adapted to mechanically communicate with the gear teeth upon linkage connections 15a and 15b. As seen in FIG. 1, linkage system 31, and more particularly outer gear 33, is not a full circular gear and is not required to be a full circular gear as will soon become apparent to those of skill in the art.
As seen in FIG. 2, elongated curved drive link 32 is fabricated to rotationally attach to circular hub 35 at pivot joint 34 which is a point that axially intersects the center of hub 35. Drive link 32 is curved at one end 32a about segmented gear pivot 39 so as not to come into contact with segmented gear pivot 39, and as shown, is designed for processing convenience to provide the necessary predetermined axial forces to achieve buckling in flexible rod 71. Optimally, when the present invention 10 is in its initial position, pivot joint 34, segmented gear pivot 39 and pivot joint 52 all line up axially to provide the greatest amount of initial force when primary driver means 11 is first engaged, and therefore, drive link 32 can be fabricated without any curved portions. This relationship, for example, is seen in FIG. 6, which graphically depicts the amount of force generated by the linkage system 31 as a function of segmented gear angle to acuate the flexible rod element 71 and mirror structure 91. Anchors tops 101a and 101b, fabricated on and attached directly to wafer 9, prevent full rotation of output gear 33, and preferably, limit total angular rotation between 0 degrees and 120 degrees. However, as those of skill in the art will come to realize, by extending the size of spokes 37, it is possible to achieve rotation up to 180 degrees. Thus, when primary driver means 11 is engaged, linkage system 31 operates to partially rotate through a predefined rotational path which defines the angle a (as seen in FIG. 3) upon which the mirror structure 91 is raised or lowered.
As seen in FIG. 2, pusher rod 51 is rotationally coupled to the other end of curved drive link 32 through pivot joint 52. Pusher rod 51 is an elongated element designed to transfer axial forces between linkage system 31 to flexible rod element 71. Because of the nature of forces involved and the axial direction required, a plurality of guides 53, 55, 57 and 59, fabricated on and attached to wafer 9, are employed to ensure that pusher rod 51 maintains an axial direction at all times during operation. Guides 53, 55, 57 and 59 are typically fixed structures fabricated apart from each other, but can include cam roller bearings for ease in guiding pusher rod 51 in an axial direction, and can also include other support structures (such as integrally formed retainer lips or interconnecting rods which interlink one or more guides) to prevent pusher rod 51 from rising out of the wafer's plane of fabrication.
At one end, flexible rod element 71 is preferably integrally formed with pusher rod 51. Flexible rod element 71 is generally designed to be thin, elongated and fabricated from polysilicon, and is necessarily fabricated to buckle or contort to form an arch-like structure when a predetermined force is applied so that it moves up and off the surface of wafer 9. When buckled, flexible rod element 71 produces a bending moment about an axis of bending which is parallel with the plane of wafer 9. With the design of the linkage system 31 and pusher rod 51, a very high initial actuation force is created when primary driver means 11 Is initially engaged, resulting in a predetermined force to buckle flexible rod element 71. As those of skill in the art may know, the critical buckling load is determined by the material used, and also generally by the equation 1/L 2 , where L is the length of the flexible rod element 71.
At the other end of flexible rod element 71 is coupled micrometer-sized mirror structure 91 as illustrated in FIG. 4. Mirror structure 91 includes reflective mirror 93 integrally attached to wafer 9 through at least one connecting means 95 anchored to wafer 9. For further support, the present invention may employ additional connecting means (such as that identified as item 97 in FIG. 2) which is integrally attached to reflective mirror 93 on one end and anchored to wafer 9 at another end. In the preferred embodiment, reflective mirror 93 is coated with a material which enhances light reflectivity, such as gold, and can be formed into any desired geometric shape such as a square. Moreover, mirror 93 is designed to reflect other electromagnetic signals depending on the composition of mirror 93 or the type of coating applied to the surface of mirror 93.
In an alternate embodiment, reflective mirror 93 is coupled to flexible rod element 71 through at least one hinge means at point 71a (as depicted in FIG. 4) which is microfabricated by techniques known in the art, and to connecting means 95 and 97 through similar hinge means at points 95a and 97a. In fact, it should be clear to those of skill in the art that the elongated leg portion of connecting means 95 and 97 are not necessary when hinge connecting means are employed at points 95a and 97a. Further, those of skill in the art will realize that other forms of surface machining which couple mirror 93 to flexible rod element 71 and wafer 9 are within the scope and spirit of this invention.
When the present invention is not in operation (as seen in FIGS. 1 and 3c), mirror structure 91 is positioned normally in wafer 9's plane of fabrication. In operation, primary driver means 11 is operated to engaged linkage system 31 through a predetermined force F. Linkage system 31, in turn, partially rotates thereby causing curved drive link 32 to transfer force F to pusher rod 51. The relationship between the amount of force F produced by the linkage system 31 to operate flexible rod element 71 and mirror structure 91 is shown in FIG. 6. Further, the amount that linkage system 31 rotates is dependant upon the placement of anchor stops 101a and 101b, but preferably rotates up to 120 degrees. Because of the position and design of curved drive link 32 within linkage system 31, and because curved drive link 32 is rotationally coupled to pusher rod 51, curved drive link 32 is adapted to provide an axial thrust force F on pusher rod 51 at any angular rotation of linkage system 31 between 0-180 degrees. Next, pusher rod 51 travels in an axial direction to generate axial force F to flexible rod element 71. Then, flexible rod element 71, upon being axially forced by pusher rod 51, buckles upon application of predetermined force F so as to move out of and into wafer 9's plane of fabrication. Because flexible rod element 71 is coupled to mirror structure 91, mirror structure likewise moves out of and into wafer 9's plane of fabrication. This arrangement is illustrated in FIG. 5. Depending upon the amount of force F supplied by primary driver means 11, mirror structure 91 moves into or out of wafer 9's plane of fabrication by angle a (as seen in FIGS. 3a-3c), which is preferably 45 degrees. As such, an external electromagnetic source, such as a laser, can direct an electromagnetic signal to mirror 93 which, due to its high reflectivity, can redirect the electromagnetic signal to a different coordinate path dependent upon the angle α.
In all embodiments described, the predetermined force F is approximately consistent at each step of operation, however, force F may vary due to natural forces such as friction. Moreover, as seen in FIG. 6, the force initially applied by primary driver means 11 to linkage system 31 is high, and as mirror 93 is raised out of the plane of wafer 9, the force F required to raise mirror 93 will decrease.
An alternate embodiment of the present invention is partially illustrated in FIG. 7. In this embodiment, two wafers (9 and 109) are placed adjacent to each other by spacers 113. Upon wafer 109 is fabricated at least one electrical circuit 111, and upon wafer 9 is fabricated at least one electrical circuit 99 which is in electrical communication with contact structure 115. Contact structure can be formed, for example, from any material which reduces contact resistance. When pusher rod 51 applies an axial force upon flexible rod element 71, flexible rod element 71 buckles and contact structure 115 substantially moves out of wafer 9's plane of fabrication and electrically contacts electrical circuit 111, thereby causing electrical circuit 111 and circuit 99 to be in electrical communication. In this fashion, the present invention allows for redirection (or, switching) of an electrical signal between two or more electrical circuits formed on different wafers.
Another alternate embodiment of the present invention is illustrated in FIG. 8. In this embodiment, electrical circuit 121 is formed upon wafer 9. Similarly, electrical circuit 123 is formed upon wafer 9 and is in electrical communication with mirror structure 91. Flexible rod element 71 is designed to buckle in the y coordinate directions so that contact structure 115 similarly follows the path of element 71's buckling direction. When flexible rod element 71 is buckled (as, for example, in the y direction as seen in FIG. 8), contact structure 115 remains within wafer 9's plane of fabrication, yet allows for electrical contact with electrical circuit 111, thereby causing electrical circuit 111 and circuit 99 to be in electrical communication. In this fashion, the present invention allows for redirection (or, switching) of an electrical signal between two or more electrical circuits formed on the same wafer.
Other variations and modifications of the present invention will be apparent to those of ordinary skill in the art, and it is the intent of the appended claims that such variations and modifications be covered. The particular values and configurations discussed above can be varied, are cited to illustrate particular embodiments of the present invention and are not intended to limit the scope of the invention. It is contemplated that the use of the present invention can involve components having different characteristics as long as the principle, the presentation of an apparatus and method which redirects electromagnetic signals, is followed. | A device fabricated to redirect electromagnetic signals, the device including a primary driver adapted to provide a predetermined force, a linkage system coupled to the primary driver, a pusher rod rotationally coupled to the linkage system, a flexible rod element attached to the pusher rod and adapted to buckle upon the application of the predetermined force, and a mirror structure attached to the flexible rod element at one end and to the substrate at another end. When the predetermined force buckles the flexible rod element, the mirror structure and the flexible rod element both move to thereby allow a remotely-located electromagnetic signal directed towards the device to be redirected. | 8 |
FIELD OF THE INVENTION
[0001] The invention relates to the textiles domain. More precisely, the invention relates to a novel pigment-dyeing method for textile materials by exhaustion.
BACKGROUND OF THE INVENTION
[0002] There are two types of products to colour textile materials: the dyes and the pigments.
[0003] The dyes are water-soluble compounds. They can be of different classes, such as direct, reactive, sulphur-based, indigo, basic or acidic. The benefit of the dye is that it penetrates the fibre itself. However, using dyes requires additional rinsing steps, which result in highly polluted water with residual dyes, which can cause ecological problems. Moreover, the colouration process is long and requires large quantities of water and energy.
[0004] The pigments are chemically inert, are not soluble in water nor in most of the solvents currently used and don't have an affinity for the fibres. Consequently, they cannot penetrate in the fibre like the dye but remain on the surface only. Their use involves the use of binders, generally of the thermoplastic elastomer type, and the use of fixing agents in order to obtain high quality of resistance of the colours to wet tests.
[0005] In the textile industry the pigments are certainly the simplest and most used method for colouring textile materials because they offer many benefits:
a versatile aspect (all fibres), their capabilities of preserving the environment (low amounts of waste, no subsequent washing, etc.), their good resistance to light, water and solvents, a wide choice of shades, less expensive application method.
[0011] It is known to a person skilled in the art that pigment-dyeing by exhaustion is possible by providing substantivity to the pigments by adding a cationic charge auxiliary which provides affinity to the pigments for the fibre. The textile supports are then cationised before the dyeing step itself.
[0012] A person skilled in the art have several cationisation agents at its disposal which allow improving the affinity of the fibre with the pigments.
[0013] The patent U.S. Pat. No. 5,006,129 describes a method of pigmenting which includes a textile pre-treatment step with a cationisation agent which includes a quaternary ammonium group. The patent U.S. Pat. No. 5,252,103 claims a method of pigmenting using cationic components that include a quaternary ammonium group. Among the components used, one can cite acrylamide/2-(Methacryloyloxy)ethyl trimethylammonium chloride copolymer.
[0014] However, the prior art is not completely satisfactory. The current problem is thus finding a pigment-dyeing method that allows dyeing cellulose-based textile supports or a combination of cellulose and synthetic fibres with the following advantages:
complete exhaustion of the dye baths, extremely high colour yields, high affinity of the pigment for the fibre, extremely short method times and low water volumes needed, extremely high solidity of the colours during wet tests, very low DCO and DBO5 charges in the effluents.
SUMMARY OF THE INVENTION
[0021] The problem that the invention purports to solve is to provide a novel pigment-dyeing method for textile materials by exhaustion showing the above-mentioned advantages while eliminating the disadvantages of the prior art.
[0022] The applicant has finalised a novel pigment-dyeing method for individualised textile fibres or textile supports obtained from the said fibres consisting of pre-treating the fibres or the support with at least one polymer then of dying the thus pre-treated fibres or support using pigments.
[0023] The method is characterised in that the polymer is a VinylAmine-based (co)polymer.
[0024] The invention is applicable in particular to the pigment-dyeing of natural and/or synthetic fibres. As natural fibres, it is possible to cite natural cellulose-based vegetable fibres, like cotton, linen, cellulose regenerated fibres like viscose, modal, modified cellulose like acetate and triacetate. We can also mention animal fibres like wool and silk. As synthetic fibres, examples include acrylic-based, modacrylic-based, polyester-based, polyamide-based fibres and their combinations.
[0025] The support obtained from the fibres can be a woven, a non-woven or a knitted support.
[0026] VinylAmine (co)Polymers (PVA)
[0027] The PVA used in the novel method can result from the various methods known by a person skilled in the art. We can cite the PVA resulting from hydrolysis of the homopolymers or copolymers of N vinylformamide, or even the PVA resulting from Hofman degradation.
PVA resulting from complete or partial hydrolysis of a (co)N-vinylformamide (co)polymer
[0029] In a first step, a N-Vinylformamide (co)polymer (NVF) must be obtained; the NVF having the following pattern:
[0000]
[0030] Consequently, this NVF patter must be converted, by hydrolysis, into VinylAmine:
[0000]
[0031] The hydrolysis can be carried out by an acidic action (acid hydrolysis) or a basic action (basic hydrolysis).
[0032] Depending on the added quantity of acid or base, the NVF polymer or copolymer will be partially or completely converted into VinylAmine.
PVA resulting from Hofman degradation
[0034] Hofman degradation is a reaction discovered by Hofmann at the end of the nineteenth century, which allows converting an amide (even an acrylonitrile) into a primary amine by elimination of carbon-dioxide. Details of the reaction mechanism are given below.
[0035] In the presence of a base (soda), a proton is pulled off from the amide.
[0000]
[0036] The resulting amidate ion then reacts with the active chloride (Cl 2 ) of the hypochloride (for example: NaClO which is in balance: 2 NaOH+Cl 2 NaClO+NaCl+H 2 O) to result in a N-chloramide. The basic solution (NaOH) pulls off a proton from the chloramide to form an anion. The anion loses a chlorine ion to form a nitrene which undergoes an isocynate transposition.
[0000]
[0037] Through a reaction between the hydroxide ion and isocynate, a carbamate is formed.
[0000] R— N ═C═ Ō +OH − →R—NH—CO 2 −
[0038] After decarboxylation (elimination of CO2) of the carbamate, a primary amine is obtained.
[0000]
[0039] For the conversion of all or part of the amide groups of an acrylamide (co)polymer in an amine group, two primary factors intervene (expressed in molar ratio). It involves: —Alpha=(alkaline hypohalite and/or alkaline earth metal/acrylamide) and —Beta=(alkaline hydroxide and/or alkaline earth metal/alkaline hypohalogenure and/or alkaline earth metal).
[0040] According to certain embodiments the PVA-based (co)polymers can include other ionic and non-ionic monomers.
[0041] The non-ionic monomer(s) that can be used within the scope of the invention can be selected, particularly, from the group consisting of water-soluble vinylic monomers in the room. Preferred monomers belonging to this class are, for example, acrylamide, N-isopropylacrylamide, N,N-dimethylacrylamide. Also, it is possible to use N-vinylformamide, and N-vinylpyrrolidone. A non-ionic monomer is preferred over acrylamide.
[0042] The cationic monomer(s) that can be used within the scope of the invention can be selected, particularly among the acrylamide, acrylic, vinylic, allelic or maleic monomers that possess a quaternary ammonium group. It is possible to cite, in particular in a non-exhaustive matter, quaternised dimethylaminoethyl acrylate (ADAME) and quaternised dimethylaminoethyl methacrylate (MADAME), dimethylkdiallylammonium chloride (DADMAC), acrylamidopropyltrimethylammonium chloride (APTAC) and methylenebisacrylamidemethacrylamidopropyltrimethylammonium chloride (MAPTAC). The anionic monomers that can be used within the scope of the invention can be chosen in a large group. These monomers can show acrylic, vinylic, maleic, fumaric, allelic groups, and contain a carboxylate, phosphonate, phosphate, sulfate, sulfonate group, or another group with an anionic charge. The monomer can be acid or even in the form of a salt or an alkaline-earth metal or alkaline-metal corresponding to such a monomer. Suitable examples of monomers include acrylic acid, methacrylic acid, itaconic acid, crotonic acid, maleic acid, fumaric acid and highly acidic type monomers, for example having a sulfonic acid or phosphonic acid type group such as 2-acrylamid 2-sulfonic methylpropane acid, vinylsulphonic acid, vinylphosphonic acid, allylsulphonic acid, allylphosphonic acid, sulphonic styrene acid and water-soluble salts of an alkaline metal, an alkaline-earth metal and ammonium.
[0043] According to a preferred method the PVA-based (co)polymer results from Hofmann degradation made on a base (co)polymer that includes acrylamide or derivatives.
[0044] According to another method of the invention, it is possible to use (co)polymers obtained by Hofman degradation made on a base (co)polymer comprising acrylamide or derivatives and at least one polyfunctional component containing at least three heteroatoms each having at least one mobile hydrogen atom.
[0045] Preferably, the polyfunctional component is selected from the group consisting of polyethyleneamine, polyamine, polyallylamine
[0046] In a general manner, polymers of the invention do not need development of a particular polymerisation method. Indeed, they can be obtained according to all polymerisation techniques which are well known to a person skilled in the art. They can particularly involve solution polymerisation; gel polymerisation; precipitation polymerisation;
[0047] emulsion polymerisation (aqueous or inverse); suspension polymerisation; or micellar polymerisation.
DETAILED DESCRIPTION OF THE INVENTION
[0048] Pre-treatment:
[0049] In accordance with the invention, the textile material first undergoes a pre-treatment step.
[0050] This step consists of putting the textile material into contact with at least one vinylamine-based (co)polymer (PVA) in a bath that contains water.
[0051] The PVA (co)polymer is used in dosages from 1 to 10% in weight of the material to be dyed, preferably from 3 to 8%.
[0052] The polymer/pigment ratio in weight is between 1:10 and 10:1, preferably between 3:1 and 7:5, and more preferably the ratio is 5:3.
[0053] The pre-treatment is generally done at a temperature between 20 and 100° C., preferably between 30 and 80° C. The duration of the pre-treatment is between 1 and 60 minutes, preferably between 5 and 40 minutes.
[0054] The bath ratio is the ratio in weight between the total dry material and the total solution constituting the bath. Thus, for example, a bath ratio of 1:10 signifies 10 litres of water for 1 kg of textile material. According to the invention, the bath ratio for pre-treatment is between 1:5 and 1:40, preferably between 1:10 and 1:30.
[0055] The pre-treatment step is done at a pH between 3 and 8, preferably the pH is between 5 and 7. The pH is maintained by adding an acid or an acid pH buffering. One can cite, for example, acetic acid, formic acid, ammonium sulfate, sodium carbonate.
[0056] After the pre-treatment the bath is emptied. The textile material is rinsed at least once with water at a temperature between 10 and 30° C.
[0057] Other components can be introduced during the pre-treatment step. An example might be anti-foam agents and anti-breakage agents.
[0058] The pre-treatment can be carried out with the resources known by a person skilled in the art. Preferably, the pre-treatment can be carried out in a dyeing device such as jet flow, over flow, bark, jigger, autoclave, industrial drum, reel and wire dyeing device or skeins.
[0059] In order to facilitate the pre-treatment, the textile material can optionally undergo at least one prior step known to a person skilled in the art. An example might be the degreasing, quenching or laundering.
[0060] The pre-treatment step can be followed by a softening, stonnage or even bio-polishing of the textile material before the dyeing step.
[0061] Dyeing:
[0062] In accordance with the invention, after the pre-treatment step, the material undergoes a dyeing step. This step consists of putting the pre-treated textile material into contact with at least one pigment in a bath containing water.
[0063] More specifically, the textile material is coloured using the exhaustion pigmentation technique. This technique consists of exhausting the pigment bath by transferring the latter towards the textile material.
[0064] The pigment(s) can be introduced in the bath in powder or liquid form. In a preferential manner, the pigments are introduced in liquid form.
[0065] In case of liquid form, the pigments are spread in at least one solvent. The concentration of pigments in the solvent is between 10 and 50%, preferably between 25 and 35%. Preferably the solvent is water.
[0066] In a general manner, the pigment(s) are added to the bath at 0.1% to 10% in weight of the material to be dyed.
[0067] The dyeing is done at a temperature between 20 and 90° C., preferably between 40 and 80° C. The increase in temperature is lower than 10° C. per minute, preferably between 1 and 4° C. per minute.
[0068] Once the target temperature is reached, this latter is maintained for 1 to 60 minutes, preferably between 5 and 40 minutes. The bath ratio for dyeing is between 1:5 and 1:40, preferably between 1:10 and 1:30.
[0069] After dyeing, the bath is emptied. The textile material is rinsed at least once with water. Preferably the water is at a temperature between 10 and 30° C.
[0070] Other components can be present during the dyeing step. An example might be anti-foam agents or anti-breakage agents.
[0071] Post-treatment
[0072] In order to improve the solidities of the textile material in the wet tests, a post-treatment can optionally be implemented.
[0073] This post-treatment consists of adding at least one binder and/or at least one fixing agent.
[0074] The binder is a composition that includes pre-polymers of low molecular weight. During the spinning and drying steps (at high temperature), these pre-polymers will react to form a film that entraps and integrates the pigments in the fibre. The binder is used at dosages between 0.1 and 15%, preferably between 1 and 10% in material weight.
[0075] The reticulation of the binder is done at a temperature between 50 and 250° C., preferably between 100 and 200° C.
[0076] The high temperature exposure lasts between 1 and 20 minutes, preferably between 3 and 10 minutes.
[0077] The binder can be acrylate-based, styrene acrylate-based, styrene butadiene based and vinyl-acrylate-based.
[0078] The fixing agent reacts to form a three-dimensional network around the fibre at the time of drying.
[0079] The fixing agent is used at dosages between 0.1 and 15% preferably between 1 and 10% in material weight.
[0080] The fixing agent is used at a temperature between 10 and 90° C., preferably between 20 and 60° C. The pH of the bath is maintained between 3 and 6 per day, by adding an acid or an acid pH buffering.
[0081] Once the fixing agent is introduced, the bath is heated. The increase in temperature is lower than 10° C. per minute, preferably between 1 and 4° C. per minute. Once the target temperature is reached, this latter is maintained for 1 to 60 minutes, preferably between 5 and 30 minutes.
[0082] The bath ratio is between 1:5 and 1:40, preferably between 1:10 and 1:30.
[0083] The fixing agent can be polyisocynate-based, melamine formol-based, dimethyl dihydroxy ethylene urea-based (DMDHEU).
[0084] After the post-treatment, the bath is emptied. The textile material is rinsed at least once with water having a temperature between 10 and 30° C.
[0085] The post-treatment step can be followed by a softening, stonnage or bio-polishing step of the textile material.
[0086] One of the advantages of the invention is in the high rate of exhaustion of the pigments in the dyeing bath, since the baths emptied in the sewage do not have a high load of pigments.
[0087] It was unexpectedly discovered that PVA allows higher quality of pigment exhaustion compared to conventional cationisation products. Indeed, it is possible to obtain exhaustion rates higher than 95% for light and medium colours, and higher than 90% for dark colours.
[0088] Moreover, without propounding any theory, it would appear that the high pigment/fibre binding avoids a systematic use of binder and/or fixing agent. During subsequent softenings, high quality pigment content was observed, with little or no disgorgement.
[0089] The following examples illustrate the invention in a non-exhaustive manner.
EXAMPLES
I/ Preparation of the Polymer
[0090] Polymer A is obtained by a Hofman degradation reaction on a basic copolymer (20% of active substance) of acrylamide (70% molar) and ramified (MBA: 1000 ppm/active substance) ammonium dimethyldiallyl chloride (DADMAC) (30% molar) modified with a polyethyleneimine polymer (of the Polymin HM type from BASF), at 1% of the active substance. To do this, polyethyleneinmine is combined with DADMAC monomer and MBA in the reactor.
[0091] Acrylamide will be incorporated by continuously pouring for 2 hours, in a reactional environment maintained at 85° C. The catalysis will be carried out with SPS and MBS, catalysers well known by a person skilled in the art. The precursor polymer thus obtained shows a viscosity of 5500 cps (LV3, 12 rpm). The Hofman degradation itself is carried out in the same manner as in example 1 of the patent of the applicant PCT/FR/2009/050456. The acrylamide derivative copolymer A thus obtained shows an intrinsic viscosity of 0.72 (25° C., Brookfield LV1, 60 rpm) and a concentration of 8%.
II/ Carrying out of the Method
Example 1
[0092] A 1:1 ratio of a knit cotton/viscose 50/50 of 150 g/m 2 is degreased in a winch. The bath ratio is 1:25. 1g/l of a wetting detergent is added to the bath. The bath is then heated and maintained at 60° C. for 25 minutes. The bath is then emptied and the material is then rinsed twice using cold water at 15° C. The pre-treatment is then carried out with a bath ratio of 1:25. The pH is adjusted at 9 with sodium carbonate and 5% in weight of polymer A material is added. The bath is heated and maintained at 60° C. for 30 minutes. The bath is emptied and the material is then rinsed twice using cold water at 15° C. The dyeing is then carried out in a bath ratio of 1:25. In the bath, which has an initial temperature of 15° C., 3% of 15/3 blue pigment is added. The heat is then set to 60° C., in increments of 3° C. per minute. The temperature is maintained for 30 minutes. The bath is emptied and the material is then rinsed twice using cold water 15° C. The treated materials is then softened with a nano-silicone emulsion type softener dosed at 2% for 15 minutes, temperature of the bath set to 40° C., pH 5 adjusted with acetic acid.
Example 2
[0093] 100% cotton material trousers twill 3/1 205 g/m 2 are firstly desized in an industrial drum machine. The bath ratio is 1:10. The pH is adjusted to 6 with acetic acid. 3 g/l of an amylase is added to the bath. The desizing is done at 60° C. for 20 minutes. The material is then cold rinsed twice using water at 15° C. The trousers are then cationised in a bath ratio of 1:10, at pH 6 adjusted with acetic acid. 5% in weight of the polymer material is added to the bath. The bath is then heated and maintained at 60° C. for 30 minutes. The material is then cold rinsed twice using water 15° C. The dyeing is then carried out in a bath ratio of 1:10. In the bath, which has an initial temperature of 15° C., 3.5% of 7 green pigment is added. The heat is then set to 60° C., in increments of 3° C. per minute. The temperature is maintained for 40 minutes. The bath is then emptied and the material is then cold rinsed twice using water 15° C. Stonnage is then carried out on the material for 20 min at a bath ratio of 1:10 at pH 4.5 with 1.5% of acid cellulase. The bath is emptied and the material is then cold rinsed twice using water 15° C. The materials is then softened with 1% of silicone micro emulsion and 1% of fatty acid for 15 minutes, temperature of the bath set to 40° C., pH 6 adjusted with acetic acid, the material is then squeezed and dried.
Example 3
[0094] A 100% cotton poplin cloth 105 g/m 2 pre-desized is firstly whitened on an overflow dyeing machine with a bath ratio of 1:20. The following products are added to the whitening bath: anti-foam, anti-breakage, oxygenated water stabiliser, oxygenated water, caustic soda. The bath is then heated at 98° C. for 30 minutes. The bath is then cooled to 70° C. and the material neutralised at pH 7 with acetic acid. The bath is then emptied and the material is then cold rinsed once. The cationisation is then carried out in a bath ratio of 1:20 at pH 5.5 adjusted with a pH acid buffer. 5% in weight of a PVA cationisation agent, an anti-breakage agent and an anti-foam agent are added to the bath. The bath is then heated and maintained at 60° C. for 30 minutes. The material is then rinsed twice using cold water at 15° C. The dyeing is then carried out in a bath ratio of 1:20 at pH 5.5. 2% of orange pigment 34, 1% of yellow pigment 83, an anti-foam agent, an anti-breakage agent and a dispersant are added to the water at a temperature of 15° C. The heat is then set to 70° C., in increments of 1° C. per minute. The temperature is maintained for 20 minutes. At 70° C. an acrylic binder is added to the bath and dosed at 5%. The bath is then emptied and the material is then cold rinsed. The material is then softened with a silicone hydrophilic emulsion type softener dosed at 2% for 20 minutes, bath temperature at 40° C., pH 5 adjusted with an acid buffer.
Example 4
[0095] The cotton cloth of example 3 is whitened continuously, rolled and dried. The cloth is then foulard finished on a sizing foulard in a bath containing 75 g/l of polymer A, at pH 6. The dye exhaust percentage is maintained at 60-80%, the material is then dried on a drying stenter at 100-120° C. The cloth thus treated and is then dyed according to the same protocol described in example 3.
Example 5
Counter-example
[0096] Example 3 is reproduced identically by replacing the polymer A by the PRECAT 3005 (homopolymer of chloromethyled MADAME) distributed by CHT, R BEITLICH GMBH used at 3%.
[0097] The bath exhaustion, colours and friction solidity inspections are carried out.
III/ Assessment Tests
[0098] Assessment of the Rate of Exhaustion:
[0099] At the end of each dyeing a bath sample is taken in order to control the rate of exhaustion E (%) of the dyeing bath pigments using a visible UV spectrophotometer (spectral range from 190 to 900 nm, quartz cell of 10 mm) This latter is calibrated using successive dilutions of the initial coloured pigment solution.
[0000] E (%)= Ci−Cf/Ci* 100.
[0100] Assessment of the Dry and Wet Solidities:
[0101] A final cloth sample is taken in order to inspect the dry and wet friction solidities following the standard NF EN ISO 105-X12(2003) and using a crockmeter. The colour fadings on the cotton samples are assessed using the gray scale and the ISO standard 105-A03(2005).
[0102] Assessment of the Colour:
[0103] The final cloth colour is compared in relation with the standard using a spectrophotometer under the D65 illuminate and at an angle of 10 degrees. The colour differences are determined by calculating the Delta E (CIE 2000) and coloured forces (%) compared to the counter-example.
[0104] Results
[0000]
Friction solidities
Tests
dry
humid
E (%)
FC (%)
Example 1
4-5
4
93.5
108.6
Example 2
4
3-4
91.2
112.4
Example 3
4-5
4
92.8
110.5
Example 4
4-5
4
90.8
109.8
Example 5
3-4
3
86.4
100
[0105] It can be observed that the novel cationisation pre-treatment allows obtaining, compared with a conventional method:
1 to 2 points in result on the dry and humid friction solidities, an increase in the rate of exhaustion E(%) of the pigments from 5 to 10%, an increase in the FC tone levels (%) from 5 to 15%. | Pigment-dyeing method for individualised textile fibres or textile supports obtained from the fibres consisting of pre-treating the fibres or the support with at least one polymer, then dying the thus pre-treated fibres or support using pigments, characterised in that the polymer is a vinylamine-based (co)polymer. | 3 |
BACKGROUND OF THE INVENTION
Woven and knitted bi-elastic textiles are known, such as are used in the garment industry, for instance, for the manufacturing of corset ware and similar textiles. The known woven and knitted bi-elastic textiles are generally not suited for use as upholstering fabrics for chairs, sofas, and similar sitting or reclining furniture since they poorly comply with the general requirements for such cover fabrics. The known bi-elastic woven textiles have, for instance, a characteristic plain, smooth surface which is disadvantageous for esthetic reasons.
Thus, known bi-elastic textiles have generally been heavily printed when intended for upholstering usage in order to try to hide the unsuitable surface characteristics of these textiles as cover fabrics for furniture.
However, because of new shapes for upholstered furniture, the demand for bi-elastic cover fabrics is steadily increasing. The growing use of load carrying furniture parts formed of plastic contributes considerably to the advancement of this development. Oftentimes it is desirable to use textiles which are foam fillable. Such foam-fillable textiles have to expand evenly in two dimensions and at the same time maintain their elasticity even when such a fabric is oppositely stressed, as when a person sits on such foam-filled upholstered and fabric covered chair. Corresponding facts, for instance, apply to the vacuum-deep-drawing.
Aside from the two requirements to possess as even a bi-directional expansive elasticity capacity as possible in warp and weft directions, as well as to retain a capacity to return, or contract, evenly, it is a further requirement for such a bi-elastic fabric that it hae a suitable surface texture which, in respect to such qualities as wear and tear, associated coarseness, esthetic appearance and hand, and the like, makes it especially favorable from a commercial view. For this purpose, generally coarsely structured textile fabrics are expecially advisable; however, known bi-elastic fabrics do not show the necessary expansion behaviour and sufficiently high elasticity, together with suitable coarse texture.
A still further requirement exists for such a bi-elastic fabric when such is to be used for filling with foam, or for vacuum deep drawing, and this is the requirement of being gas tight.
BRIEF SUMMARY OF THE INVENTION
The invention provides an improvement over known textile fabrics by avoiding their above indicated drawbacks and by meeting the above indicated requirements. This invention is directed to a bi-elastic textile fabric bonded on its underside to an elastomeric gas tight film. The fabric shows in each of its warp and weft directions a practically uniform elasticity with relatively large expansion capacity which can be maintained even in case of maximum expansion. This fabric, is rendered air or gas tight by means of an elastomeric, non-porous bonded backing coating which makes possible, for example, the filling of the furniture cavity with foam, or, for another example, the vacuum-deep-drawing of a fabric-covered plastic sheet member, without thereby loosing excessive amounts of the bi-elasticity characteristics of such combination of fabric and bonded film.
The invention utilizes in this bi-elastic fabric for each of the warp and weft fibers a ply yarn which comprises three components. One component is an elastomeric thread of approximately .Badd..[.140 to 280 denier.]..Baddend. .Iadd.154 dtex to 313 dtex.Iaddend.. The second and third components are each yarns of natural and/or synthetic fibers which typically each have maximum tensile strengths of only about one-tenth that of the first component (the elastomeric thread). Typically and preferably, the second component is a coarse yarn of about .Badd..[.10 to 15 denier.]..Baddend. .Iadd.3300 to 12500 dtex.Iaddend., and the third component is a fine yarn of about .Badd..[.4 to 6 denier.]..Baddend. .Iadd.100 to 3300 dtex.Iaddend.. Independently of whether or not the second and third component yarns consist of natural or synthetic fibers, a relatively high spinning rotation in such component fibers of such yarns has been found to be very favorable and preferable for the present invention.
BRIEF DESCRIPTION OF DRAWINGS
In the drawings:
FIG. 1 is a view in perspective illustrating a bi-elastic fabric construction of this invention; and
FIG. 2 is a flow sheet illustrating the technique employed to form the elastomeric, gas-tight film on the back of the fabric of FIG. 1.
DETAILED DESCRIPTION
For use in the yarn 10 (referring to FIG. 1), a preferred elastomeric thread 11 is comprised of a polyurethane elastomer in polyfilament form. Suitable materials are available commercially under the trademark "Dorlaston" from the firm Farbenfabriken Bayer AG, West Germany, and "Lycra" from the E. I. du Pont de Nemours and Company, Wilmington, Del. Thread 11 .[.has a denier of from about 140 to 280.]. .Iadd.of about 154 dtex to 313 dtex.Iaddend..
The second and third components 12 and 13 respectively of a yarn 10 may each be comprised, for example, of polyamides, polyesters, polyacrylics (preferred), polyvinyls, polyolefins, cellulosics (including regenerated cellulose, cellulose acetate, cellulose diacetate, and cellulose triacetates), and the like as synthetic fibers, and/or cotton, wool (preferred), and the like as natural fibers, or mixtures thereof. The second component 12 is preferably a fine yarn; the third component 13 is preferably a coarse yarn. Suitable fine yarns have .[.deniers ranging.]. .Iadd.range .Iaddend.from about .Badd..[.4 to 6 denier.]..Baddend. .Iadd.100 to 3300 dtex.Iaddend.; suitable coarse yarns have .[.deniers ranging.]. .Iadd.range .Iaddend.from about .Badd..[.10 to 15 denier.]..Baddend. .Iadd.3300 to 12500 dtex.Iaddend.. One preferred fine yarn has a .[.denier.]. .Iadd.thickness .Iaddend.of about .Badd..[.3.].ep .Iadd.100 dtex..Iaddend.; one preferred coarse yarn has a .[.denier.]. .Iadd.thickness .Iaddend.of about .Badd..[.16.]..Baddend. .Iadd.12500 dtex.Iaddend..
The combination of the elastomeric threads with the second and third components into a ply yarn 10 which is then woven into a bi-elastic fabric 14 which not only has high elastic requirements, but also has a relatively coarse-structured, desirably lively surface. Such product fabric is relatively not especially heavy, and is relatively not very expensive.
The elastomeric thread 11 is generally not colored and has a white appearance, but is completely enclosed in the twisted, finished ply yarn 10 when such is viewed in side elevation. This effect is generally achieved even though the two yarn components 12 and 13 are each black. Preferably, the ply yarn 10 has an alpha value which lies between about 100 and 150. Thus, this ply yarn 10 differs substantially from such prior art yarn as the spun fiber covered elastomeric yarns wherein sich a twisting does not take place, as those skilled in the art will appreciate.
The number of twists for individual component yarns ranges between about 110 and 425 per meter in the case of a yarn of about .Badd..[.16 denier.]..Baddend. .Iadd.12500 dtex .Iaddend.and between about 130 to 225 per meter in the case of a yarn of about .Badd..[.3 denier.]..Baddend. .Iadd.100 dtex.Iaddend., for the individual components 12 and 13. The number of twists for the ply yarn 10 are: (a) 350 to 370 twists per meter in case of a ply yarn comprising the elastomer thread and two individual component yarns of .Badd..[.16 denier.]..Baddend. .Iadd.12500 dtex.Iaddend., (b) 300 to 310 twists per meter in case of ply yarn comprising one individual component yarn of .Badd..[.3 denier.]..Baddend. .Iadd.100 dtex.Iaddend., a second individual component yarn of .Badd..[.16 denier.]..Baddend. .Iadd.12500 dtex.Iaddend., and the elastomer thread, and (c) from 170 to 190 twists per meter in case of a ply yarn comprising two individual component yarns of .Badd. .[.3 denier.]..Baddend. .Iadd.100 dtex .Iaddend.and the elastomer thread. The direction of the twist of the individual component yarns is z.
The coarse yarn has a staple length of between about 100 and 120 mm. The staple length of the fine yarn is between about 60 and 70 mm. The direction of twist for the ply yarn is s.
A weaving of ply yarn herein described by the prior art conventional looms employing variable warp and weft stresses is not possible. The weft members, ever the weaving width in such known looms, are characteristically subject to varying tension during weaving, and so such looms are generally unsuited for achieving the desired even elastic attitude for both warp and weft members in weaving a fabric of this invention. In addition, such variable tension looms tend to place the weft and warp members under high tension as laid into a fabric being woven, which causes an undesirable expansion on ply yarn members during weaving, so that ply yarn members can be stretched to their limits in a fabric being formed on such a known loom.
Consequently, in weaving a fabric for use in this invention, one uses a type of loom wherein the warp and weft members are maintainable under a minimum, or very low, constant tension. One suitable and preferred loom is a gripper loom, for example, of the type available commercially from Gusken of West Germany.
In addition, the weft density as well as the warp density are each adjusted in such a way that a product textile fabric shows, in both warp and weft directions, an evenly large expansion optionally ranging from about 15 to 50% over their relaxed state. Thereby, the raw, woven width (which is later adjusted), depends, on the one hand, on a prescribed finished width, and, on the other hand, on a prescribed degree of elasticity. The latter can be adjusted exactly by the warp-density and the weft density, and thus also by the woven textile width. Since the degree of elasticity is achieved by respective reed widths and weft widths, special reed widths are preferably used. For a finished width, of, for instance, more than about 1 m, one may use a reed width of up to about 2.5 m.
Varying warp and weft ply yarn densities per centimeter may be employed. For examples:
a. When using as warp and weft ply yarn a ply yarn comprised of an elastomer thread and two individual yarn components each of about .Badd..[.3 denier.]..Baddend. .Iadd.100 dtex.Iaddend., one can use a warp ply yarn density of about 5 ply yarns per centimeter and a weft ply yarn density of about 5 ply yarns per centimeter.
b. When using warp and weft ply yarn comprised of elastomer thread, one component yarn of .Badd..[.3 denier.]..Baddend. .Iadd.100 dtex .Iaddend.and one component yarn of .Badd..[.16 denier.]..Baddend. .Iadd.12500 dtex.Iaddend., one can use a warp ply yarn density of about 5.5 to 5.7 of ply yarn per centimeter and a weft ply yarn density of between about 5.5 and 9.5 ply yarns per centimeter.
c. When using warp and weft ply yarn comprised of elastomer thread and two individual component yarns of .Badd..[.16 denier.]..Baddend. .Iadd.12500 dtex.Iaddend., one can use a warp ply yarn of about 10.5 to 13 yarns per centimeter and a weft ply yarn density of between about 12 and 13.5 yarns per centimeter.
After being woven, a thus produced fabric needs a certain stabilization before it can be used for the desired purposes, as those skilled in the art will appreciate. In one preferred stabilization procedure, at first the fabric is steam shrunk tension-free, until the widened fibers adjoin, and then, after decondensing, the tension-free or relaxed fabric is washed before being dried. To maintain the fabric in a relaxed state, it is advisable to roll up the fabric prior to the decondensing in one procedure.
Although not common with known textile fabrics which can obtain their fixed width after steaming in a drying frame, a fabric of this invention after steam shrinking is preferably washed in a nonacid aqueous liquid, such as a die bath liquor, which may be neutral or slightly alkaline, and is maintained preferably at about 40° to 50° C. Preferably, a residual oil content of less than about 0.5 wt. % may be attempted.
Thereafter, the fabric can optionally be conventionally padded, if desired, under slight warp and weft stretching tension, for example, under about 3%. If padded under relaxed conditions, a fabric may be treated with a small quantity of softener and/or an anti-static agent of the types known to the prior art conventionally.
Next, the fabric is dried. Preferably, drying of a thus processed fabric is accomplished at about 100° C. while the fabric is preferably simultaneously stretched in a weft direction by about 3 to 5% in order to balance a shrinking which characteristically can take place during processing and which can offset warp direction effects. Such a stretching can take place by means of warp holders in a stretching frame, if desired. Drying is accomplished preferably under conditions such that a fabric can subsequently be stretched equally in each of the warp and weft directions.
After the fabric has been preferably substantially completely dried, it is fixed. A fixing can take place, for example, preferably at about 175° to 185° C., and preferably in the presence of flowing hot air, using total time of preferably from about 30 to 40 seconds.
Now the fabric is stabilized in such a way that changes in length or width characteristically will no longer occur. Also, aging of the thus treated fabric characteristically will not take place.
To coat the bi-elastic fabric with an elastomeric, gas tight layer on its back face, the following procedure as illustrated in FIG. 2 is used:
A first film 17 of polyurethane is produced on the back of the stabilized, preferably fixed bi-elastic fabric 14 by solution coating using a conventional technique, such as a roller, doctor blade, or the like. For example, one can employ a solution of the one-component polyurethane available commercially under the trade mark "Impranil c" from Farbenfabriken Bayer of West Germany, such as a 30 weight percent solution of Impranil c in ethyl acetate. After application, this coating is dried preliminarily at, in this example, about 80° to 90° C. The coating thickness is sufficient to produce a layer after such a drying operation of about 15 to 25 microns in thickness, though thicker and thinner layers can be used. This first film 17 is directly adhered to the fabric 14 and functions to produce a smooth surface for a second film 18.
Independently, though conveniently concurrently, with the production of the first film 17 there is produced a second film 18 of a polyurethane. Film 18 can be conveniently produced by solution coating a sheet of release paper or the like. For example, one can use as the release paper a siliconized paper sheet, and, as the coating solution, a 30 weight percent of a polyurethane such as one available commercially under the trade designation ENB 01, or under the trade designation ENB 02, from Farbenfabriken Bayer of W. Germany. The solvent can be a mixture, such as a mixture of dimethylformamide and methyl ethylketone. The solution is coated on the release paper by any conventional technique using a roller, doctor blade or the like. Thereafter, the coated film is dried preliminarily at, in this example, about 90° to 110° C. The coating thickness is sufficient to produce a layer after such a drying operation of about 15 to 25 microns in thickness, though thicker and thinner layers can be used.
Next, the film formed on the release paper is brought into face to face, uniform contact with the film formed on the back side of the bi-elastic fabric, after which the composite is heated at a temperature in the range, in this example, of from about 80° to 90° C. Thereafter, the release sheet is pressed by roller means against the fabric whereby the two initially separate polyeurathane films are laminated together.
Finally, the release sheet is pulled or drawn from the final composite film which is adhered to the back of the bi-elastic fabric. The composite film ranges preferably from about b 45 to 50 microns, though thicker and thinner layers can be used.
One preferred class of stabilized fabrics of this invention has from about 12 to 25 warp members per lineal inch and from about 12 to 25 weft members per lineal inch.
PREFERRED EMBODIMENTS
The present invention is further illustrated by reference to the following examples. Thos skilled in the art will appreciate that other and further embodiments are obvious and within the spirit and scope of this invention from the teachings of these present examples taken with the accompanying specification.
EXAMPLE 1
For the production of a fabric of the present invention with a finished width of 1 meter, there is employed for both the warp and weft a twisted ply yarn composed of three components. The first component is a polyurethane thread of .Badd..[.200 denier.]..Baddend. .Iadd.220 dtex.Iaddend., the second component is a polyacrylic yarn of .Badd..[.15 denier.]..Baddend. .Iadd.12500 dtex.Iaddend., and the third component is a polyacrylic yarn of .Badd..[.5 denier.]..Baddend. .Iadd.2000 dtex.Iaddend..
Using a loom with a reed width of about 2.5 meters, the warp and weft members are woven with substantially the same tension, whereby the weft threads are placed one in front of the other with equal tension on each and the weft as well as the warp density are each adjusted in such a way that the product fabric has an equal stretch of 30% in each of the warp and weft directions.
EXAMPLE 2
The finished fabric of Example 1 is steam shrunk in a relaxed state and is decondensed in rolled-up condition. Then, a 20 to 30 long washing of the relaxed fabric is done in a slightly alkaline aqueous wash liquor at 40°-50° C. in the presence of about 0.2 gms/liter of dissolved "Levapon" 150, a trademark of the Bayer Company of a non-ionic surfactant, together with about 0.5 g per 1. Of dissolved trisodium phosphate. After a subsequent rinsing with water, a dipping of the relaxed fabric at about 40° C. is carried out in an aqueous bath which has been acidified by means of acetic acid to a pH of about 5 to 6.
Next, puffing or freshening treatment is undertaken by dipping the relaxed fabric in a solution of 0.5 wt % per kilogram of "Persoftal" WKF (a trademark of Bayer for a fabric softener).
Thereafter, the fabric is dried at about 100° C. with the weft fibers particularly being under a constant low tension so as to permit the dried fabric to be equally stretchable in both weft and warp directions.
The so dired fabric is then fixed at about 175° to 180° C. in the presence of flowing hot air for 30 to 40 seconds.
EXAMPLE 3
The fabric of Example 2 is roller coated with a 30 wt. % solution in ethyl acetate of a one component polyurethane available commercially under the trade mark Impranil c from Farbenfabriken Bayer. After application this coating is dried preliminarily at a temperature in the range from about 80° to 90° C. to produce a coating thickness of from about 15 to 20 microns.
Separately upon a sheet of siliconized paper there is coated a 30 wt. % solution of polyurethane available commercially under the trade designation ENB 01 from Farbenfabriken Bayer, the solution is a mixture of dimethylformamide and methyl ethylketone. The coating is dried at a temperature of from about 90° to 110° C. to produce a film having a thickness from about 15 to 20 microns in thickness.
The film formed on the release paper is conducted with a film formed on the bi-elastic fabric, after which the composite is heated and further dried at a temperature in the range of from about 80° to 90° C. Thereafter, the release sheet is pressured by a roller and the two polyurethane films are laminated together to form two-ply filaminants.
The product stabilized bi-elastic fabric construction is adapted for use in film filling or in vacuum deep drawing. | A stabilized bi-elastic fabric bonded on its underside to an elastomeric, gas-tight film adapted for use in covering upholstered furniture. The fabric is formed from a ply yarn of elastomeric filaments, coarse yarn, and fine yarn. After being woven, the fabric is stabilized by a process involving steam shrinking, washing, drying and fixing. The stabilized fabric is then heat bonded to the film which makes the composite fabric well suited for filling with foam or for vacuum deep drawing. | 3 |
SUMMARY OF THE INVENTION
This invention relates to a new indole derivative which is useful as an agent of treating therapeutically gastric ulcer or duodenal ulcer in mammalian animals. This invention also relates to a process for the production of the new indole derivative. This invention further relates to a pharmaceutical composition for therapeutic treatment of gastrointestinal ulcer.
BACKGROUND OF THE INVENTION
In one of the known methods of treating therapeutically gastrointestinal inflammatory diseases, especially the gastric ulcer or the duodenal ulcer, the administration of a medicinal compound having an activitiy to inhibit the secretion of gastric acid is performed. The medicinal compound administered for that purpose includes cimetidine (see "Merck Index" 10th Edition, Monograph No. 2254) which is known as an antagonist to the histamine H 2 -receptors. Recently, it was discovered that the secretion of gstric acid is governed by an enzyme, H + , K + -ATPase having the specific property that this enzyme can be activated by potassium cation. It is thus revealed that an inhibitor to said enzyme may be useful as an agent of inhibiting or suppressing the secretion of gastric acid and hence be useful as an agent of treating therapeutically the ulcer in the gastrointestinal tract (see a Japanese medicinal journal "I-gaku no Ayumi" Vol. 128, page 296 (1984); a Japanese medicinal journal "Sa-i-shin I-gaku" Vol. 37, page 481 (1982); the "Nature" Vol. 290, 159-161 (March 1981) and "Drugs" Vol. 25, 315-330 (1983). As example of the known compounds having the activity to inhibit the H + , K + -ATPase is mentioned a group of benzimidazole derivatives which is typically represented by omeprazole (identified as 2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]-5-methoxybenzimidazole (see Japanese patent application first publication "Kokai" No. 141783/79; U.S. Pat. No. 4,255,431; No. 4,337,257 and No. 4,508,905). It is also known that some of the above-mentioned benzimidazole derivatives exhibit an activity to effect the gastrointestinal cytoprotection (see Japanese patent application first publication "Kokai" No. 53406/82; U.S. Pat. No. 4,359,465).
The antagonists to the histamine H 2 -receptors which are typically represented by cimethidine, as well as the inhibitors to the H + , K + -ATPase which are typically represented by omeprazole show a high activity to inhibit the secretion of gastric acid, and owing to this activity, they are able to exhibit good curative effects in the therapeutic treatment of the gastric ulcer. However, it has often been observed that when the ulcer has been cured through the administrations of the aforesaid drug and thus the administration of the drug is stopped, the ulcer is very much likely to return with the lapse of time after the stoppage of the drug administration. Therefore, it is not worthy to say that cimetidine and omeprazole are a fully satisfactory drug for therapeutic treatment of the gastrointestinal ulcers.
Accordingly, it has been a lasting demand to exploit a better antiulcer drug effective in the therapeutic treatment of gastrointestinal ulcers. We, the present inventors, have paid our attention on indole derivatives, and we have made extensive researches in an attempt to provide a class of new indole derivatives which exhibit the activity to inhibit the gastric acid secretion and are useful as an antiulcer agent having such further advantages that long successive administrations of the drug to the patients is allowable and the relapse or return of the ulcer as once healed is effectively prevented even after the stopped administration of the durg. As a result, we have succeeded in synthetizing a class of new indole derivatives which have now been found by us to exhibit a mild activity of inhibiting the gastric acid secretion as well as remarkable cytoprotective effects on the gastrointestinal tract, in combination, as will be demonstrated by the pharmacological experiments shown hereinafter. Thus, we have accomplished this invention.
DETAILED DESCRIPTION OF THE INVENTION
According to a first aspect of this invention, therefore, there is provided as the new indole derivative a compound of the general formula (I): ##STR2## wherein R 1 is a hydrogen atom, a halogen atom, a lower alkyl group, a trifluoromethyl group, a lower alkoxy group, an acyl group or a lower alkoxycarbonyl group; R 2 is a hydrogen atom or a lower alkyl group; R 3 is a hydrogen atom, a lower alkyl group, a lower alkoxy group or a lower alkylthio group; R 4 is hydrogen atom, a lower alkyl group, a lower alkoxy group, a halogen atom, a hydroxy group, a lower alkoxycarbonyl group, a substituted or ansubstituted aralkyloxy group, or a group of the formula --NR a R b where R a and R b are the same or different and each are a hydrogen atom or a lower alkyl group, or R a and R b taken together with the adjacent nitrogen atom form a 5-membered or 6-membered heterocyclic group containing optionally a further hetero-atom therein; R 5 is a hydrogen atom, a lower alkyl group, a lowr alkoxy group, an aralkyl group or a substituted or unsubstituted aralkyloxy group; and n is an integer of zero or 1, p is an integer of 1, 2, 3 or 4; and q is an integer of 1, 2 or 3, or a pharmaceutically acceptable salt of said compound.
According to a particular embodiment of the first aspect of this invention, there is provided a new compound of the formula (I'): ##STR3## wherein R 1 is a hydrogen atom, a halogen atom, a lower alkyl group, a trifluoromethyl group, a lower alkoxy group, a lower alkanoyl group or a lower alkoxycarbonyl group; R 2 is a hydrogen atom or a lower alkyl group; R 3 is a hydrogen atom, a lower alkyl group or a lower alkylthio group; R 4 is a hydrogen atom, a lower alkyl group, a lower alkoxy group, a halogen atom, a hydroxy group, a lower alkoxycarbonyl group, an amino group, a mono-lower-alkylamino group, a di-lower-alkylamino group, or R 4 is a group of the formula ##STR4## where R a and R b taken together form an alkylene group of 2 to 5 carbon atoms which is optionally interrupted by an oxygen atom, a sulfur atom or a nitrogen atom as the hetero-atom interposed in the chain of the alkylene group, so that R a and R b taken together with the adjacent nitrogen atom form a 5-membered or 6-membered heterocyclic group optionally containing further an oxygen atom, a sulfur atom or a nitrogen atom as the hetero-atom therein; R 5 is a hydrogen atom, a lower alkyl group or a lower alkoxy group; and n is zero or 1; p is 1, 2, 3 or 4; and q is 1, 2 or 3, or a pharmaceutically acceptable salt of said compound. In the compound of the above formula (I'), it is preferable that R 4 is particularly such a group of the formula ##STR5## which forms a pyrrolidino group, a piperidino group, a morpholino group, a thiomorpholino group or a piperadino group and of which the heterocyclic group is unsubstituted or substituted by a lower alkyl group, or that R 4 is a group of the formula ##STR6## where R a and R b each are a lower alkyl group.
The indole compound of the formula (I) according to this invention may be divided into the undermentioned four types (Ia), (Ib), (Ic) and (Id), depending on the different steps which are involved in the process for the production of them:
(i) A compound represented by the formula ##STR7##
(ii) A compound represented by the formula ##STR8##
(iii) A compound represented by the formula ##STR9##
(iv) A compound represented by the formula ##STR10## wherein R 1 , R 3 , R 4 , R 5 , p and q are as defined above and R 6 is a lower alkyl group.
In this specification, the various terms described here have the following meanings:
By the term "lower alkyl group" is meant a linear or branched alkyl group containing 1 to 6 carbon atoms, particularly 1-4 carbon atoms, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, iso-butyl, sec-butyl, tert-butyl, n-pentyl, isopentyl and n-hexyl groups. By the term "lower alkoxy group" is meant a linear or branched alkoxy group containing 1 to 6 carbon atoms, particularly 1-4 carbon atoms, for example, methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, isobutoxy, sec-butoxy, tert-butoxy and n-pentoxy groups.
An "aralkyl" group includes an aralkyl group containing 7 to 12 carbon atoms, for example, a phenyl-(C 1 -C 4 )alkyl group such as benzyl, phenetyl and phenylpropyl groups, as well as a naphthyl-(C 1 -C 4 )-alkyl group such as (1-naphthyl)methyl group.
The term "an acyl group" includes an alkanoyl group of 2 to 6 carbon atoms, particularly 1-4 carbon atoms, such as acetyl, propionyl and butyryl group, as well as an aroyl group such as benzoyl and toluoyl groups. The group of the formula --NR a R b where R a and R b are as defined hereinbefore includes an amino group (--NH 2 ) and a mono-lower-alkylamino group or a di-lower-alkylamino group, for example, methylamino, dimethylamino, ethylamino, diethylamino, n-propylamino, di-n-propylamino, isopropylamino, di-isopropylamino, n-butylamino, di-n-butylamino, tert-butylamino and di-tert-butylamino groups. The group of the formula --NR a R b further includes a 5-membered or 6-membered nitrogen-containing cyclic group optionally containing a further hetero-atom therein. In particular, the group of the formula --NR a R b may be a cyclic group of the formula ##STR11## where R a and R b taken together form an alkylene group of 2 to 5 carbon atoms containing no further hetero-atom or containing an oxygen atom or a sulfur atom or a nitrogen atom as the further hetero-atom interposed in the chain of the alkylene group, so that R a and R b taken together with the adjacent nitrogen atom form a 5 -membered or 6-membered cyclic group or ring containing said adjacent nitrogen atom optionally together with or without an oxygen atom or a sulfur atom or a nitrogen atom as the further hetero-atom interposed in said ring.
When the group of the formula --NR a R b forms a 5-membered or 6-membered nitrogen-containing heterocyclic group or a cyclic amino group, the cyclic groups may be substituted by one or more of substituents which may be a lower alkyl group or a hydroxyl group. Particular examples of such group of the formula ##STR12## where R a and R b together with the adjacent nitrogen atom form the heterocyclic group or the cyclic amino group include a pyrrolidino group, a piperidino group, a morpholino group, a thiomorpholino group, a piperazino group and N-methylpiperazino group.
By the term "lower alkoxycarbonyl group" is meant an alkoxycarbonyl group containing 2 to 6 carbon atoms, for example, methoxycarbonyl, ethoxycarbonyl, n-propoxycarbonyl, isopropoxycarbonyl, n-butoxycarbonyl, iso-butoxycarbonyl, sec-butoxycarbonyl, tert-butoxycarbonyl and n-pentoxycarbonyl groups.
By the term "lower alkylthio group" is meant an alkylthio group containing 1 to 6 carbon atoms, particularly 1-4 carbon atoms, for example, methylthio, ethylthio, n-propylthio, isopropylthio, n-butylthio, isobutylthio, sec-butylthio and tert-butylthio groups.
By the term "aralkyloxy" group is meant a phenyl-(C 1 -C 4 )alkyloxy group such as benzyloxy, phenethyloxy and phenylpropoxy groups.
The "halogen atom" includes a chlorine atom, a bromine atom, an iodine atom and a fluorine atom.
The new compound of this invention may be converted into its pharmaceutically acceptable salt, such as a pharmaceutically acceptable acid addition salt thereof by reacting with a pharmaceutically acceptable acid, for example, an inorganic acid, especially hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid and the like; and an organic acid, especially formic acid, acetic acid, propionic acid, succinic acid, glycollic acid, lactic acid, malic acid, tartaric acid, citric acid, maleic acid, phenylacetic acid, benzoic acid, salicylic acid, methanesulfonic acid, p-toluenesulfonic acid, benzenesulfonic acid and the like, including an amino acid such as aspartic acid, glutamic acid and the like.
According to preferred embodiments of the first aspect of this invention, there are provided first to seventh, preferred groups of the new compounds of the formula (I) of this invention which are as follows:
Thus, the first preferred group of the compounds (I) of this invention includes a compound of the formula (I-1): ##STR13## wherein R 7 is a hydrogen atom, an alkyl group of 1-6 carbon atoms or an alkylthio group of 1-6 carbon atoms; R 8 , R 9 , R 10 and R 11 are the same or different and each are a hydrogen atom, a halogen atom, an alkyl group of 1-6 carbon atoms, a trifluoromethyl group, an alkoxy group of 1-6 carbon atoms, an alkanoyl group of 2-6 carbon atoms or an alkoxycarbonyl group of 2-6 carbon atoms; R 12 , R 13 , R 14 and R 15 are the same or different and each are a hydrogen atom, an alkyl group of 1-6 carbon atoms or an alkoxy group of 1-6 carbon atoms; and n is zero or 1, or a pharmaceutically acceptable salt of said compound. In the compound of the formula (I-1), it is preferred that R 7 is a hydrogen atom, a methyl group or a methylthio group; R 8 and R 10 each are a hydrogen atom; R 9 is a hydrogen atom, a halogen atom, an alkyl group of 1-6 carbon atoms, a trifluoromethyl group, an alkoxy group of 1-6 carbon atoms, an alkanoyl group of 2-6 carbon atoms or an alkoxycarbonyl group of 2-6 carbon atoms; R 11 is a hydrogen atom or a trifluoromethyl group; R 12 and R 14 each are a hydrogen atom or an alkyl group of 1-6 carbon atoms; and R 13 is an alkoxy group of 1-6 carbon atoms; R 15 is a hydrogen atom; and n is zero or 1.
The second preferred group of the compound (I) of this invention includes a compound of the formula (I-2): ##STR14## wherein R 7 is a hydrogen atom or an alkyl group of 1-6 carbon atoms; R 8 , R 9 , R 10 and R 11 are the same or different and each are a hydrogen atom, a halogen atom, an alkyl group of 1-6 carbon atoms, a trifluoromethyl group, and alkoxy group of 1-6 carbon atoms, an alkanoyl group of 2-6 carbon atoms or an alkoxycarbonyl group of 2-6 carbon atoms; R 12 , R 13 , R 14 and R 15 are the same or different and each are a hydrogen atom, an alkyl group of 1-6 carbon atoms or an alkoxy group of 1-6 carbon atoms; n is zero or 1, or a pharmaceutically acceptable salt of said compound.
In the compound of the formula (I-2), it is preferred that R 7 is a hydrogen atom or a methyl group; R 8 and R 10 are each a hydrogen atom; R 9 is a hydrogen atom, a halogen atom, an alkyl group of 1-6 carbon atoms, a trifluoromethyl group, an alkoxy group of 1-6 carbon atoms, an alkanoyl group of 2-6 carbon atoms, or an alkoxycarbonyl group of 2-6 carbon atoms; R 11 is a hydrogen atom or a trifluoromethyl group; R 12 and R 14 are each a hydrogen atom or an alkyl group of 1-6 carbon atoms; and R 13 is an alkoxy group of 1-6 carbon atoms; R 15 is a hydrogen atom; and n is zero or 1.
The third preferred group of the compound (I) of this invention includes a compound of the formula (I-3): ##STR15## wherein R 7 is a hydrogen atom, an alkyl group of 1-6 carbon atoms or an alkylthio group of 1-6 carbon atoms; R 8 , R 9 , R 10 and R 11 are the same or different and each are a hydrogen atom, a halogen atom, an alkyl group of 1-6 carbon atoms, a trifluoromethyl group, an alkoxy group of 1-6 carbon atoms, an alkanoyl group of 2-6 carbon atoms or an alkoxycarbonyl group of 2-6 carbon atoms; R 13 , R 14 , R 15 and R 16 are the same or different and each are a hydrogen atom, an alkyl group of 1-6 carbon atoms or an alkoxy group of 1-6 carbon atoms; and n is zero or 1, or a pharmaceutically acceptable salt of said compound. In the compound of the formula (I-3), it is preferred that R 7 is a hydrogen atom, a methyl group or a methylthio group; R 8 , R 10 and R 11 are each a hydrogen atoms; R 9 is a hydrogen atom, an alkyl group of 1-6 carbon atoms, a trifluoromethyl group, an alkoxy group of 1-6 carbon atoms, an alkanoyl group of 2-6 carbon atoms, or an alkoxycarbonyl group of 2-6 carbon atoms; R 13 is a hydrogen atom, an alkyl group of 1-6 carbon atoms or an alkoxy group of 1-6 carbon atoms; and R 14 , R 15 and R 16 each are a hydrogen atom; and n is zero or 1.
The fourth preferred group of the compound (I) of this invention includes a compound of the formula (I-4) ##STR16## wherein R 7 is a hydrogen atom, a methyl group or a methylthio group; R 8 , R 9 , R 10 and R 11 are the same or different and each are a hydrogen atom, a halogen atom, an alkyl group of 1-6 carbon atoms, a trifluoromethyl group, an alkoxy group of 1-6 carbon atoms, an alkanoyl group of 2-6 carbon atoms or an alkoxycarbonyl group of 1-6 carbon atoms; R 12 , R 14 , R 15 and R 16 are the same or different and each are a hydrogen atom, an alkyl group of 1-6 carbon atoms or an alkoxy group of 1-6 carbon atoms; and n is zero or 1, or a pharmaceutically acceptable salt of said compound. In the compound of the formula (I-4), it is preferred that R 7 is a hydrogen atom, a methyl group or a methylthio group; R 8 , R 10 and R 11 are each a hydrogen atom; R 9 is a hydrogen atom, an alkyl group of 1-6 carbon atoms, a trifluoromethyl group, an alkoxy group of 1-6 carbon atoms, an alkanoyl group of 2-6 carbon atoms or an alkoxycarbonyl group of 2-6 carbon atoms; R 12 , R 14 , R 15 and R 16 are each a hydrogen atom; and n is zero or 1.
The fifth preferred group of the compound (I) of this invention includes a compound of the formula (I-5): ##STR17## wherein R 2 is a hydrogen atom or an alkyl group of 1-6 carbon atoms; R 17 is a hydrogen atom or an alkyl group of 1-6 carbon atoms; R 18 , R 19 , R 20 and R 21 are the same or different and each are a hydrogen atom, a halogen atom, an alkyl group of 1-6 carbon atoms, a trifluoromethyl group, an alkoxy group of 1-6 carbon atoms, an alkanoyl group of 2-6 carbon atoms or an alkoxycarbonyl group of 2-6 carbon atoms; R 22 , R 24 and R 25 are the same or different and each are a hydrogen atom or an alkyl group of 1-6 carbon atoms; R 23 is a group of the formula ##STR18## where R a and R b are the same or different and each are a hydrogen atom or an alkyl group of 1-6 carbon atoms, or R a and R b taken together with the adjacent nitrogen atom form a 5-membered or 6-membered heterocyclic group; and n is zero or 1, or a pharmaceutically acceptable salt of said compound.
In the compound of the formula (I-5), it is preferred that R 2 is a hydrogen atom or a methyl or ethyl group; R 17 is a hydrogen atom or a methyl group; R 18 is a hydrogen atom or an alkyl group of 1-6 carbon atoms; R 19 is a hydrogen atom, a halogen atom, an alkyl group of 1-6 carbon atoms, a trifluoromethyl group, an alkoxy group of 1-6 carbon atoms; an alkanoyl group of 2-6 carbon atoms, or an alkoxycarbonyl group of 2-6 carbon atoms; R 20 is a hydrogen atom, an alkyl group of 1-6 carbon atoms, an alkanoyl group of 2-6 carbon atoms or a trifluoromethyl group; R 21 is a hydrogen atom, an alkyl group of 1-6 carbon atoms or a trifluoromethyl group; R 22 and R 24 are each a hydrogen atom or an alkyl group of 1-6 carbon atoms; R 23 is an amino group or a mono- or di-(C 1 -C 6 )alkylamino group or a 5-membered or 6-membered heterocyclic group containing a nitrogen atom together with or without an oxygen atom, a sulfur atom or a further nitrogen atom as the hetero-atom; R 25 is a hydrogen atom or an alkyl group of 1-6 carbon atoms; and n is zero or 1. More preferably, the group R 23 is a piperidino group, a pyrrolidino group, a morpholino group, a thiomorpholino group, a piperazino group or N-methylpiperazino group as the heterocyclic group. Also, the group R 23 may preferably be a group of the formula ##STR19## where R a and R b are each an alkyl group of 1-6 carbon atoms.
The sixth preferred group of the compound (I) of this invention includes a compound of the formula (I-6): ##STR20## wherein R 2 is a hydrogen atom or an alkyl group of 1-6 carbon atoms; R 17 is a hydrogen atom or an alkyl group of 1-6 carbon atoms; R 18 , R 19 , R 20 and R 21 are the same or different and each are a hydrogen atom, a halogen atom, an alkyl group of 1-6 carbon atoms, a trifluoromethyl group, an alkoxy group of 1-6 carbon atoms, an alkanoyl group of 2-6 carbon atoms or an alkoxycarbonyl group of 2-6 carbon atoms; R 22 , R 24 and R 25 are the same or different and each are a hydrogen atom or an alkyl group of 1-6 carbon atoms; R 23 is a group of the formula ##STR21## where R a and R b are each a hydrogen atom or an alkyl group of 1-6 carbon atoms, or R a and R b taken together with the adjacent nitrogen atom form a 5-membered or 6-membered heterocyclic group; and n is zero or 1, or a pharmaceutically acceptable salt of said compound.
In the compound of the formula (I-6), it is preferable that R 2 is a hydrogen atom or a methyl or ethyl group; R 17 is a hydrogen atom or a methyl group; R 18 , R 20 and R 21 are each a hydrogen atom; R 19 is a hydrogen atom, a halogen atom, an alkyl group of 1-6 carbon atoms, a trifluoromethyl group, an alkoxy group of 1-6 carbon atoms, an alkanoyl group of 2-6 carbon atoms or an alkoxycarbonyl group of 2-6 carbon atoms; R 22 and R 24 are each a hydrogen atom or an alkyl group of 1-6 carbon atoms; R 23 is an amino group or a mono- or di-(C 1 -C 6 )alkylamino group or a 5-membered or 6-membered heterocyclic group containing a nitrogen atom together with or without an oxygen, atom, a sulfur atom or a further nitrogen atom as the hetero-atom: R 25 is a hydrogen atom; and n is zero or 1. More preferably, the group R 23 is a piperidino group, a pyrrolidino group, a morpholino group a thiomorpholino group or a piperazino group or N-methylpiperazino group as the heterocyclic group. The group R 23 may also be preferably a group of the formula ##STR22## where R a and R b are each an alkyl group of 1-6 carbon atoms.
The seventh preferred group of the compound (I) of this invention includes a compound of the formula (I-7): ##STR23## wherein R 2 is a hydrogen atom or an alkyl group of 1-6 carbon atoms; R 27 is a hydrogen atom or an alkyl group of 1-6 carbon atoms; R 28 , R 29 , R 30 and R 31 are the same or different and each are a hydrogen atom, a halogen atom, an alkyl group of 1-6 carbon atoms, a trifluoromethyl group, an alkoxy group of 1-6 carbon atoms, an alkanoyl group of 2-6 carbon atoms or an alkoxycarbonyl group of 2-6 carbon atoms; R 32 , R 34 and R 35 are the same or different and each are a hydrogen atom or an alkyl group of 1-6 carbon atoms; R 33 is a halogen atom, a hydroxy group or an alkoxycarbonyl group of 2-6 carbon atoms, and n is zero or 1, or a pharmaceutically acceptable salt of said compound.
In the compound of the formula (I-7), it is preferred that R 2 is a hydrogen atom, R 27 , R 28 , R 29 , R 30 , R 31 , R 32 , R 34 and R 35 are each a hydrogen atom; and R 33 is a halogen atom, a hydroxy group or an alkoxycarbonyl group of 2-6 carbon atoms, and n is zero.
In the following are listed particular examples of the new compounds according to the formula (I).
1. 2-[(5-ethyl-4-piperidino-2-pyridyl)methylthio]indole
2. 2-[(5-butyl-4-piperidino-2-pyridyl)methylthio]indole
3. 2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
4. 5-methyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
5. 5-fluoro-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
6. 2-{[5-methyl-4-(3-methylpiperidino)-2-pyridyl]methylthio}indole
7. 2-{[5-methyl-4-(4-methylpiperidino)-2-pyridyl]methylthio}indole
8. 5-ethyl-2-[(5-methyl-4-dimethylamino-2-pyridyl)methylthio]indole
9. 5-acetyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
10. 5-ethoxycarbonyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
11. 2-[(3-methyl-4-piperidino-2-pyridyl)methylthio]indole
12. 2-[(5-methyl-4-morpholino-2-pyridyl)methylthio]indole
13. 5-ethyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
14. 6-methyl-2-[(4-piperidino-2-pyridyl)methylthio]indole
15. 5,6-dimethyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
16. 2-[(5-methyl-4-pyrrolidino-2-pyridyl)methylthio]indole
17. 2-[(4-dimethylamino-2-pyridyl)methylthio]indole
18. 5-methyl-2-[(4-dimethylamino-2-pyridyl)methylthio]indole
19. 5-methoxy-2-[(4-dimethylamino-2-pyridyl)methylthio]indole
20. 5-fluoro-2-[(4-dimethylamino-2-pyridyl)methylthio]indole
21. 4,7-dimethyl-2-[(4-piperidino-2-pyridyl)methylthio]indole
22. 5-ethoxycarbonyl-6-methyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
23. 5-propoxy-2-[(4-piperidino-2-pyridyl)methylthio]indole
24. 6-acetyl-5-methyl-2-[(3-methyl-4-piperidino-2-pyridyl)methylthio]indole
25. 6-trifluoromethyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
26. 5-trifluoromethyl-2-[(4-dimethylamino-2-pyridyl)methylthio]indole
27. 5-acetyl-2-[(4-dimethylamino-2-pyridyl)methylthio]indole
28. 5-ethoxycarbonyl-2-[(4-dimethylamino-2-pyridyl)methylthio]indole
29. 6,7-dimethyl-2-[(4-dimethylamino-2-pyridyl)methylthio]indole
30. 2-[(4-pyrrolidino-2-pyridyl)methyl]indole
31. 5-methoxy-2-[(5-ethyl-4-pyrrolidino-2-pyridyl)methylthio]indole
32. 5-ethoxycarbonyl-2-[(4-pyrrolidino-2-pyridyl)methylthio]indole
33. 5-methyl-2-[(4-pyrrolidino-2-pyridyl)methylthio]indole
34. 5-trifluoromethyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
35. 2-[(5-methyl-4-thiomorpholino-2-pyridyl)methylthio]indole
36. 2-{[4-(4-methylpiperazino)-2-pyridyl]methylthio}indole
37. 2[(4-piperidino-2-pyridyl)methylthio]indole
38. 5-methoxy-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
39. 5-fluoro-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
40. 2-(2-pyridylmethylthio)-5-methoxyindole
41. 2-(3-pyridylmethylthio)-5-methoxyindole
42. 2-(4-pyridylmethylthio)-5-methoxyindole
43. 2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
44. 3-methyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
45. 5-methyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
46. 5-trifluoromethyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
47. 5-methoxy-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
48. 5-methoxycarbonyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
49. 5-acetyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
50. 3-methylthio-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
51. 7-trifluoromethyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
52. 3-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
53. 3-[(4-dimethylamino-2-pyridyl)methylthio]indole
54. 3-[(4-piperidino-2-pyridyl)methylthio]indole
55. 3-[(4-chloro-2-pyridyl)methylthio]indole
56. 3-[(4-ethoxycarbonyl-2-pyridyl)methylthio]indole
57. 3-[(4-hydroxy-2-pyridyl)methylthio]indole
58. 3-[(5-methyl-4-pyrrolidino-2-pyridyl)methylthio]indole
59. 3-[(2-pyridyl)methylthio]indole
60. 5-fluoro-3-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
61. 3-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
62. 2-methyl-3-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
63. 5-methoxy-3-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
64. 5-methoxycarbonyl-3-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
65. 2-[(5-ethyl-4-piperidino-2-pyridyl)methylsulfinyl]indole
66. 2-[(5-methyl-4-piperidino-2-pyridyl)methylsulfinyl]indole
67. 2-{[6-methyl-4-(4-methylpiperidino)-2-pyridyl]methylsulfinyl}indole
68. 1-methyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylsulfinyl]indole
69. 2-[(5-methyl-4-pyrrolidino-2-pyridyl)methylsulfinyl]indole
70. 5-fluoro-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
71. 2-(2-pyridylmethylsulfinyl)-5-methoxyindole
72. 2-(3-pyridylmethylsulfinyl)-5-methoxyindole
73. 2-(4-pyridylmethylsulfinyl)-5-methoxyindole
74. 2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
75. 3-methyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
76. 5-methyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
77. 5-trifluoromethyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
78. 5-methoxy-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
79. 5-methoxycarbonyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
80. 5-acetyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
81. 7-trifluoromethyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
82. 3-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
83. 2-methyl-3-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
84. 5-methoxycarbonyl-3-[(3,5-dimethyl-4-methoxy-2-pyridyl)methysulfinyl]indole
85. 1-methyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
86. 1-ethyl-2-[(4-piperidino-2-pyridyl)methylthio]indole
87. 1-methyl-2-[(5-methyl-4-pyrrolidino-2-pyridyl)methylthio]indole
Now, the production of the new compounds of the general formula (I) or a salt thereof according to this invention, is described. Thus, the compound of the formula (I) may be produced by reacting a thiol compound of the formula (II) ##STR24## wherein R 1 , R 3 and p are as defined hereinbefore or a functionally equivalent derivative of said thiol compound with a pyridine compound of the formula (III) ##STR25## wherein R 4 , R 5 and q are as defined hereinbefore and X 1 is a leaving group, or a salt of said pyridine compound in an organic solvent, either anhydrous or aqueous, to produce a condensation product compound of the formula (Ia) ##STR26## wherein R 1 , R 3 , R 4 , R 5 , p and q are as defined above, and then, if necessary, subjecting the condensation product compound of the above formula (Ia) to either one or both of the following two steps (a) and (b):
(a) an alkylation step of reacting the compound of the formula (Ia) with a compound of the formula (IV)
X.sup.2 --R.sup.6 (IV)
wherein R 6 is a lower alkyl group and X 2 is a leaving group, to alkylate the nitrogen atom at the 1-position of the compound of the formula (Ia), and
(b) an oxidation step of converting the sulfide form of the compound of the formula (Ia) or the N-alkylated product of the above alkylation step (a) into a corresponding sulfoxide form by oxidation of the thio group present in said compound.
Thus, such compound of the formula (I) where n is 1 and which is of the form of sulfoxide may be produced by oxidizing the thio group of such compound of the formula (I) where n is zero and which is of the form of sulfide and has been prepared by the condensation reaction of the thiol compound of the formula (II) with the pyridine compound of the formula (III).
According to a second aspect of this invention, therefore, there is provided a process for the production of the compound of the formula (I) ##STR27## wherein R 1 is a hydrogen atom, a halogen atom, a lower alkyl group, a trifluoromethyl group, a lower alkoxy group, an acyl group or a lower alkoxycarbonyl group; R 2 is a hydrogen atom or a lower alkyl group; R 3 is a hydrogen atom, a lower alkyl group, a lower alkoxy group or a lower alkylthio group; R 4 is a hydrogen atom, a lower alkyl group, a lower alkoxy group, a halogen atom, a hydroxy group, a lower alkoxycarbonyl group, a substituted or unsubstituted aralkyloxy group, or a group of the formula --NR a R b where R a and R b are the same or different and each are a hydrogen atom or a lower alkyl group, or R a and R b taken together with the adjacent nitrogen atom form a 5-membered or 6-membered heterocyclic group containing optionally a further hetero-atom therein; R 5 is a hydrogen atom, a lower alkyl group, a lower alkoxy group, an aralkyl group or a substituted or unsubstituted aralkyloxy group; and n is an integer of zero or 1, p is an integer of 1, 2, 3 or 4; and q is an integer of 1, 2 or 3, or a salt of said compound, which comprises reacting a thiol compound of the formula (II) ##STR28## wherein R 1 , R 3 and p are as defined above, or a functionally equivalent derivative of said thiol compound with a pyridine compound of the formula (III) ##STR29## wherein R 4 , R 5 and q are as defined above or a salt of said pyridine compound to produce the condensation product, and then, if necessary, further subjecting the resulting condensation product compound to at least one of the following two steps (a) and (b):
(a) the step of alkylating the nitrogen atom in the indole ring of said condensation product compound or its sulfoxide derivative with a compound of the formula (IV)
X.sup.2 --R.sup.6 (IV)
wherein R 6 is a lower alkyl group equal to that as represented by the group R 2 in the compound of the formula (I) where R 2 is a lower alkyl group and wherein X 2 is a leaving group, and
(b) the step of converting the sulfide form of said condensation product compound or of the N-alkylated product compound of the above step (a) into a corresponding sulfoxide by oxidation of the thio group present therein.
The group X 1 in the compound of the formula (III) as used in the process of this invention is a leaving group of such nature that it can be liberated with formation of the compound HX 1 when the compound (III) is reacted with the compound (II). Similarly, the group X 2 in the compound of the formula (IV) is a leaving group of such nature that it can be liberated with formation of the compound HX 2 when the compound (IV) is reacted with the indole compound of the formula (Ia) shown hereinbefore. Suitable examples of the leaving groups X 1 and X 2 may be, for example, a halogen atom such as chlorine, bromine and iodine atoms; an arylsulfonyloxy group such as benzenesulfonyloxy and p-toluenesulfonyloxy groups; and an alkylsulfonyloxy group such as methanesulfonyloxy and ethanesulfonyloxy groups. Suitable example of a functionally equivalent derivative of the thiol compound of the formula (II) may be a salt of said thiol compound, such as an alkali metal salt (mercaptide) such as sodium and potassium salts.
In the process of the second aspect of this invention, the condensation reaction of the compound (II) with the compound (III) may be carried out in a water-miscible organic solvent such as a lower alkanol, especially methanol and ethanol; acetone, tetrahydrofuran, N,N-dimethylformamide, dimethylsulfoxide and the like, or in a mixture of said organic solvent with water at a temperature of 0° C. to 150° C., preferably at a temperature of from ambient temperature to 100° C., and, if desired, in the presence of an acid-binder which may be an inorganic base or an organic base. The base suitable as the acid-binder may be an inorganic base, for example, an alkali metal hydroxide such as sodium hydroxide and potassium hydroxide; an alkali metal (hydrogen) carbonate such as sodium hydrogen carbonate, potassium hydrogen carbonate, sodium carbonate, and potassium carbonate; and an organic base, for example, amines such as a tri-lower-alkylamine, especially tri-ethylamine and pyridine. After completion of the condensation reaction, the reaction solution may be processed in a known manner to recover the desired condensation product compound of this invention therefrom. Isolation and purification of the product compound of this invention may be achieved by ordinary procedures such as extraction with organic solvent, recrystallization and chromatography.
The condensation step of reacting the thiol compound (II) with the pyridine compound (III) gives, as the condensation product, the new compound of this invention of such type shown by the formula (Ia) above.
In the process according to the second aspect of this invention, if necessary, the compound of the formula (Ia) as produced or a salt thereof may further be subjected to the step (a) of reacting said compound (Ia) or a salt thereof with the alkylating agent compound of the formula (IV) to produce a compound of this invention of such type shown by the formula (Ic): ##STR30## wherein R 1 , R 3 , R 4 , R 5 , R 6 , p and q are as defined hereinbefore. This alkylation step (a) of reacting the compound (Ia) or a salt thereof with the alkylating agent compound (IV) may be carried out in the same manner as for the step of reaction of the compound (II) with the compound (III) and thus at a temperature of 0° C. to 150° C. in an a water-miscible organic solvent or a mixture of such organic solvent with water and, if desired, in the presence of an acid-binder which may be the inorganic or organic bases mentioned hereinbefore.
Besides, in the process of the second aspect invention, the compound of the formula (Ia) (in the sulfide form) as produced or a salt thereof may, if necessary, be further subjected to the oxidation step (b) of converting the compound (Ia) or a salt thereof into its sulfoxide derivative of the formula (Ib): ##STR31## wherein R 1 , R 3 , R 4 , R 5 , p and q are as defined above or a salt thereof.
Furthermore, in the process of the second aspect invention, the compound of the formula (Ia) (in the sulfide form) as produced or a salt thereof may, if necessary, be further subjected to the alkylation step (a) of reacting the compound (Ia) with the alkylation agent (IV) and also to the oxidation step (b) of converting the resulting N-alkylated product compound of the step (a) into the sulfoxide type of the compound represented by the formula (Id): ##STR32## wherein R 1 , R 3 , R 4 , R 5 , R 6 , p and q are as defined hereinbefore, or a salt thereof.
The above-mentioned oxidation step (b) of converting the compound of the formula (Ia) or the compound of the formula (Ic) (in the sulfide form) into the corresponding sulfoxide compound of the formula (Ib) or (Id) may be carried out by reacting the compound (Ia) or (Ic) with an oxidizing agent at a temperature of -30° C. to 60° C., preferably at a temperature of from 0° C. to 10° C. in such a reaction medium which may be water or a water-miscible organic solvent such as a lower alkanol, especially methanol and ethanol, and acetic acid, or a water-immiscible organic solvent such as benzene, methylene chloride, chloroform and the like or mixed solvents of two or more of said solvents. The oxidizing agent available in this oxidation step may be such an oxidizing compound which has usually been employed for the oxidation of sulfides into sulfoxides. Suitable examples of the available oxidizing agent include hydrogen peroxide, peracetic acid, m-chloroperbenzoic acid, sodium metaperiodate and the like. The oxidizing agent may preferably be used in a proportion of 1 to 1.2 equivalents per equivalent of the compound (Ia) or (Ic). After completion of the oxidation reaction, the reaction mixture may be processed in a known manner to recover the desired sulfoxide derivative of the formula (Ib) or (Id). Isolation and purification of the compound (Ib) or (Id) may be performed by ordinary procedures such as organic solvent extraction, recrystallization, and chromatography.
In the process of the second aspect invention, if desired, the oxidation step (b) may preceed the alkylation step (a), and in other words, the oxidation step (b) may be carried out with the condensation product compound of the formula (Ia) to oxidize the thio group (--S--) present therein into the sulfoxide group ##STR33## before the indole ring nitrogen atom in the sulfoxide derivative of the formula (Ib) as produced is alkylated with the alkylating agent (IV) in the alkylation step (a).
The thiol compound of the formula (II) which is used as a starting compound in the process of the second aspect of this invention may be prepared by the following methods. For instance, a 2-mercaptoindole compound of the formula (IIa) ##STR34## which is covered by the compound of the general formula (II) and in which R 1 and p have the same meanings as above may be prepared by such a method comprising producing 2-oxiindoles from an aniline compound according to the process of P. G. Gassman et al (see "J. Am. Chem. Soc." 95, 2718 (1973); ditto 96, 5508 (1974)) and then reacting the 2-oxiindoles e.g. with phosphorus pentasulfide in an organic solvent such as benzene, toluene, pyridine and tetrahydrofuran at a temperature of 20° C. to 100° C. When the reaction of the 2-oxiindoles with phosphorus pentasulfide is conducted in a neutral organic solvent, the reaction may preferably be carried out in the presence of an appropriate base such as triethylamine in order to promote the reaction.
A starting 3-mercaptoindole compound of the formula (IIb) ##STR35## which is also covered by the compound of the general formula (II) and in which R 1 and p have the same meanings as above may be prepared by such a method comprising producing an indole compound from an aniline compound according to the process of P. G. Gassman et al (see "J. Am. Chem. Soc." 96, 5495 (1974)) and then treating the resulting indole product with the process of R. L. N. Harrison et al. (see "Tetrahedron Letters" page 4465 (1965)), or alternatively by such a method comprising reacting a 3-halogeno-indole with thiourea and then reacting the resulting isothiuronium salt with an alkali metal hydroxide or sodium sulfide.
If desired, the starting compound (II) may be prepared by an appropriate synthetic method in situ in the reaction medium in which the reaction of the compound (II) with the compound (III) is to be effected according to the process of this invention, and the compound (II) as thus prepared may directly be used for the subsequent reaction with the compound (III), without being previously isolated and purified. For instance, a starting 3-mercapto-indole compound according to the formula (II) may be prepared in situ by reacting an S-(3-indolyl)-isothiuronium halide of the formula (IIc) ##STR36## wherein R 1 , R 3 and p are as defined hereinbefore and X 3 is a halogen atom such as iodine, bromine or chlorine atom, in ethanol with aqueous sodium hydroxide.
Pharmacological Activities
The inhibitory effects of the new compound of this invention on the gastric acid secretion and the cytoprotective effects of the new compound of this invention on the gastric mucosa have been estimated by the following pharmacological tests.
TEST 1
Inhibitory Effects on Aminopyrine Uptake into Gastric Glands
The production of gastric acid in the gastric mucosa is known to be performed by the parietal cells which are one kind of the cells constituting the gastric glands. The extent of the gastric acid secretion by the parietal cells has been deduced to be proportional to the rate of aminopyrine uptake into the gastric glands. Accordingly, the investigation of aminopyrine uptake into the gastric glands has been generally used as the indirect method for measuring the gastric acid secretion. Therefore, suspension of the rabbit gastric glands was prepared according to the method of Berglindh et al (see "Acta Physiol. Scand." 97, 401-414 (1976)). A mixture of the gastric gland suspension (1 ml) and 0.05 μCi 14 C-aminopyrine (specific radio-activity of 103.2 mCi/m mol) was incubated at 37° C. for 30 minutes in the presence of 10 μl of methanol. After this incubation, the reaction mixture obtained was centrifuged so that the gastric glands were spun down and separated from the incubation mixture. The gastric glands so collected were liophylized and the dry weight of the glands was measured. The dried gastric glands were then solubilized with aqueous 0.5N sodium hydroxide and then admixed with a toluene-Triton scintillator, and the radio-activity was determined by the liquid scintillation counter (Packard 460 CD-model). The so determined value of the radio-activity was assumed as the concentration or level of the aminopyrine uptaken into the gastric glands. According to the report of Berglindh et al (see "Acta Physiol. Scand." 96, 150-159 (1976)), it was assumed that the volume of the intraglandular water was amounting to a value of 2 times as much as the dry weight of the gastric glands. The radio-activity of the supernatant of the incubation mixture was determined in the same manner as above by the liquid scintillation counter, and the so determined value of the radio-activity of the supernatant was assumed to be the concentration or level of the aminopyrine present in the extraglandular water with the assumption that the so determined concentration of the aminopyrine in the supernatant was a measure of showing the quantity of the aminopyrine remaining not uptaken into gastric glands. Rate of aminopyrine uptake into gastric glands was calculated according to the following equation: ##EQU1##
The above experiment was repeated without the test compound as the Control test (untreated with test compound), and the rate of aminopyrine uptake as determined for this control test (untreated) was assumed to be 100%. The value (% of Control) was taken as showing the inhibitory effects of the test compound on the acid secretion. The estimated values (as % of Control) of the test compounds for the aminopyrine uptake rate are shown in Table 1 below.
As a comparative drug, omeprazole was tested in the same way as above.
TABLE 1______________________________________ Aminopyrine uptake (% of Control) Concentration (M) of test compound*Test Compound 10.sup.-6 10.sup.-5 10.sup.-4______________________________________Example 1 Compound 44 14 7Example 2 Compound 111 72 24Example 3 Compound 99 64 54Example 4 Compound 50 8 7Example 5 Compound 56 18 11Example 6 Compound 48 76 14Example 7 Compound 55 17 14Example 9 Compound 61 20 15Example 10 Compound 71 19 4Example 11 Compound 106 56 3Example 12 Compound 48 11 10Example 13 Compound 118 48 3Example 37 Compound 114 105 95Example 38 Compound 120 103 141Example 39 Compound 120 109 105Omeprazole (comparative) 34 25 18______________________________________ *This concentration (M) shows the final concentration of the test compoun in the incubation mixture.
From the results of Table 1, it is clear that the compounds of this invention exhibit the inhibitory effects on the aminopyrine uptake into the gastric glands and thus exhibit the inhibitory effects on the gastric acid secretion.
The identification of the tested compounds are as follows:
Example 1 Compound: 2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
Example 2 Compound: 3-[(4-dimethylamino-2-pyridyl)methylthio]indole
Example 3 Compound: 2-[(5-methyl-4-piperidino-2-pyridyl)methylsulfinyl]indole
Example 4 Compound: 1-methyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
Example 5 Compound: 5-methyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
Example 6 Compound: 5-fluoro-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
Example 7 Compound: 5-trifluoromethyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
Example 9 Compound: 5-ethoxycarbonyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
Example 10 Compound: 2-[(3-methyl-4-piperidino-2-pyridyl)methylthio]indole
Example 11 Compound: 2-[(5-methyl-4-morpholino-2-pyridyl)methylthio]indole
Example 12 Compound: 2-[(5-methyl-4-pyrrolidino-2-pyridyl)methylthio]indole
Example 13 Compound: 2-[(4-dimethylamido-2-pyridyl)methylthio]indole
Example 37 Compound: 3-[(4-chloro-2-pyridyl)methylthio]indole
Example 38 Compound: 3-[(4-ethoxycarbonyl-2-pyridyl)methylthio]indole
Example 39 Compound: 3-[(4-hydroxy-2-pyridyl)methylthio]indole
Omeprazole: 2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]-5-methoxybenzimidazole.
TEST 2
Inhibitory Effects on the Enzymatic Activity of H + ,K + -ATPase
The rabbit gastric glands were homogenized and the microsomal fractions were prepared by differential centrifugation of the resultant homogenate. The microsomal fractions were layered on a linear continuous sucrose gradient ranging from 20 to 55% (W/V) sucrose and centrifuged to obtain the light membrane fractions sedimenting between 30% sucrose and 40% sucrose. The light membrane fractions containing the H + ,K + -ATPase so obtained were used to estimate the inhibitory effects of the new compound of this invention or omeprazole on the enzymatic activity of H + ,K + -ATPase. Test compounds were pre-incubated with the reaction mixture containing the enzyme (20-50 μg as protein) for 30 minutes at 37° C. After this, the enzymatic activity of the reaction mixture was determined by incubating for 20 minutes at 37° C. with the following reactant mixture comprising 10 mM MgCl 2 , 10 mM ATP disodium salt and 400 mM Tris-HCl (pH 7.3) with or without 50 mM KCl. From the results obtained, for instance, it was seen that the IC 50 value of the Example 1 Compound of this invention required for 50% inhibition of the enzymatic activity was 5×10 -5 M and the IC 50 value of the Example 13 Compound of this invention was 7×10 -4 M, whereas the IC 50 value of omeprazole (as a comparator) was 9.4×10 -6 M. These results have revealed that the test compounds, Examples 1 and 13 of this invention, are H + ,K + -ATPase inhibitors.
TEST 3
Effects of Preventing the Gastric Ulcer Induced by Ethanol-Hydrochloric Acid
It is known that some prostaglandins possess the remarkable and unique property of protecting the gastric mucosa against damaging agents (for exampoe, ethanol and/or hydrochloric acid), and this phenomenon has been called "cytoprotection". It is also known that prostaglandins exhibit the cytoprotective effect even at the nonantisecretory doses, so that the cytoprotection seems to be independent of the gastric acid inhibition.
The following test were made to demonstrate that the new compound of this invention exhibits the effects of the gastric cytoprotection, namely the effects of preventing the gastric ulcer induced by oral administration of ethanol-hydrochloric acid. Thus, according to the method of Robert et al (see "Gastroenterology" 77, 433-443 (1979)), SD-strain rats (male, weighing 200 to 220 g, 8 rats in each group) were deprived of food for 24 hours and deprived of water for 19 hours. The rats were then administered orally with a suspension of the test compound in aqueous 0.5% carboxymethylcellulose solution at a dosage of 6, 10 or 20 mg/kg of the test compound.
30 minutes later than the administration of the test compound, 1 ml of 0.2N hydrochloric acid-50% aqueous ethanol per rat was orally given to the rats. One hour after the administration of the ethanolic hydrochloric acid, the rats were killed. Their stomacks were dissected out, and the lower part of the esophagus was nipped with a clip. Aqueous 1% formalin solution (12.0 ml) was poured into the stomacks from duodenum and then the duodenal part was nipped by a clip. The whole stomacks were immersed in aqueous 1% formalin solution for about 10 minutes for the fixation, the pyloric stomacks were opened along the greater curvature and then rinsed with water. The gastric mucosa was examined and the necrotic lesions or errosions as formed in the glandular stomack and in the pylorus were examined under anatomic microscope to determine the length (in mm) of the lesions.
From the test results obtained by the above procedure, the ED 50 value of the tested compound effective for 50% inhibition to the formation of necrotic lesions was evaluated. The ED 50 data so obtained are shown in Table 2 below.
Omeprazole as the comparative drug was tested in the same manner as above.
TABLE 2______________________________________Test Compound ED.sub.50 (mg/kg, p.o.)______________________________________Example 1 Compound 11.54Example 5 Compound 8.59Example 6 Compound 12.65Example 7 Compound 9.77Example 13 Compound 9.17Example 21 Compound 14.60Example 22 Compound 8.13Example 40 Compound 2.84Omeprazole (comparative) 34.06______________________________________
From the test results of the above table, it is clear that the effective dose of the compound of this invention for 50% inhibition (ED 50 ) to the necrotic lesions is remarkably superior to the ED 50 value of omeprazole in respect of their effects of preventing the gastic ulcer induced by the ethanolic hydrochloric acid and thus in respect of their gastric cytoprotective effects.
Identification of the tested compounds of Examples 21, 22 and 40 according to this invention are as follows:
Example 21 Compound: 5-methoxy-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
Example 22 Compound: 2-[(4-piperidino-2-pyridyl)methylthio]indole
Example 40 Compound: 3-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole.
TEST 4
Gastric Acid Antisecretory Activity
Donryu-strain rats (male, weighing 210-240 g) were deprived of food for 24 hours and then anaesthetized by intraperitoneal injection of 1.2 g/kg of urethane. The bilateral vagus nerves in the cervical region of the rats were surgically cut and cannulas were inserted into the pylorus and also into the esophagus, respectively, and tied in place according to the method of Ghosh and Schild (see "Brit. J. Pharmacol." 13, 54 (1958)). Aqueous 0.9% saline solution (pH 8.5) as warmed to 40° C. was passed through the esphagal cannula into the stomack at a rate of 1 ml/min. for the perfusion. The pH value of the effluent coming from the pyloral cannula was measured. At the stage when the pH value of said effluent became steady, 5 μg/kg of tetragastrin, a stimulant for the gastric acid secretion, was administered through a cannula which had been inserted into the cervical vein. After the administration of tetragastrin, the decreasing change of pH value in the effluent was measured at constant intervals of time. Subsequently, a solution of the test compound in methanol was intraveously administered to the rat, and 15 minutes later tetragastrin was again administered.
From the test data of the pH measurements so obtained was evaluated the ED 50 value of the tested compound effective for 50% inhibition of the gastric acid secretion. The ED 50 data of the tested compounds are shown in Table 3 below.
TABLE 3______________________________________Test Compound ED.sub.50 (mg/kg, i.v.)______________________________________Example 1 Compound 7.58Omeprazole (comparative) 0.24______________________________________
From the ED 50 data of the above Table 3, it is clear that the new compound of this invention represented by the tested Example 1 Compound has a higher ED 50 value than that of the comparative omeprazole for the effective dose for 50% inhibition to the gastric acid secretion, revealing that the gastric acid antisecretory activity of the new compound of this invention is remarkedly milder than that of opeprazole.
Thus, the results of the above Tests 1-4 have demonstrated that the compound of this invention exhibits a mild inhibitory activity to the gastric acid secretion and a remarkably high cytoprotective activity on the gastric mucosa, in combination.
The new compound of this invention is administrable as an antiulcer agent to mammalian animals and humans for the therapeutic treatment of gastric ulcers. The compound of this invention may be administered orally or non-orally, for instance, intramuscularly, intrasubcutaneously, intrarectally or intracutaneously. Oral administration is preferred. When used as the antiulcer agent, the compound of this invention may be formulated into various forms suitable for oral or non-oral administration. For example, the compound of this invention may be formulated into a pharmaceutical composition by mixing with one or more of the solid or liquid carrier (excipient), binder, lubricant, disintegrator, antiseptic agent, isotonic additives, stabilizer, dispersing agent, anti-oxidant, coloring agent, favoring agent and buffering agent which are usually employed for the formulation of the antiulcer drugs. The pharmaceutical composition so formulated may be in the form of a solid form such as tablet, hard capsule, soft capsule, granules, powder, fine powder, pills and troach and the like; and in a semi-solid form such as suppository and ointment, as well as in a liquid form such as injectable solution or suspension, emulsion, syrup and the like.
Suitable examples of the additives which may be incorporated into the pharmaceutical composition comprising the compound of this invention as the active ingredient include lactose, fructose, glucose, starch, gelatin, magnesium carbonate, magnesium aluminum metasilicate, synthetic aluminum silicate, silica, talc, magnesium stearate, methylcellulose, carboxymethylcellulose or a salt thereof, arabic gum, polyethylene glycol, p-hydroxybenzoic acid alkyl esters, sugar syrup, ethanol, propylene glycol, vaseline, carbowax, glycerine, sodium chloride, sodium sulfite, sodium phosphate, citric acid and others.
The proportion of the compound of this invention in the pharmaceutical composition may vary depending on the type of the formulation and may usually be in the range of 5% to 100% by weight of the formulation when the formulation is in the state of a solid or a semi-solid. The compound of this invention may be incorporated at a concentration of 0.1 to 10% by weight in the liquid formulations. The dosage of the compound of this invention may vary, depending on the nature of the mammalian animals (including humans) to be treated, the route of administration and conditions of the disease and other factors, but the compound of this invention may normally be administered at a dosage of 0.01 to 20 mg/kg a day for an adult person for a general guideline. Of course, the dosage of the compound may be changed according to the conditions of the diseases and the judgement of the doctors. The above dosage may be given at one time or separately at several times a day.
According to the third aspect of this invention, therefore, there is provided a pharmaceutical composition comprising a compound of the formula (I) or a pharmaceutically acceptable salt thereof as the active ingredient in a therepeutically effective amount, in association with a pharmaceutically acceptable carrier for the active ingredient. This pharmaceutical composition may be particularly for use in the treatment for inhibiting the gastric acid secretion and effecting the gastric cytoprotection in a mammalian animal, including human, and the compound of this invention in said composition may be present in a therapeutically effective amount to inhibit the gastric acid secretion and to effect the gastric cytoprotection in the mammalian animal.
According to a further aspect of this invention, there is provided a method for inhibiting the gastric acid secretion and effecting the gastric cytoprotection in a mammalian animal, including human, which comprises administering to the animal suffering from the gastric acid secretion disturbances and the gastrointestinal ulcer a compound of the formula (I) as defined above or a pharmaceutically acceptable salt of said compound in an amount effective to inhibit the gastric acid secretion and effect the gastric cytoprotection in the gastrointestines.
According to another aspect of this invention, there is provided a method for the treatment or prevention of gastrointestinal ulcer in a mammalian animal, including human, suffering from or susceptible to the development of the ulcer, which comprises administering to the animal a compound of the formula (I) as defined above or a pharmaceutically acceptable salt of said compound in an amount effective to therapeutically treat or prevent the ulcer.
The following Examples illustrate the preparation of typical compounds according to this invention.
EXAMPLE 1
Preparation of 2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
To a solution of 2-mercaptoindole (1.34 g, 8.98 mmol) and 2-chloromethyl-5-methyl-4-piperidinopyridine hydrochloride (2.35 g, 9.00 mmol) in ethanol (90 ml) was added a 2N aqueous sodium hydroxide solution (9.0 ml) under ice-cooling, and the mixture was stirred at room temperature for 30 minutes. After the removal of the organic solvent by evaporation under a reduced pressure, a saturated sodium chloride solution was added to the residue and the mixture was extracted with chloroform. The chloroform layer separated was dried over anhydrous magnesium sulfate and then concentrated in vacuo. The residue was purified by a silica gel column chromatography [eluent: chloroform and then chloroform-methanol (50:1)] whereby to yield the titled compound (2.51 g) as a crystalline substance.
Yield: 83%. m.p.: 138°-139° C.
IR (KBr, cm -1 ): 2930, 2800, 1600, 1440, 1420, 1400, 1380, 1350, 1240, 1230, 755, 740.
NMR (DMSO-d 6 , ppm): 1.30-1.90 (6H, m), 2.17 (3H, s), 2.60-3.00 (4H, m), 3.99 (2H, s), 6.48 (2H, s), 6.80-7.60 (4H, m), 8.20 (1H, s), 10.80 (1H, br.s).
EXAMPLE 2
Preparation of 3-[(4-dimethylamino-2-pyridyl)methylthio]indole
To a solution of S-(3-indolyl)isothioronium iodide (180 mg, 0.75 mmol) of the formula ##STR37## in ethanol (5 ml) was added a 2N aqueous sodium hydroxide solution (0.86 ml) under ice-cooling, and the mixture obtained was stirred at room temperature for 1 hour. The resultant reaction solution containing 3-mercapto-indole so formed was then admixed with 2-chloromethyl-4-dimethylaminopyridine hydrochloride (118 mg, 0.75 mmol), followed by stirring the mixture at room temperature for 1 hour. The resulting reaction was made strongly alkaline with a 2N aqueous sodium hydroxide solution (1.0 ml) and then diluted with water (20 ml) to precipitate crystals, affording the titled compound (130 mg) after filtration.
Yield: 47%, m.p. 189°-191° C.
IR (KBr, cm -1 ): 1610, 1520, 1430, 1380, 1230, 1010, 820, 750.
NMR (DMSO-d 6 , ppm): 2.70 (6H, s), 3.74 (2H, s), 6.10 (1H, d, J=2 Hz), 6.30 (1H, dd, J=2.7 Hz), 6.85-7.50 (5H, m), 7.90 (1H, d, J=6 Hz), 11.20 (1H, br, s).
EXAMPLE 3
Preparation of 2-[(5-methyl-4-piperidino-2-pyridyl)methylsulfinyl]indole
To a solution of 2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole (80 mg, 0.24 mmol) in chloroform (2.4 ml) was added m-chloroperbenzoic acid (60 mg, 0.35 mmol) under ice-cooling, and the mixture was stirred at that temperature for further 30 minutes. The reaction solution was diluted with chloroform (10 ml) and then washed with a 1% aqueous sodium hydrogen carbonate solution (2.5 ml) and then with a saturated aqueous sodium chloride solution (1 ml). The resulting chloroform layer was dried over anhydrous magnesium sulfate and then concentrated in vacuo. Ethylether (20 ml) was added to the resulting concentration residue to precipitate crystals. After filtration, the titled compound (68 mg) was obtained. Yield: 81%, m.p.: 178° C.
IR (KBr, cm -1 ): 2950, 1595, 1235, 1020, 1010, 985, 815, 745.
NMR (DMSO-d 6 , ppm): 1.10-1.70 (6H, m), 2.08 (3H, s), 2.20-2.70 (4H, m), 4.48 (1H, d, J=12 Hz), 4.78 (1H, d, J=12 Hz), 6.18 (1H, s), 6.68 (1H, br.s), 6.90-7.70 (4H, m), 8.09 (1H, s).
EXAMPLE 4
Preparation of 1-methyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
2-[(5-Methyl-4-piperidino-2-pyridyl)methylthio]indole (80 mg, 0.24 mmol) was added to a suspension of potassium hydroxide (finely ground) (62 mg) in dimethylsulfoxide (0.5 ml), and the mixture was stirred for 30 minutes. Methyl iodide (34 mg, 0.24 mmol) was then added to the mixture and the stirring was continued at room temperature for further 30 minutes. Then, water (20 ml) was added to the reaction solution and the mixture was extracted with ethyl ether. The ether layer so separated was washed with water, dried over magnesium sulfate and concentrated in vacuo. The residue was purified by a silica gel column chromatography (eluent: chloroform), yielding the titled compound (75 mg) as an oil. Yield: 90%.
IR (CHCl 3 solution, cm -1 ): 2940, 1590, 1460, 1450, 1325, 750.
NMR (CDCl 3 , ppm): 1.20-1.80 (6H, m), 2.12 (3H, s), 2.30-2.70 (4H, m), 3.44 (3H, s), 3.89 (2H, s), 6.07 (1H, s), 6.60 (1H, s), 6.80-7.60 (4 H, m), 8.09 (1H, s).
EXAMPLES 5-36
The following compounds of Examples Nos. (5) to (36) were prepared in the same manner as that described in Example 1.
(5) 5-Methyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
m.p. 129°-132° C.
IR (KBr, cm -1 ): 2950, 2800, 1600, 1500, 1450, 1260, 1240, 1180, 1050, 800.
NMR (CDCl 3 , ppm): 1.60 (6H, m), 2.20 (3H, s), 2.40 (3H, s), 2.80-3.10(4H, m), 4.00(2H, s), 6.42(1H, s), 6.50(1H, s), 6.90(1H, dd, J=2, 10 Hz), 7.20(1H, d, J=10 Hz), 7.21(1H, s), 8.24 (1H, s), 10.50(1H, s).
(6) 5-Fluoro-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
m.p. 136°-137° C.
IR (KBr, cm -1 ): 2950, 2850, 1600, 1500,, 1440, 1260, 1150, 870, 800.
NMR (CDCl 3 , ppm): 1.50-1.90(6H, m), 2.28(3H, s), 2.70-3.10(4H, m), 4.06(2H, s), 6.48(1H, s), 6.80(1H, d, J=7 Hz), 7.10(1H, d, J=7 Hz), 7.24(1H, s), 8.26(1H, s), 11.35(1H, br.s).
(7) 5-Trifluoromethyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
m.p. 103°-104° C.
IR (KBr, cm -1 ): 2950, 2850, 1600, 1460, 1340, 1280, 1160, 1120, 1060, 850.
NMR (CDCl 3 , ppm): 1.40-1.90(6H, m), 2.23(3H, m), 2.70-3.10(4H, m), 4.05(2H, s), 6.55(1H, s), 6.60(1H, s), 7.34(2H, s), 7.74(1H, s), 8.25(1H, s).
(8) 5-Acetyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
m.p. 136°-137° C.
IR (KBr, cm -1 ): 2950, 2800, 1670, 1600, 1550, 1350, 1050, 820.
NMR (CDCl 3 , ppm): 1.50-1.90(6H, m), 2.24(3H, s), 2.62(3H, s), 2.75-3.10(4H, m), 4.07(2H, s), 6.58(1H, s), 6.61(1H, s), 7.31(1H, d, J=10 Hz), 7.80(1H, dd, J=2, 10 Hz), 8.13(1H, d, J=1 Hz), 8.28(1H, s), 12.05(1H, br.s).
(9) 5-Ethoxycarbonyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylthio]indole
m.p. 153°-154° C.
IR (KBr, cm -1 ): 2950, 2850, 1700, 1600, 1520, 1460, 1320, 1280, 1000, 780.
NMR (CDCl 3 , ppm): 1.44(3H, t, J=7 Hz), 1.05-2.00(6H, m), 2.26(3H, s), 2.70-3.20(4H, m), 4.08(2H, s), 4.40(2H, q, J=7 Hz), 6.58(1H, s), 6.63(1H, s), 7.34(1H, d, J=9 Hz), 7.86(1H, dd, J=2, 9 Hz), 8.28(2H, s), 11.85(1H, br.s).
(10) 2-[(3-Methyl-4-piperidino-2-pyridyl)methylthio]indole
m.p. 134°-137° C.
IR (KBr, cm -1 ): 2950, 1600, 1460, 1450, 1400, 1360, 1265.
NMR (CDCl 3 , ppm): 1.40-1.90(6H, m), 2.14(3H, s), 2.60-3.00(4H, m), 4.16(2H, m), 6.46(1H, m), 6.67(1H, d, J=6 Hz), 6.80-7.60(4H, m), 8.25(1H, d, J=6 Hz), 10.60(1H, br.s).
(11) 2-[(5-Methyl-4-morpholino-2-pyridyl)methylthio]indole
m.p. 142°-143° C.
IR (KBr, cm -1 ): 2830, 1600, 1260, 1125, 990.
NMR (CDCl 3 , ppm): 2.19(3H, s), 2.70-3.00(4H, m), 3.60-3.90(4H, m), 4.02(2H, s), 6.46(1H, s), 6.48(1H, s), 6.80-7.60(4H, m), 8.25(1H, s), 10.6(1H, br.s).
(12) 2-[(5-Methyl-4-pyrrolidino-2-pyridyl)methylthio]indole
m.p. 179°-180° C.
IR (KBr, cm -1 ): 3060, 2950, 1610, 1540, 1510, 1360, 1330, 1150, 1035, 850, 760.
NMR (CDCl 3 , ppm): 1.75-2.10(4H, m), 2.38(3H, s), 3.15-3.60(4H, m), 4.04(2H, s), 6.27(1H, s), 6.53(1H, s), 6.90-7.70(4H,s), 8.06(1H,s), 11.45(1H,br.s).
(13) 2-[(4-Dimethylamino-2-pyridyl)methylthio]indole
m.p. 128°-129° C.
IR (KBr, cm -1 ): 2900, 1620, 1400, 1360, 1240, 1100, 830, 770.
NMR (DMSO-d 6 , ppm): 2.76(6H, s), 4.05(2H, s), 6.35(3H, d, J=1 Hz), 6.80-7.50(4H, m), 7.98(1H, d, J=7 Hz), 11.55(1H, br.s).
(14) 5-Methyl-2-[(4-dimethylamino-2-pyridyl)methylthio]indole
m.p 109°-112° C.
IR (KBr, cm -1 ): 2920, 1615, 1520, 1440, 1390, 1240, 1220, 1015, 820, 805.
NMR (CDCl 3 , ppm): 2.37(3H, s), 2.82(6H, s), 3.99(2H, s), 6.20-6.50(3H, m), 6.86(1H, dd, J=2, 9 Hz), 7.10-7.30(2H, m), 8.00-8.30(1H, m), 11.30(1H, br.s).
(15) 2-[(4-Dimethylamino-2-pyridyl)methylthio]-5-methoxyindole
m.p. 108°-110° C.
IR (KBr, cm -1 ): 2930, 1615, 1440, 1420, 1390, 1240, 1170, 1015, 810.
NMR (CDCl 3 , ppm): 2.80(6H, s), 3.76(3H, s), 3.97(2H, s), 6.10-6.50(3H, m), 6.60-7.20(3H, m), 8.00-8.30(1H, m), 11.30(1H, br.s).
(16) 5-Fluoro-2-[(4-dimethylamino-2-pyridyl)methylthio]indole
m.p. 146°-148° C.
IR (KBr, cm -1 ): 2950, 1620, 1460, 1445, 1290, 1185, 1140, 1115, 1065, 1010, 905, 815.
NMR (CDCl 3 , ppm): 2.83(6H, s), 3.96(2H, s), 6.20-6.50(3H, m), 6.60-7.30(3H, m), 8.00-8.30(1H, m), 11.90(1H, br.s).
(17) 5-Trifluoromethyl-2-[(4-dimethylamino-2-pyridyl)methylthio]indole
m.p. 178°-180° C.
IR (KBr, cm -1 ): 2400, 1605, 1520, 1455, 1440, 1385, 1160, 1110, 1015, 850, 765.
NMR (CDCl 3 , ppm): 2.75(6H, s), 3.99(2H, s), 6.13(1H, d, J=3 Hz), 6.36(1H, dd, J=3, 6 Hz), 6.46(1H, s), 7.30-7.50(2H, m), 7.70-7.80(1H, m), 7.93(1H, d, J=6 Hz).
(18) 5-Acetyl-2-[(4-dimethylamino-2-pyridyl)methylthio]indole
m.p. 136°-138° C.
IR (KBr, cm -1 ): 2930, 1660, 1605, 1515, 1365, 1350, 1315, 1265, 1010, 805.
NMR (CDCl 3 , ppm): 2.69(3H, s), 2.93(6H, s), 4.00(2H, s), 6.30-6.50(2H, m), 6.55(1H, s), 7.31(1H, d, J=9 Hz), 7.73(1H, dd, J=1, 9 Hz), 8.10-8.40(2H, m), 12.60(1H, br.s).
(19) 5-Ethoxycarbonyl-2-[(4-dimethylamino-2-pyridyl)methylthio]indole
m.p. 113°-116° C.
IR (KBr, cm -1 ): 2900, 1705, 1610, 1350, 1315, 1300, 1265, 1240, 1200, 1010, 775.
NMR (CDCl 3 , ppm): 1.37(3H, t, J=7 Hz), 2.85(6H, s), 3.97(2H, s), 4.82(2H, q, J=7 Hz), 6.20-6.40(2H, m), 6.50(1H, s), 7.27(1H, d, J=10 Hz), 7.78(1H, dd, J=2, 10 Hz), 8.10-8.30(2H, m), 12.30(1H, br.s).
(20) 6,7-Dimethyl-2-[(4-dimethylamino-2-pyridyl)methylthio]indole
m.p. 134°-137° C.
IR (KBr, cm -1 ): 2880, 1600, 1440, 1385, 1005, 805.
NMR (CDCl 3 , ppm): 2.34(3H, s), 2.41(3H, s), 2.33(6H, s), 3.94(2H, s), 6.20-6.50(3H, m), 6.78(1H, d, J=8 Hz), 7.18(1H, d, J=8 Hz), 8.18-8.30(1H, m), 11.90(1H, br.s).
(21) 2-[(5-Methyl-4-piperidino-2-pyridyl)methylthio]-5-methoxy indole
m.p. 100°-101° C.
IR (KBr, cm -1 ): 2930, 1600, 1260, 1235, 1170.
NMR (CDCl 3 , ppm): 1.40-1.90(6H, m), 2.20(3H, s), 2.60-3.10(4H, m), 3.80(3H, s), 4.03(2H, s), 6.45(1H, m), 6.54(1H, s), 6.79(1H, dd, J=2, 9 Hz), 6.97(1H, d, J=2 Hz), 7.23(1H, d, J=9 Hz), 8.28(1H, s).
(22) 2-[(4-Piperidino-2-pyridyl)methylthio]indole
m.p. 130°-131° C.
IR (KBr, cm -1 ): 2930, 1600, 1535, 1500, 1275, 990.
NMR (CDCl 3 , ppm): 1.30-1.80(6H, m), 3.00-3.50(4H, m), 3.99(2H, s), 6.30-6.60(3H, m), 6.80-7.60(4H, m).
(23) 2-{[4-(4-Methylpiperazino-2-pyridyl]methylthio}indole
m.p. 163°-164° C.
IR (KBr, cm -1 ): 2820, 1615, 1275, 1160, 1010.
NMR (CDCl 3 , ppm): 2.26(3H, s), 2.20-2.70(4H, m), 3.00-3.50(4H, m), 4.00(2H, s), 6.20-6.70(3H, m), 6.90-7.60(4H, m), 8.28(1H, d, J=6 Hz).
(24) 5-Fluoro-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
m.p. 109°-111° C.
IR (KBr, cm -1 ): 1560, 1410, 1260, 1210, 1140, 1070, 1000, 950, 850, 790, 770.
NMR (DMSO-d 6 , ppm): 2.19(3H, s), 2.21(3H, s), 3.71(3H, s), 4.33(2H, s), 6.46(1H, br.s), 6.92(1H, ddd, J=9, 9 Hz), 7.20(1H, dd, J=9, 3 Hz), 7.32(1H, dd, J=9, 6 Hz), 8.15(1H, s), 11.70(1H, s).
(25) 2-(2-Pyridylmethylthio-5-methoxyindole
m.p. 101°-102° C.
IR (KBr. cm -1 ): 1580, 1420, 1330, 1290, 1215, 1190, 1150, 1020.
NMR (DMSO-d 6 , ppm): 3.73(3H, s), 4.30(2H, s), 6.33(1H, br.s), 6.74(1H, dd, J=8, 2 Hz), 6.93(1H, d, J=2 Hz), 7.24(3H, m), 7.7(1H, dd, J=8, 8 Hz), 8.48(1H, d, J=4 Hz), 11.45(1H, br.s).
(26) 2-(3-Pyridylmethylthio)-5-methoxyindole
m.p. 106°-108° C.
IR (Kbr, cm -1 ): 1565, 1480, 1410, 1320, 1280, 1210, 1180, 1150, 1020, 820, 800, 770.
NMR (DMSO-d 6 , ppm): 3.76(3H, s), 4.19(2H, s), 6.33(1H, s), 6.76(1H, dd, J=9, 2 Hz), 6.94(1H, d, J=2 Hz), 7.23(1H, d, J=9 Hz), 7.26(1H, dd, J=7, 4 Hz), 7.51(1H, d, J=7 Hz), 7.38(1H, s), 7.40(1H, d, J=4 Hz), 11.44(1H, s).
(27) 2-(4-Pyridylmethylthio)-5-methoxyindole
m.p. 129°-131° C.
IR (KBr, cm -1 ): 1590, 1420, 1400, 1340, 1220, 1150, 1020, 820, 800, 780.
NMR (DMSO-d 6 , ppm): 3.74(3H, s), 4.17(2H, s), 6.34(1H, br.s), 6.73(1H, dd, J=8, 2 Hz), 6.93(1H, d, J=2 Hz), 7.20(1H, d, J=8 Hz), 7.22(2H, d, J=5 Hz), 8.45(2H, d, J=5 Hz), 11.3(1H, br.s).
(28) 2-[(3,5-Dimethyl-4-methoxy-2-pyridyl)methylthio]indole
m.p. 125°-127° C.
IR (KBr, cm -1 ): 1565, 1470, 1440, 1410, 1340, 1260, 1120, 1060, 1000, 750, 730.
NMR (DMSO-d 6 , ppm): 2.16(3H, s), 2.18(3H, s), 3.70(3H, s), 4.30(2H, s), 6.45(1H, br.s), 6.95(1H, dd, J=6, 6 Hz), 7.09(1H, dd, J=6, 6 Hz), 7.33(1H, d, J=6 Hz), 7.43(1H, d, J=6 Hz), 8.13(1H, s), 11.35(1H, s).
(29) 3-Methyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
m.p. 150°-151° C.
IR (KBr, cm -1 ): 1470, 1440, 1345, 1330, 1260, 1110, 1060, 1000, 740.
NMR (DMSO-d 6 , ppm): 2.00(3H, s), 2.02(3H, s), 2.18(3H, s), 3.63(3H, s), 4.13(2H, s), 6.95(1H, dd, J=6, 6 Hz), 7.12(1H, dd, J=6, 6 Hz), 7.30(1H, d, J=6 Hz), 7.40(1H, d, J=6 Hz), 8.09(1H, s), 11.30(1H, s).
(30) 5-Methyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
m.p. 110°-112° C.
IR (KBr, cm -1 ): 1555, 1460, 1425, 1390, 1320, 1260, 1215, 1070, 990, 860, 790.
NMR (CDCl 3 , ppm): 2.20(3H, s), 2.26(3H, s), 2.31(3H, s), 3.72(3H, s), 4.20(2H, s), 6.44(1H, s), 6.96(1H, d, J=9 Hz), 7.22(1H, d, J=9 Hz), 7.30(1H, s) 8.28(1H, s), 10.25(1H, s).
(31) 5-Trifluoromethyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
m.p. 131°-132° C.
IR (KBr, cm -1 ): 1320, 1260, 1140, 1070, 1040, 800.
NMR (DMSO-d 6 , ppm): 2.20(6H, s), 3.70(3H, s), 4.36(2H, s), 6.64(1H, s), 7.35(1H, d, J=9 Hz), 7.42(1H, d, J=9 Hz), 7.83(1H, s), 8.14(1H, s), 12.03(1H, s).
(32) 2-[(3,5-Dimethyl-4-methoxy-2-pyridyl)methylthio]-5-methoxyindole
m.p. 130°-131° C.
IR (KBr, cm -1 ): 1430, 1340, 1265, 1220, 1190, 1155, 1080, 1020, 850, 790.
NMR (DMSO-d 6 , ppm): 2.13(3H, s), 2.19(3H, s), 3.69(3H, s), 3.73(3H, s), 4.27(2H, s), 6.37(1H, br.s), 6.74(1H, dd, J=9, 2 Hz), 6.93(1H, d, J=2 Hz), 7.22(1H, d, J=9 Hz), 8.15(1H, s), 11.40(1H, s).
(33) 2-[(3,5-Dimethyl-4-methoxy-2-pyridyl)methylthio]-5-methoxycarbonylindole
m.p. 172°-173° C.
IR (KBr, cm -1 ): 1680, 1430, 1310, 1260, 1190, 1120, 1080, 770.
NMR (DMSO-d 6 , ppm): 2.19(6H, s), 3.68(3H, s), 3.83(3H, s), 4.33(2H, s), 6.60(1H, s), 7.36(1H, d, J=8 Hz), 7.72(1H, d, J=8 Hz), 8.11(1H, s), 8.12(1H, s), 11.95(1H, s).
(34) 5-Acetyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
m.p. 149°-151° C.
IR (KBr, cm -1 ): 1640, 1350, 1340, 1290, 1240, 1070, 800.
NMR (DMSO-d 6 , ppm): 2.20(6H, s), 2.60(3H, s), 3.70(3H, s), 4.35(2H, s), 6.65(1H, br.s), 7.38(1H, d, J=9 Hz), 7.75(1H, d, J=9 Hz), 8.14(1H,s), 8.18(1H, s), 12.0(1H, br.s).
(35) 3-Methylthio-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
m.p. 167°-168° C.
IR (KBr, cm -1 ): 1460, 1420, 1330, 1250, 1110, 1050, 980, 735.
NMR (DMSO-d 6 , ppm): 2.15(3H, s), 2.19(3H, s), 2.22(3H, s), 3.70(3H, s), 4.37(2H, s), 7.0-7.6(4H, m), 8.10(1H, s), 11.95(1H, br.s).
(36) 7-Trifluoromethyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
m.p. 74° C.
IR (KBr, cm -1 ): 1430, 1320, 1300, 1180, 1140, 1105, 1080, 800, 730.
NMR (DMSO-d 6 , ppm): 2.20(6H, s), 3.70(3H, s), 4.38(2H, s), 6.63(1H, br.s), 7.13(1H, dd, J=8, 8 Hz), 7.41(1H, d, J=8 Hz), 7.73(1H, d, J=8 Hz), 8.18(1H, s), 12.2(1H, br.s).
EXAMPLES 37-47
The following compounds of Examples Nos. (37) to (47) were prepared in the same manner as described in Example 2.
(37) 3-[(4-Chloro-2-pyridyl)methylthio]indole
m.p. 126°-128° C.
IR (KBr, cm -1 ): 3160, 2900, 1580, 1495, 1425, 1390, 1340, 1240, 1100.
NMR (DMSO-d 6 , ppm): 3.90(2H, s), 6.90-7.50(7H, m), 8.28(1H, d, J=5 Hz), 11.25(1H, br.s).
(38) 3-[(4-Ethoxycarbonyl-2-pyridyl)methylthio]indole
It was in the form of an oil.
IR (CHCl 3 solution, cm -1 ): 2950, 1780, 1600, 1200, 1020, 900.
NMR (CDCl 3 , ppm): 1.40(3H, t, J=7 Hz), 3.85(2H, s), 4.45(2H, q, J=7 Hz), 6.90-8.00(7H, m), 8.48(1H, d, J=7 Hz), 9.15(1H, br.s).
(39) 3-[(4-Hydroxy-2-pyridyl)methylthio]indole
m.p. 191°-192° C.
IR (KBr, cm -1 ): 3200, 2900, 1620, 1515, 1490, 1420, 1245, 1160, 865.
NMR (DMSO-d 6 , ppm): 3.70(2H, s), 4.75(2H, br.s), 5.95(1H, s), 6.20(1H, d, J=7 Hz), 6.90-7.90(5H, m).
(40) 3-[(5-Methyl-4-piperidino-2-pyridyl)methylthio]indole
m.p. 170°-171° C.
IR (KBr, cm -1 ): 1605, 1460, 1410, 1235, 1055, 1010, 990.
NMR (DMSO-d 6 , ppm): 1.30-1.70(6H, m), 2.08(3H, s), 2.40-2.80(4H, m), 3.83(2H, s), 6.29(1H, s), 6.90-7.60(5H, m).
(41) 3-[(4-Piperidino-2-pyridyl)methylthio]indole
m.p. 145°-147° C.
IR (KBr, cm -1 ): 2930, 1605, 1510, 990, 750.
NMR (DMSO-d 6 , ppm): 1.1-1.8(6H, m), 2.7-3.4(4H, m), 3.88(2H, s), 6.25(1H, d, J=2 Hz), 6.43(1H, dd, J=2, 6 Hz), 6.8-7.7(5H, m), 8.08(1H, d, J=6 Hz), 10.3(1H, br.s).
(42) 3-[(2-Pyridyl)methylthio]indole
m.p. 124°-125° C.
IR (KBr, cm -1 ): 3150, 3120, 3080, 2900, 1600, 1445, 1005, 790, 740.
NMR (CDCl 3 , ppm): 3.94(2H, s), 6.8-7.2(6H, m), 7.2-7.6(2H, m), 8.2-8.4(1H, m), 9.6(1H, br.s).
(43) 5-Fluoro-3-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
m.p. 178° C.
IR (KBr, cm -1 ): 1550, 1450, 1260, 1210, 1140, 1060, 990, 920, 845, 785.
NMR (DHSO-d 6 , ppm): 2.02(3H, s), 2.16(3H, s), 3.50(3H, s), 3.96(2H, s), 6.75-7.05(2H, m), 7.30-7.50(2H, m), 8.04(1H, s), 11.50(1H, s).
(44) 3-[(3,5-Dimethyl-4-methoxy-2-pyridyl)methylthio]indole
m.p. 121°-122° C.
IR (KBr, cm -1 ): 1565, 1480, 1450, 1440, 1265, 1230, 1080, 1010, 745.
NMR (DMSO-d 6 , ppm): 2.06(3H, s), 2.18(3H, s), 3.62(3H, s), 4.00(2H, s), 7.10(2H, m), 7.40(3H, m), 8.07(1H, s), 11.50(1H, s).
(45) 2-Methyl-3-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylthio]indole
m.p. 185°-187° C.
IR (KBr, cm -1 ): 1260, 1225, 1080, 1000, 730.
NMR (DMSO-d 6 , ppm): 1.97(3H, s), 2.13(3H, s), 2.16(3H, s), 3.57(3H, s), 3.86(2H, s), 7.00(2H, m), 7.30(2H, m), 8.03(1H, s), 11.40(1H, s).
(46) 3-[(3,5-Dimethyl-4-methoxy-2-pyridyl)methylthio]-5-methoxyindole
m.p. 170°-172° C.
IR (KBr, cm -1 ): 1450, 1260, 1190, 1160, 1060, 1020, 980, 900, 830, 790.
NMR (DMSO-d 6 , ppm): 1.95(3H, s), 2.15(3H, s), 3.52(3H, s), 3.70(3H, s), 3.94(2H, s), 6.65(1H, s), 6.70(1H, d, J=9 Hz), 7.27(1H, d, J=9 Hz), 7.30(1H, s), 8.06(1H, s), 11.35(1H, s).
(47) 3-[(3,5-Dimethyl-4-methoxy-2-pyridyl)methylthio]-5-methoxycarbonylindole
m.p. 194°-197° C.
IR (KBr, cm -1 ): 1700, 1440, 1290, 1260, 1230, 1220, 1200, 1070, 1000, 810, 770.
NMR (DMSO-d 6 , ppm): 1.94(3H, s), 2.13(3H, s), 3.50(3H, s), 3.90(3H, s), 4.00(2H, s), 7.46(1H, d, J=9 Hz), 7.56(1H, br.s), 7.74(1H, d, J=9 Hz), 7.80(1H, s), 8.05(1H, s), 11.90(1H, br.s).
EXAMPLES 48-63
The following compound of Examples Nos (48) to (63) were prepared in the same manner as described in Example 3.
(48) 1-Methyl-2-[(5-methyl-4-piperidino-2-pyridyl)methylsulfinyl]indole
It was in the form of an oil.
IR (CHCl 3 solution, cm -1 ): 2900, 1600, 1260, 1245, 1235, 1070, 1050, 760.
NMR (CDCl 3 , ppm): 1.20-1.70(6H, m), 2.13(3H, s), 2.30-2.80(4H, m), 3.72(3H, s), 4.35(1H, d, J=12Hz), 4.69(1H, d, J=12Hz), 6.26(1H, s), 6.86(1H, s), 6.90-8.00(4H, m), 8.12(1H, s).
(49) 5-Fluoro-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
m.p. 192°-195° C. (with decomposition).
IR (KBr, cm -1 ): 1560, 1460, 1435, 1150, 1070, 1000, 800.
NMR (DMSO-d 6 , ppm): 2.11(3H, s), 2.19(3H, s), 3.65(3H, s), 4.63(2H, ABq, J=13 Hz), 6.80(1H, br.s), 7.10(1H, ddd, J=9,9, 3 Hz), 7.35(1H, dd, J=9, 3 Hz), 7.51(1H, dd, J=9, 6 Hz), 8.20(1H, s), 12.40(1H, s).
(50) 2-(2-Pyridylmethylsulfinyl)-5-methoxyindole
m.p. 168°-169° C.
IR (KBr, cm 31 1): 1500, 1430, 1190, 1155, 1005.
NMR (DMSO-d 6 , ppm): 3.77(3H, s), 4.64(2H, ABq, J=13 Hz), 6.75(1H, br.s), 6.89(1H, dd, J=9, 2 Hz), 7.08(1H, d, J=2 Hz), 7.33(3H, m), 7.72(1H, dd, J=7, 7 Hz), 8.53(1H, d, J=5 Hz), 12.2(1H, br.s).
(51) 2-(3-Pyridylmethylsulfinyl)-5-methoxyindole
m.p. 178°-180° C.
IR (KBr, cm -1 ): 1490, 1440, 1420, 1410, 1280, 1210, 1150, 1010, 1000, 835, 790.
NMR (DMSO-d 6 , ppm): 3.76(3H, s), 4.52(2H, s), 6.70(1H, s), 6.91(1H, dd, J=9, 2 Hz), 7.07(1H, d, J=2 Hz), 7.28(1H, dd, J=8, 5 Hz), 7.40(1H, d, J=9 Hz), 7.55(1H, d, J=8 Hz), 8.28(1H, s), 8.45(1H, d, J=5 Hz), 11.86(1H, s).
(52) 2-(4-Pyridylmethylsulfinyl)-5-methoxyindole
m.p. 188°-190° C. (with decomposition).
IR (KBr, cm -1 ): 1590, 1500, 1440, 1405, 1220, 1190, 1160, 1040, 840, 810.
NMR (DMSO-d 6 , ppm): 3.78(3H, s), 4.53(2H, s), 6.73(1H, br.s), 6.92(1H, dd, J=9, 2 Hz), 7.06(1H, d, J=2 Hz), 7.17(2H, d, J=5 Hz), 7.40(1H, d, J=9 Hz), 8.47(2H, d, J=5 Hz), 12.1(1H, br.s).
(53) 2-[(3,5-Dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
m.p. 200°-203° C. (with decomposition).
IR (KBr, cm -1 ): 1560, 1460, 1420, 1340, 1285, 1260, 1090, 1070, 1005, 800, 750, 730.
NMR (DMSO-d 6 , ppm): 2.12(3H, s), 2.18(3H, s), 3.63(3H, s), 4.63(2H, ABq, J=13 Hz), 6.80(1H, br.s), 7.06(1H, dd, J=6, 6 Hz), 7.25(1H, dd, J=6, 6 Hz), 7.51(1H, d, J=6 Hz), 7.59(1H, d, J=6 Hz), 8.20(1H, s), 12.32(1H, s).
(54) 3-Methyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
m.p. 158°-159° C.
IR (KBr, cm -1 ): 1460, 1440, 1200, 1065, 1000, 740.
NMR (DMSO-d 6 , ppm): 1.96(3H, s), 2.02(3H, s), 2.17(3H, s), 3.56(3H, s), 4.62(2H, ABq, J=13 Hz), 7.05(1H, dd, J=6, 6 Hz), 7.47(1H, d, J=6 Hz), 7.51(1H, d, J=6 Hz), 8.18(1H, s), 12.03(1H, s).
(55) 5-Methyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
m.p. 189°-191° C. (with decomposition).
IR (KBr, cm -1 ): 1560, 1460, 1440, 1300, 1085, 1070, 1010, 810.
NMR (DMSO-d 6 , ppm): 2.13(3H, s), 2.20(3H, s), 2.38(3H, s), 3.66(3H, s), 4.64(2H, ABq, J=13 Hz), 6.70(1H, br.s), 7.08(1H, d, J=8 Hz), 7.37(1H, s), 7.40(1H, d, J=8 Hz), 8.20(1H, s), 12.2(1H, br.s).
(56) 5-Trifluoromethyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
m.p. 218° C. (with decomposition).
IR (KBr, cm -1 ): 1340, 1320, 1270, 1150, 1100, 1070, 1045, 1000, 800.
NMR (DMSO-d 6 , ppm): 2.14(3H, s), 2.20(3H, s), 3.67(3H, s), 4.67(2H, ABq, J=13 Hz), 6.98(1H, s), 7.52(1H, d, J=9 Hz), 7.71(1H, d, J=9 Hz), 8.03(1H, s), 8.20(1H, s), 12.75(1H, s).
(57) 2-[(3,5-Dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]-5-methoxyindole
m.p. 170°-171° C.
IR (KBr, cm -1 ): 1460, 1200, 1160, 1070, 1000, 855, 800.
NMR (DMSO-d 6 , ppm): 2.10(3H, s), 2.18 (3H, s), 3.63(3H, s), 3.75(3H, s), 4.60(2H, ABq, J=13 Hz), 6.70(1H, br.s), 6.90(1H, dd, J=9, 2 Hz), 7.05(1H, d, J=2 Hz), 7.38(1H, d, J=9 Hz), 8.20(1H, s), 12.13(1H, s).
(58) 2-[(3,5-Dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]-5-methoxycarbonylindole
m.p. 205°-208° C.
IR (KBr, cm -1 ): 1700, 1430, 1300, 1250, 1200, 1120, 1100, 1070, 1010, 770.
NMR (DMSO-d 6 , ppm): 2.12(3H, s), 2.18(3H, s), 3.65(3H, s), 3.87(3H, s), 4.64(2H, ABq, J=13 Hz), 6.96(1H, s), 7.55(1H, d, J=9 Hz), 7.85(1H, d, J=9 Hz), 8.18(1H, s), 8.30(1H, s), 12.66(1H, s).
(59) 5-Acetyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
m.p. 205° C.
IR (KBr, cm -1 ): 1660, 1300, 1250, 1070, 1000, 820
NMR (DMSO-d 6 , ppm): 2.13(3H, s), 2.20(3H, s), 2.62(3H, s), 3.67(3H, s), 4.68(2H, ABq, J=13 Hz), 7.00(1H, s), 7.56(1H, d, J=9 Hz), 7.88(1H, d, J=9 Hz), 8.20(1H, s), 8.35(1H, s), 12.7(1H, br.s).
(60) 7-Trifluoromethyl-2-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
m.p. 153°-156° C.
IR (KBr, cm -1 ): 1320, 1300, 1190, 1150, 1100, 1010.
NMR (DMSO-d 6 , ppm): 2.20(6H, s), 3.67(3H, s), 4.78(2H, s), 7.12(1H, s), 7.27(1H, dd, J=8, 8 Hz), 7.63(1H, d, J=8 Hz), 7.96(1H, d, J=8 Hz), 8.22(1H, s), 12.6(1H, br.s).
(61) 3-[(3,5-Dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
m.p. 176°-177° C.
IR (KBr, cm -1 ): 1560, 1470, 1460, 1430, 1280, 1245, 1075, 1005, 750.
NMR (DMSO-d 6 , ppm): 2.10(3H, s), 2.20(3H, s), 3.65(3H, s), 4.43(2H, ABq, J=12 Hz), 7.22(2H, m), 7.55(1H, d, J=9 Hz), 7.82(2H, m), 8.20(1H, s), 11.97(1H, s).
(62) 2-Methyl-3-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
m.p. 107°-109° C.
IR (KBr, cm -1 ): 1290, 1080, 1070, 1005, 990, 755.
NMR (DMSO-d 6 , ppm): 1.95(3H, s), 2.20(6H, s), 3.60(3H, s), 4.50(2H, ABq, J=13 Hz), 7.12(2H, m), 7.39(1H, dd, J=5, 5 Hz), 7.88(1H, d, J=5 Hz), 8.16(1H, s), 11.71(1H, s).
(63) 5-Methoxycarbonyl-3-[(3,5-dimethyl-4-methoxy-2-pyridyl)methylsulfinyl]indole
m.p. 152°-154° C.
IR (KBr, cm -1 ): 1720, 1470, 1430, 1310, 1250, 1220, 1090, 1080, 995.
NMR (DMSO-d 6 , ppm): 1.96(3H, s), 2.15(3H, s), 3.52(3H, s), 3.90(3H, s), 4.60(2H, ABq, J=13 Hz), 7.58(1H, d, J=9 Hz), 7.84(1H, d, J=9 Hz), 7.92(1H, br.s), 8.16(1H, s), 8.20(1H, s), 12.3(1H, br.s). | This invention provides a class of new indole derivatives which are useful as medicinal compounds having a mild inhibitory effect on the gastric acid secretion as well as a remarkably cytoprotective effects on gastric muscosa, and which are represented by the general formula: ##STR1## | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims the priority of Japanese Patent Application No. 00-0392952, filed in Japan on Dec. 25, 2000, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device that generates highly accurate three-dimensional data at a high speed.
2. Description of the Related Art
In recent years, three-dimensional CG (three-dimensional Computer Graphics) technology has often been used in movies and games. Because three-dimensional CG places and moves three-dimensional models and lighting in a virtual three-dimensional space, a high level of freedom of expression may be obtained.
Non-contact three-dimensional measuring devices using the light-section method and similar methods have conventionally been used commercially. If measurement is performed using such a device, three-dimensional data of the object may be generated.
Furthermore, a stereo imaging device is known that obtains multiple images of an object using two cameras, and that generates three-dimensional data from these images. It comprises multiple cameras in which external parameters (the positions and orientations of the cameras) and internal parameters (the focal lengths, pixel pitch) are calibrated. Mutually corresponding points are sought (this operation is termed ‘searching’ or ‘detection’) regarding the multiple images obtained, and distances are measured based on the principle of triangulation. As a search method for the corresponding points, the correlation method or slope method may be used.
The three-dimensional data generated in the manner described above has a uniform resolution throughout. Therefore, if there is an excessively large amount of data, processing takes a long time, while if there is an excessively small amount of data, poor precision results.
For example, in the case of a stereo imaging device, the distance precision, i.e., the precision regarding the configuration of the object, depends on the accuracy in the search for corresponding points. The precision regarding corresponding points increases as the image resolution increases. However, as the precision or resolution regarding corresponding points increases, the time required for processing also increases. Accordingly, the amount of resulting three-dimensional data also increases.
Normally, an object to be modeled has areas that have complex shape characteristics and areas that do not. For example, in the case of a person's head, the eyes, nose, mouth and ears have complex shape characteristics, but the cheeks and forehead have relatively simple shape characteristics.
Conventionally, where an object to be modeled has both areas with complex shape characteristics and areas with simple shape characteristics, as described above, imaging or measurement is performed using the precision required to perform modeling of a complex configuration, and the amount of the resulting three-dimensional data is reduced by reducing the data in accordance with the three-dimensional characteristics of each area.
However, in the conventional art, because high-precision three-dimensional data is generated first and the data reduction process takes place afterward, the problem arises that the entire processing sequence is time-consuming.
OBJECTS AND SUMMARY
The present invention was created in view of the problem identified above, and an object thereof is to provide a three-dimensional data generating device that can maintain the high resolution of areas having complex shape characteristics and still reduce the processing time.
According to one aspect of the present invention, an apparatus for generating a three-dimensional data set comprises an acquiring portion for acquiring a first original data set and a second original data set, the first original data set and the second original data set respectively representing first and second original images, each of the first and second original images being obtained by imaging a same object from differing observation points; a resolution multiplication unit for converting the first original data set and the second original data set to a first low resolution data set and a second low resolution data set, respectively; and a three-dimensional generating portion for generating a three-dimensional data set using the first original data set and the second original data set and the first low resolution data set and the second low resolution data set; wherein the three-dimensional data set comprises a first part and a second part, the first part is generated using the first original data set and the second original data set, and the second part is generated using the first low resolution data set and the second low resolution data set.
According to another aspect of the present invention, a three-dimensional data generating device comprises means for inputting multiple images having a first resolution from different viewpoints of an object; a converter for performing a resolution conversion of each of the input multiple images to generate converted images having a second resolution that is different than the first resolution; a characteristic area extraction unit for detecting characteristic areas of the object from at least one of the input multiple images; and a three-dimensional construction unit for constructing three-dimensional data by using data from the input images for the characteristic areas of the object and by using data from the converted images for remaining areas of the object.
According to another aspect of the present invention, a three-dimensional data generating device comprises means for inputting multiple images that include multiple images obtained from different viewpoints of an object and having different resolutions; a characteristic area extraction unit for selecting specific areas from at least one image; and a three-dimensional construction unit for reconstructing three-dimensional data by using, from among said multiple images having different resolutions, high-resolution images for the selected areas, and low-resolution images for the non-selected areas, and by seeking correspondence between the images obtained from different viewpoints.
According to yet another aspect of the present invention, a three-dimensional data generating device comprises means for inputting multiple images obtained from different viewpoints; means for performing resolution conversion regarding each of the input multiple images and generating multiple images having different resolutions; means for seeking correspondence between the images obtained from different viewpoints using low-resolution images and reconstructing low-resolution three-dimensional data; means for fitting a standard model to the reconstructed low-resolution three-dimensional data; means for projecting the specific areas specified in said standard model to an image having a higher resolution than said image based on the result of the fitting; means for seeking correspondence between the images obtained from different viewpoints using the high-resolution image regarding the areas projected on the higher-resolution image and reconstructing high-resolution three-dimensional data; and means for replacing the low-resolution three-dimensional data regarding said specific areas with high-resolution three-dimensional data.
According to still yet another aspect of the present invention, a method for generating a three-dimensional data set comprises acquiring a first original data set and a second original data set, the first original data set and the second original data set respectively representing first and second original images, each of the first and second original images being obtained by imaging a same object from differing observation points; converting the first original data set and the second original data set to a first low resolution data set and a second low resolution data set, respectively; and generating a three-dimensional data set using the first original data set and the second original data set and the first low resolution data set and the second low resolution data set; wherein the three-dimensional data set comprises a first part and a second part, the first part is generated using the first original data set and the second original data set, and the second part is generated using the first low resolution data set and the second low resolution data set.
According to another aspect of the present invention, a method of generating three-dimensional data comprises the steps of inputting multiple images having a first resolution from different viewpoints of an object; performing a resolution conversion of each of the input multiple images to generate converted images having a second resolution that is different than the first resolution; detecting characteristic areas of the object from at least one of the input multiple images; and constructing three-dimensional data by using data from the input images for the characteristic areas of the object and by using data from the converted images for remaining areas of the object.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a modeling device pertaining to the present invention;
FIG. 2 is a block diagram showing the functions of the modeling device of FIG. 1 ;
FIG. 3 is a block diagram showing the construction of a resolution multiplication unit;
FIG. 4 is a block diagram showing the construction of a corresponding searching unit;
FIG. 5 is a drawing showing the method of extraction of characteristic areas of a person's head;
FIG. 6 is a block diagram showing the functions of a modeling device of another embodiment of the present invention; and
FIG. 7 is a flow chart showing the sequence of operation for the modeling device of another embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a block diagram showing a modeling device 1 pertaining to the present invention.
In this embodiment, images of the head of a person are captured using two cameras from different viewpoints, and a three-dimensional model (three-dimensional data) ML of the head is generated based on the two images obtained.
As shown in FIG. 1 , the modeling device 1 comprises a processor 10 , a magnetic disk device 11 , a medium drive 12 , a display 13 , a keyboard 14 , a mouse 15 , a scanner 16 and cameras CMa and CMb.
The processor 10 comprises a CPU, a RAM, a ROM, a video RAM, an I/O port and various controllers. When the CPU executes the programs stored in the RAM and the ROM, the various features explained below are implemented on the processor 10 .
In the magnetic disk device 11 are stored the OS (Operating System), a modeling program PR for generating the three-dimensional model ML, other programs, a standard model (standard model data) DS, two-dimensional images (two-dimensional image data) FT, the resulting three-dimensional model ML and other data. These programs and data are loaded in the RAM of the processor 10 from time to time, as needed.
The modeling program PR includes processes for multiplication of resolution, extraction of characteristic areas, corresponding point searching, positioning, transformation, modeling and other types of processing.
The medium drive 12 accesses a CD-ROM (CD), a floppy disk FD, a photomagnetic disk, a semiconductor memory HM, such as a compact flash, or other recording medium to perform read and write of data or programs. An appropriate drive is used depending on the type of recording medium. The modeling program PR mentioned above may be installed from this recording medium. The standard model DS and two-dimensional images FT may also be input via the recording medium.
The various data mentioned above, the three-dimensional model ML, which is generated by the modeling program PR, and other data or images are displayed on the screen HG of the display 13 .
The keyboard 14 and mouse 15 are used to input data or provide instructions to the processor 10 .
The scanner 16 scans letters or images, and converts them into image data. In this embodiment, the images captured by the cameras CMa and CMb are converted into two-dimensional images FT.
The cameras CMa and CMb are located such that there is a prescribed distance between the principal points of the lenses. The cameras CMa and CMb capture two images of the object from different viewpoints.
Two cameras may be located at appropriate locations as cameras CMa and CMb, or a camera incorporating two cameras may be used. Alternatively, one camera may be moved to perform multiple sessions of imaging.
Where digital cameras are used as cameras CMa and CMb, two-dimensional images FT may be directly obtained. The two-dimensional images FT obtained may be incorporated into the magnetic disk device 11 via the semiconductor memory HM, or via an interface such as an RS-232C or USB.
The modeling device 1 may comprise a personal computer, a workstation or the like. The programs and data mentioned above may be obtained by receiving them via the network NW.
The sequence of the processing performed by the modeling device 1 will be explained with reference to block diagrams, which show the functions of the modeling device 1 , and a flow chart.
FIG. 2 is a block diagram showing the functions of the modeling device 1 , FIG. 3 is a block diagram showing the construction of the resolution multiplication unit 22 a , FIG. 4 is a block diagram showing the construction of the corresponding point searching unit 24 , and FIG. 5 is a drawing showing the process of extraction of characteristic areas of a person's head.
The image FSa captured using the camera CMa is deemed the standard image. The AD converters 21 a and 21 b and the resolution multiplication units 22 a and 22 b each have the same construction. Therefore, only one of each type of unit will be explained. In addition, they may be referred to as an AD converter 21 or as a resolution multiplication unit 22 , indicating one unit or both units.
Referring to FIG. 2 , the images FSa and FSb captured by the cameras CMa and CMb are quantized by the AD converters 21 a and 21 b , respectively, whereupon two-dimensional images FTa and FTb are generated. These two-dimensional images FTa and FTb are high-resolution images.
Low-resolution images are generated from the two-dimensional images FTa and FTb by the resolution multiplication units 22 a and 22 b.
As shown in FIG. 3 , the input two-dimensional image FTa is stored in the memory 221 . It is then converted into a low-resolution image by the resolution converting unit 222 and stored in the memory 223 . Storage and conversion are performed regarding the two-dimensional images FTa and FTb that are input. Consequently, a high-resolution image and a low-resolution image result from each of the two-dimensional images FTa and FTb.
The resolution converting unit 222 reduces the two-dimensional image FTa stored in the memory 221 , for example, so that the resolution is reduced to half of the original image in both the horizontal and vertical directions. Consequently, the resolution is converted into half of the original resolution. If the original image is reduced by one-third in both directions, the resolution is converted into one-third of the original resolution. Various appropriate resolutions may be achieved through this conversion.
Therefore, multiple high-resolution images FHa are stored in the memory 221 , while multiple low-resolution images FLa are stored in the memory 223 . When a needed image is designated, a high-resolution image FHa and a low-resolution image FLa that correspond to the designated image are read from the prescribed areas of the memories 221 and 223 , respectively. The thus read images are output to the characteristic area extraction unit 23 and the corresponding point searching unit 24 .
The characteristic area extraction unit 23 separates, using a two-dimensional image processing technology, areas that require high-precision three-dimensional modeling and areas that do not from the high-resolution image FHa, which was obtained via the camera CMa and comprises the standard.
In other words, from the high-resolution image FHa shown in FIG. 5 (A), only the person's head (i.e., the face area) is extracted to obtain the head image FA 1 shown in FIG. 5 (B). The eye, nose and mouth areas, which are areas requiring high precision, are extracted from the head image FA 1 to obtain the high-precision area images FA 2 shown in FIG. 5 (C).
The technology to extract the face area and the face components, such as the eyes, nose and mouth, from a two-dimensional image as described above is in the public-domain. Extraction of these areas may be attained automatically using this technology or manually by the operator.
The area AR 1 shown in FIG. 5 (D) includes both high-precision areas and low-precision areas. The area AR 1 comprises the same area as the head image FA 1 shown in FIG. 5 (B).
The areas AR 2 shown in FIG. 5 (E) are high-precision areas. The areas AR 2 comprise the same areas as the high-precision area images FA 2 shown in FIG. 5 (C). The area AR 3 shown in FIG. 5 (F) is a low-precision area. It is what remains by subtracting the areas AR 2 shown in FIG. 5 (E) from the area AR 1 shown in FIG. 5 (D).
For the high-precision areas, those parts that play an important role in the facial expression are selected. High-precision areas are also referred to as ‘characteristic areas’ and ‘specific areas’ in the present invention.
Returning to FIG. 2 , the corresponding point searching unit 24 searches for points corresponding to the extracted areas. For the area AR 3 , which is a low-precision area, corresponding points are sought using the low-resolution images FL, and for the areas AR 2 , which are high-precision areas, corresponding points are sought using the high-resolution images FH. The corresponding point data FC, which is the result of the corresponding point searching, is then output to the three-dimensional reconstruction unit 25 . This process will be explained in detail below.
The three-dimensional reconstruction unit 25 seeks from the corresponding point data FC, using public-domain technology based on the principle of triangulation, three-dimensional position data FD for point groups comprising each corresponding point.
The surface model generating unit 26 converts the three-dimensional position data FD into a surface model (three-dimensional model ML) appropriate for three-dimensional display. This is publicly known as modeling technology. A three-dimensional model ML is output from the surface model generating unit 26 .
Referring to FIG. 4 , the corresponding point searching unit 24 includes a low-resolution corresponding point searching unit 241 , a high-resolution corresponding point searching unit 242 and a corresponding point memory 243 .
The low-resolution corresponding point searching unit 241 seeks correspondence between the low-resolution images FLa and FLb, which were obtained from different viewpoints, with regard to the low-precision area (AR 3 ) and the high-precision areas (AR 2 ).
For the method of corresponding point search, various public-domain technologies, such as the block correlation method or the gradient equation solution method, are used. Correspondence of image coordinates in the low-resolution image FLb, which is the input image for the corresponding point search, to each pixel of the low-resolution image FLa, which is the standard input image, is sought. When this is done, the image coordinate in the low-resolution image FLb regarding which correspondence to the low-resolution image FLa is sought may be a pixel or a sub-pixel, which is smaller than a pixel, depending on the method used. In either case, the precision is proportional to the pixel precision, i.e., the resolution, of the input image.
When corresponding point searching performed by the low-resolution corresponding point searching unit 241 is completed, the result of the search is stored in the corresponding point memory 243 .
Correspondence between the high-resolution images FHa and FHb is then sought regarding the high-precision areas (AR 2 ) by the high-resolution corresponding point searching unit 242 . When this is done, the result of the corresponding point search that was performed by the low-resolution corresponding point searching unit 241 and was stored in the corresponding point memory 243 is used as the default value. Consequently, the corresponding point search performed by the high-resolution corresponding point searching unit 242 may be carried out more accurately and rapidly.
When the corresponding point search performed by the high-resolution corresponding point searching unit 242 is completed, the result regarding the above areas is stored in the corresponding point memory 243 in such a manner that it replaces the result of the corresponding point search performed by the low-resolution corresponding point searching unit 241 .
As described above, for low-precision areas, corresponding point searching is performed based on low-resolution images FL, and low-resolution, low-precision corresponding points are obtained. For high-precision areas, corresponding point searching is performed based on high-resolution images FH, and high-resolution, high-precision corresponding points are obtained.
The corresponding point memory 243 stores the corresponding point data FC, which is the result of combining the low-precision corresponding points and the high-precision corresponding points.
It is also acceptable if the low-precision corresponding points and the high-precision corresponding points are not combined, but are separately stored in the corresponding point memory 243 .
Three-dimensional positions are reconstructed by the three-dimensional reconstruction unit 25 from the corresponding points obtained in this way, as described above, and three-dimensional position data FD is sought. Consequently, the processing speed may be increased and the data amount may be reduced while the precision of important areas is maintained at a high level.
In addition, because the result of the low-resolution corresponding point search is used as the default value for the high-resolution corresponding point search, the processing speed and precision may be further increased.
While the corresponding point searching unit 24 shown in FIG. 4 includes a low-resolution corresponding point searching unit 241 and a high-resolution corresponding point searching unit 242 , which are separate from each other, the construction may instead employ a common corresponding point searching unit that alternates between use for low-resolution corresponding point searching and use for high-resolution corresponding point searching.
Furthermore, the resolution multiplication unit 22 was explained as creating images having two different resolutions in order to simplify the explanation, but it may also generate images having three or more different resolutions.
A modeling device 1 B of another embodiment will now be explained.
FIG. 6 is a block diagram showing the functions of the modeling device 1 B.
The modeling device 1 B shown in FIG. 6 uses the same hardware construction as the modeling device 1 shown in FIG. 1 , and has many common functions. Therefore, identical numbers are used for members having the same function as in the modeling device 1 shown in FIG. 1 , and explanations regarding such members will accordingly be omitted or simplified.
In the modeling device 1 B, a standard model DS, which is prepared in advance, is fit to the three-dimensional position data FD obtained by the three-dimensional reconstruction unit 25 regarding the person's head. The first three-dimensional data to be generated is low-resolution three-dimensional position data FDL, and fitting is performed by the model fitting unit 27 to this low-resolution three-dimensional position data FDL.
Subsequently, using the transformation parameters obtained through the low-resolution fitting, high-precision areas are extracted by the high-precision area extracting unit 28 . Therefore, the positions of the high-precision areas, such as the eyes, nose and mouth, are specified in advance in the standard model DS.
Corresponding point searching is performed by the corresponding point searching unit 24 regarding the extracted high-precision areas. Using the result of the corresponding point search for the high-precision areas, the three-dimensional reconstruction unit 25 generates high-resolution three-dimensional position data FDH. It is also acceptable if the resulting high-resolution three-dimensional position data FDH replaces appropriate parts of the previously-obtained low-resolution three-dimensional position data FDL. The standard model DS, which was used for low-resolution fitting, is then fit to the high-resolution three-dimensional position data FDH by the model fitting unit 27 .
During the fitting by the model fitting unit 27 , the standard model DS is positioned to match the three-dimensional data DT (initial fitting), and is subsequently transformed. For the fitting method, any public-domain method or other method may be used.
As described above, the model fitting method is used in which the standard model DS is transformed and fit to the three-dimensional position data FD, and a three-dimensional model ML is expressed using the transformation parameters therefrom. Consequently, partial loss of the three-dimensional position data FD that may be caused by the effect of the light source during imaging of the object, or by occlusion, may be compensated for.
In addition, because only transformation parameters are required as output data, compression of the modeling data may be simultaneously achieved.
FIG. 7 is a flow chart showing the sequence of the operation of the modeling device 1 B.
Referring to FIG. 7 , the cameras CMa and CMb capture stereo images (# 11 ). Images having different resolutions are generated from the two-dimensional images FT thus obtained (# 12 ).
The position of the face area is extracted from the standard input image (# 13 ). Corresponding points are searched for using the low-resolution images FL of this face area (# 14 ), and three-dimensional reconstruction is performed using the low-resolution, low-precision corresponding points obtained (# 15 ).
The standard model DS is fit to the resulting low-resolution, low-precision three-dimensional position data FDL.
First, initial fitting of the standard model DS is performed with regard to the three-dimensional position data FDL (# 16 ). In the initial fitting, the position, posture and size of the standard model DS is changed as a whole so that it matches the three-dimensional position data FDL to the extent possible, and the standard model DS is fit to the three-dimensional position data FDL. The standard model DS is then transformed such that it matches each part of the three-dimensional position data FDL, and is further fit to the three-dimensional position data FD (# 17 ).
As a result of the fitting in steps # 16 and # 17 , the standard model DS is transformed into and fit to the low-precision three-dimensional position data FDL. Consequently, the image coordinates when each point of the standard model DS is projected onto a two-dimensional image are sought.
The positions of the facial components that require high-precision, such as the eyes, mouth and nose, are designated in the standard model DS in advance. The high-precision areas of the standard model DS are projected onto the standard input image, and the projected areas are extracted as high-precision areas (# 18 ).
Corresponding point searching is performed with regard to the high-precision areas using the high-resolution images FH (# 19 ). Using the high-resolution, high-precision corresponding points obtained, high-resolution, high-precision three-dimensional reconstruction is performed as to appropriate areas (# 20 ).
Appropriate areas of the three-dimensional position data FDL obtained in step # 15 are replaced with the high-precision three-dimensional position data FDH obtained via the three-dimensional reconstruction (# 21 ).
Consequently, three-dimensional position data FDM, which comprises high-resolution, high-precision data for the high-precision areas, and low-resolution, low-precision data for the other areas (low-precision areas), is obtained. The standard model DS is again fit to the three-dimensional position data FDM (# 22 ), and is then transformed (# 23 ).
When this is done, because the results of the initial fitting and transformation carried out in steps # 16 and # 17 are used as the default value for the transformation in step # 23 , duplication of transformation processing may be prevented.
As described above, high-precision areas are extracted, and high-resolution correspondence is sought and three-dimensional reconstruction is performed with regard to high-precision areas only. Therefore, the processing speed may be increased. In addition, because during fitting, transformation processing is performed with regard to the three-dimensional position data FD, which has the optimal resolution for each area, the processing speed may be increased.
In the above embodiments, the construction of the modeling device 1 or 1 B, the circuits, the number of components, the details of processing, the process sequences, and the timing at each process takes place may be varied within the scope of the present invention.
Using the present invention, the precision of areas having complex shape characteristics may be maintained at a high level while the processing time is reduced.
Although the present invention has been described in connection with exemplary embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without departing from the spirit and scope of the invention as defined in the appended claims. | A method of generating three-dimensional data includes the steps of inputting multiple images having a first resolution from different viewpoints of an object; storing the input multiple images; performing a resolution conversion of each of the input multiple images to generate converted images having a second resolution that is different than the first resolution; storing the converted images; detecting characteristic areas of the object from at least one of the input multiple images; and constructing three-dimensional data by using data from the input images for the characteristic areas of the object and by using data from the converted images for remaining areas of the object. A device for performing the method is also disclosed. | 6 |
PRIORITY
This application is a continuation application of a prior application Ser. No. 13/091,565, filed on Apr. 21, 2011, which claimed the benefit under 35 U.S.C. §119(a) of a Korean patent application filed in the Korean Intellectual Property Office on Apr. 22, 2010 and assigned Serial number 10-2010-0037237, the entire disclosures of each of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and method for charging in a portable terminal. More particularly, the present invention relates to an apparatus and method for, when a portable terminal with a solar cell charges a battery by a solar light while the portable terminal is powered off, preventing the shortening of a battery lifetime that can take place as a charging temperature of a battery cell increases.
2. Description of the Related Art
In recent years, the use of portable terminals is increasing due to the convenience they provide. Accordingly, service providers (i.e., system manufacturers) are competitively developing portable terminals having more convenient functions to increase their user base.
For example, portable terminals are providing functions of a phone book, a game, a scheduler, a Short Message Service (SMS), a Multimedia Message Service (MMS), a Broadcast Message Service (BMS), an Internet service, an Electronic mail (e) mail service, a wake-up call, a Motion Picture Expert Group (MPEG)-1 or MPEG-2 Audio Layer-3 (MP3) player, a digital camera, and other similar products and services.
In order to provide mobility, portable terminals make use of chargeable batteries as a power supply. Since the chargeable battery is limited in capacity, if the use of the portable terminal increases, a battery consumption time is shortened. This creates an issue in that users have to determine a State Of Charge (SOC) of the chargeable battery for a long travel or outing, and have to charge the chargeable battery by supplying an external power source to the chargeable battery.
In order to address the above issues, portable terminals having solar cells are being introduced that employ solar power to charge the battery.
Portable terminals with solar cells can discontinue a charging function depending on a charging temperature of a battery cell while charging a battery using solar power. This prevents reductions in the useful lifetime and damage to the battery cell resulting from continuous charging using solar power.
However, portable terminals can control an operation of the charging function through the above function only while powered on. When the portable terminal performs a process of charging using solar power while powered off, the portable terminal cannot control the charging function because the portable terminal cannot sense the charging temperature of the battery cell while the portable terminal is powered off. As a result, when the portable terminal performs a continuous charging process via solar power while powered off, the battery may be damaged and its useful life reduced.
SUMMARY OF THE INVENTION
Aspects of the present invention are to address at least the above problems and/or disadvantages and to provide at least the advantages described below. Accordingly, an aspect of the present invention is to provide an apparatus and method for improving the charging performance of a portable terminal using a solar light.
Another aspect of the present invention is to provide an apparatus and method for, when absorbing a solar light while powered off, allowing automatic entry into a power on state in a portable terminal using the solar light.
A further aspect of the present invention is to provide an apparatus and method for, while absorbing a solar light while powered off, generating a signal for allowing entry into a power on state in a portable terminal using the solar light.
The above aspects are achieved by providing an apparatus and method for battery charging in a portable terminal with a solar cell.
In accordance with an aspect of the present invention, an apparatus for charging a battery in a portable terminal with a solar cell is provided. The apparatus includes a controller and a charging management unit. The controller controls the charging management unit, absorbs a solar light, and charges the battery. The charging management unit senses a charging temperature of a battery cell when the portable terminal charges the battery while the portable terminal is powered off.
In accordance with another aspect of the present invention, a method for charging a battery in a portable terminal with a solar cell is provided. The method includes absorbing a solar light and charging the battery, and sensing a charging temperature of a battery cell when the portable terminal charges the battery while the portable terminal is powered off.
In accordance with another aspect of the present invention, a charging apparatus using a solar cell is provided. The apparatus includes a solar cell panel for absorbing a solar light for charging a battery of a portable terminal and for providing an output power source to the battery, a battery state determiner for measuring a charging voltage of the battery charged based on the solar light absorbed through the solar cell panel, a signal generator for generating a booting signal for booting the portable terminal, and an operation determiner for determining a terminal operation state at a time when the solar cell panel operates.
In accordance with another aspect of the present invention, a portable terminal is provided. The portable terminal includes a battery for supplying power to the portable terminal, and a charging apparatus including a solar cell panel for generating power based on solar light incident on the solar cell panel, a battery state determiner for measuring a charging voltage of the power supplied to charge the battery by the solar cell panel, a signal generator to generate a booting signal to boot the portable terminal when the portable terminal is powered off, and an operation determiner for determining whether to control the signal generator to generate the booting signal.
Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features, and advantages of certain exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a block diagram illustrating a construction of a portable terminal performing a battery charging process according to an exemplary embodiment of the present invention;
FIG. 2 is a diagram illustrating a battery charging process of a charging management unit according to an exemplary embodiment of the present invention;
FIG. 3 is a flowchart illustrating a process of automatically powering on while absorbing a solar light while powered off in a portable terminal according to an exemplary embodiment of the present invention; and
FIG. 4 is a diagram illustrating a battery charging process of a portable terminal according to an exemplary embodiment of the present invention.
Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiments of the invention as defined by the claims and their equivalents. It includes various specific details to assist in that understanding, but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. In addition, descriptions of well-known functions and constructions may be omitted for clarity and conciseness.
The terms and words used in the following description and claims are not limited to the bibliographical meanings, but are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention is provided for illustration purposes only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a component surface” includes reference to one or more of such surfaces.
By the term “substantially” it is meant that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.
Exemplary embodiments of the present invention provide an apparatus and method for controlling to allow automatic entry into a power on state and sense a charging temperature of a battery cell in case of absorbing a solar light in a power off state in a portable terminal using the solar light according to the present invention and, due to this, improving the charging performance of the portable terminal.
FIGS. 1 through 4 , described below, and the various exemplary embodiments of the present invention provided are by way of illustration only and should not be construed in any way that would limit the scope of the present invention. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged communications system. The terms used to describe various exemplary embodiments of the present invention are provided merely to aid the understanding of the description, and their use and definitions in no way limit the scope of the invention. Terms first, second, and the like are used to differentiate between objects having the same terminology and are in no way intended to represent a chronological order, unless where explicitly state otherwise. A set is defined as a non-empty set including at least one element.
FIG. 1 is a block diagram illustrating a construction of a portable terminal performing a battery charging process according to an exemplary embodiment of the present invention.
Referring to FIG. 1 , the portable terminal includes a controller 100 , a charging management unit 102 , a memory unit 112 , an input unit 114 , a display unit 116 , and a communication unit 118 . The charging management unit 102 includes a solar cell panel 104 , a battery state determiner 106 , a signal generator 108 , and an operation determiner 110 . The portable terminal may include additional units that are not illustrated here merely for sake of clarity. Similarly, the functionality of two or more of the above units may be integrated into a single component.
The controller 100 controls general operations of the portable terminal. For example, the controller 100 performs processing and control for voice call and data communication. In addition to these general functions, the controller 100 performs a booting process for controlling a charging function making use of solar light. In order to address the reduction in battery lifetime due to the inability to measure a charging temperature of a battery cell when performing a charging process while the portable terminal is powered off, when the controller 100 receives a booting signal from the charging management unit 102 , the controller 100 performs a booting process and powers on the portable terminal 100 .
When the solar cell panel 104 absorbs the solar light and provides an output power source, the charging management unit 102 determines an operation state of the portable terminal. If the charging management unit 102 determines that the portable terminal is powered off, the charging management unit 102 powers on and boots the portable terminal.
The charging management unit 102 continuously determines a charging voltage of a battery of the portable terminal while the portable terminal charges the battery in the power off state. When the charging voltage is greater than or equal to a threshold, the charging management unit 102 boots the portable terminal.
The solar cell panel 104 of the charging management unit 102 absorbs the solar light for charging the battery of the portable terminal, and provides an output power source to the battery.
The battery state determiner 106 of the charging management unit 102 measures a charging voltage of a battery charged using a solar light under the control of the charging management unit 102 . In order to determine when to boot the portable terminal, the battery state determiner 106 measures the charging voltage of the battery. The battery state determiner 106 can determine if circumstances indicate that the useful lifetime of the battery may be reduced (e.g., the charging temperature of a battery cell is increasing, and the like) in order to boot the portable terminal.
The signal generator 108 of the charging management unit 102 generates a signal for booting the portable terminal being in the power off state. The signal generator 108 generates a signal for powering on the portable terminal and provides the signal to the controller 100 , when the charging management unit 102 determines that the portable terminal is powered off and is performing a charging process using a solar light.
The operation determiner 110 determines an operation state of the portable terminal. The operation determiner 110 determines if the portable terminal is powered on or powered of, when the solar cell panel 104 operates.
The memory unit 112 may include a Read Only Memory (ROM), a Random Access Memory (RAM), a flash ROM, or other similar storage devices. The ROM stores a microcode of a program for processing and controlling the controller 100 and the charging management unit 102 and a variety of kinds of reference data.
The RAM, a working memory of the controller 100 , stores temporary data generated in execution of a variety of kinds of programs. The flash ROM stores several types of updateable depository data such as a phone book, an outgoing message, an incoming message, and the like.
The input unit 114 may include numeral key buttons ‘0’ to ‘9’, a menu button, a cancel button, an OK button, a talk button, an end button, an Internet button, navigation key buttons, a plurality of function keys such as a character input key and other similar input keys and buttons. The input unit 114 provides key input data corresponding to a key pressed by a user to the controller 100 .
The display unit 116 displays state information generated during the operation of the portable terminal, limited number of characters, a large amount of moving pictures and still pictures, and the like. The display unit 116 can be a color Liquid Crystal Display (LCD), an Active Mode Organic Light Emitting Diode (AMOLED) display, and other similar display apparatuses. When the display unit 116 includes a touch input device and is applied to a portable terminal of a touch input scheme, the display unit 116 can be used as an input device of the portable terminal.
The communication unit 118 transmits/receives and processes a wireless signal of data input/output through an antenna (not illustrated). For example, in a transmission mode, the communication unit 118 processes original data through channel coding and spreading, converts the original data into a Radio Frequency (RF) signal, and transmits the RF signal. In a reception mode, the communication unit 118 converts a received RF signal into a baseband signal, processes the baseband signal through de-spreading and channel decoding, and restores the signal to original data.
A role of the charging management unit 102 can be implemented by the controller 100 of the portable terminal. However, these are separately constructed and shown herein as an exemplary construction for description convenience, and not to limit the scope of the present invention. It would be understood by those skilled in the art that various modifications of construction can be made within the scope of the present invention. For example, construction can also be such that all of the disclosed functions are processed in the controller 100 .
FIG. 2 is a diagram illustrating a battery charging process of a charging management unit according to an exemplary embodiment of the present invention.
Referring to FIG. 2 , when the charging management unit 102 charges a battery using a solar light while the portable terminal is powered off, the charging management unit 102 can discontinue a charging function depending on a charging temperature of a battery cell.
The charging management unit 102 absorbs, by a solar cell panel 104 , a solar light and provides the solar light as an output power source 103 of a battery 105 , thereby attempting battery charging.
The operation determiner 110 of the charging management unit 102 determines an operation state of the portable terminal. For example, the operation determiner 110 determines whether the portable terminal is powered off in order to determine when to perform a booting process for controlling a charging function making use of a solar light (i.e., a charging function discontinued depending on a charging temperature of a battery cell).
When the operation determiner 110 determines that the portable terminal is in a power on state, the controller 100 can discontinue the charging function depending on the charging temperature of the battery cell.
On the other hand, when the operation determiner 110 determines that the portable terminal is powered off, the controller 100 is unable to determine the charging temperature of the battery cell.
Accordingly, the battery state determiner 110 processes a signal generator 108 to generate a booting signal when the battery state determiner 110 determines that a charging voltage of a battery 105 is greater than or equal to a threshold or determines that the solar cell panel 104 operates while the portable terminal is powered off.
If the signal generator 106 receives a request for generating a booting signal from the battery state determiner 106 as above, the signal generator 108 provides the booting signal to the controller 100 and changes an operation mode from the power off state to the power on state.
FIG. 3 is a flowchart illustrating a process allowing automatic entry into a power on state when absorbing a solar light while a portable terminal is powered off according to an exemplary embodiment of the present invention.
Referring to FIG. 3 , the portable terminal and determines whether a solar cell panel operates in step 301 . The portable terminal determines if the solar cell panel is exposed to a solar light to absorb the solar light and charge a solar cell.
If it is determined that the solar cell panel does not operate in step 301 , the portable terminal proceeds to step 315 and performs a corresponding function (e.g., a wait mode).
On the other hand, if it is determined that the solar cell panel operates in step 301 , the portable terminal proceeds to step 303 and processes to generate an output power for battery charging through the solar cell panel that absorbs the solar light. In this fashion, the portable terminal enables the battery charging using the solar light without external power source supply.
The portable terminal proceeds to step 305 and determines an operation state of the portable terminal. The portable terminal determines whether the portable terminal is powered on or powered off. This is to determine when to boot the portable terminal, because the portable terminal cannot control a charging function making use of a solar light, e.g., cannot discontinue the charging function depending on a charging temperature of a battery cell while the portable terminal is powered off.
The portable terminal proceeds to step 307 and determines the result of step 305 . If it is determined that the portable terminal is powered off in step 307 , the portable terminal determines that it is time to perform a booting process for controlling the charging function making use of the solar light in the portable terminal.
After determining that it is time to perform the booting process as above, the portable terminal proceeds to step 309 and generates a signal for terminal operation. The portable terminal proceeds to step 311 and boots the portable terminal. The portable terminal processes a signal generator of a charging management unit to generate a signal for terminal operation and, after determining that the signal generator generates the signal for terminal operation, the charging management unit boots the portable terminal.
The portable terminal proceeds to step 313 and charges a battery. The portable terminal proceeds to step 317 and determines a state of the battery. The portable terminal determines the state of the battery in order to discontinue the charging function depending on the charging temperature of the battery cell.
If it is determined that the portable terminal is in the power on state in step 307 , the portable terminal proceeds to step 317 and determines the state of the battery.
The portable terminal proceeds to step 319 and determines whether circumstances indicate that the useful lifetime of the battery is being reduced. Such circumstances may occur, for example, when the charging temperature of the battery cell is greater than or equal to a threshold or more. This may indicate that the charging function is to be automatically discontinued.
If it is determined that the situation of shortening the lifetime of the battery does not take place in step 319 , the portable terminal again performs the procedure of step 317 .
On the other hand, if it is determined that the useful lifetime of the battery is being reduced in step 319 , the portable terminal proceeds to step 321 and terminates the operation of the solar cell panel to prevent this reduction.
FIG. 4 is a diagram illustrating a battery charging process of a portable terminal according to an exemplary embodiment of the present invention.
Referring to FIG. 4 , the portable terminal can charge a solar cell through a solar cell panel. The portable terminal can be located in an area 403 exposed to a solar light or an area 401 not exposed to the solar light.
As the solar cell panel absorbs a solar light and charges the solar cell, the portable terminal can charge the solar cell when the portable terminal is located ( 410 ) in the exposure area 403 , and the portable terminal cannot charge the solar cell when the portable terminal is located ( 412 ) in the non-exposure area 401 .
For example, when the portable terminal located ( 410 ) in the exposure area 403 charges the solar cell while powered on, the portable terminal periodically determines a state of a battery (i.e., a charging temperature of a battery cell) and determines whether circumstances indicate that the useful lifetime of the battery is being reduced. If these circumstances are occurring, the portable terminal discontinues an operation of the solar cell panel, discontinuing a process of charging the solar cell.
On the other hand, when the portable terminal located ( 410 ) in the exposure area 403 moves ( 412 ) to the non-exposure area 401 , the portable terminal cannot perform the process of charging the solar cell by a solar light. If the portable terminal remains in the non-exposure area 401 , battery consumption occurs and a situation where the portable terminal powers off takes place ( 414 ).
In addition, if the portable terminal moves to the exposure area 403 after power is off as heavy battery consumption takes place although the portable terminal is located ( 410 ) in the exposure area 403 or power is off as the portable terminal remains in the non-exposure area 401 as described above, the portable terminal charges ( 416 ) the solar cell in a power off state.
When the portable terminal charges ( 416 ) the solar cell in the power off state as above, the portable terminal cannot sense the charging temperature of the battery cell, so the portable terminal is not able to control a battery charging function. As a result, if the portable terminal performs a continuous charging procedure while powered off ( 418 ), the useful lifetime of the battery may be reduced and damage to the battery may occur due to the solar light.
In order to address the above issue, the portable terminal determines ( 420 ) when the solar cell is charged while the portable terminal is powered off or a time when a battery voltage is greater than or equal to a threshold in course of charging the solar cell while the portable terminal is powered off, through a separate charging management unit such as a MIcroCOMputer (MICOM), and generates a signal for booting the portable terminal at the determined time. If the signal is generated, the portable terminal powers on. Accordingly, when the charging temperature of the battery cell is greater than or equal to a threshold, the portable terminal can discontinue ( 422 ) a battery charging process using a solar light. The charging management unit can be composed of a separate device such as a MICOM, so the charging management unit can perform, though the portable terminal powers off, a procedure for booting the portable terminal through low power charged by the solar light.
In this fashion, the portable terminal can address the battery lifetime shortening problem that occurs as the solar cell is continuously charged while the portable terminal is powered off due to battery consumption.
As described above, exemplary embodiments of the present invention, which relate to an apparatus and method for improving charging performance in a portable terminal making use of a solar light, in a case where a solar cell panel operates in a power off state, can generate a signal for booting the portable terminal, thereby allowing entry into a power on state and then measuring a charging temperature of a battery cell.
While the invention has been shown and described with reference to certain exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims and their equivalents. | A method for charging in a portable terminal is provided. The method includes charging a battery of an electronic device, using a natural resource, monitoring a charging state of the battery, and booting the electronic device based at least in part on the charging state and a determination that the electronic device is powered off. | 7 |
FIELD OF THE INVENTION
This invention relates to dredges and, more particularly, to improvements in the cutter heads of suction dredges for crushing solids to minimize clogging of and damage to suction and discharge pipes and dredge pumps. This invention especially relates to an improvement or modification of the cutter head invention disclosed in the copending application of Marion R. Chapman, Jr. Ser. No. 285,527, filed July 21, 1981, now U.S. Pat. No. 4,365,427.
BACKGROUND OF THE INVENTION
Suction dredges normally have a downwardly and forwardly inclined ladder carrying a suction pipe which has a suction mouth at its forward end and a rotatable cutter head just forward of such mouth. The head normally is driven by a shaft extending along the ladder from a motor on the upper end of the shaft. Usually the cutter head has a plurality of angularly spaced, toothed ribs spiralling divergently rearwardly from a hub at the forward end of the drive shaft. When sand or muck is being dredged, no problems normally arise. When the cutter head is working in hard lumpy clay, sandstone, coral, or other fossil or rock formations, however, problems are encountered in the production of large hard lumps that pass through the cutter head and are large enough to clog or damage the suction and discharge lines and the dredge pump. Clogging or stopping of the lines necessitates time-consuming down-time clean-out operations. Pump damage necessitates expensive down-time replacement or repair.
The foregoing problems were solved by the invention disclosed in my aforesaid copending patent application by the provision of an open-work rotatable crusher journalled on the cutter head drive shaft and driven by a gear train between the cutter head and the crusher. Such a solution, however, while most effective, is somewhat complicated and expensive because the crusher is mounted for rotation and requires a gear drive.
BRIEF SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to incorporate in the cutting head of a suction dredge simple, inexpensive, non-rotatable, efficient means for crushing large hard lumps of material dug by the head before they enter the suction pipe in order to minimize or prevent clogging of and/or damage to the suction and discharge lines and the dredge pump.
It is another object of this invention to provide such crushing means in the form of a crusher that can be easily installed within a conventional cutter head with few modifications thereto.
The foregoing objects are accomplished by an openwork crusher fixed to the ladder within the rotatable cutter head and arranged to cooperate with the head so that rotation of the latter crushes large lumps of material dug by the head to a smaller size before entry into the suction pipe.
Other objects and advantages of the invention will become apparent from the following detailed description and accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of a suction dredge ladder equipped with a cutter head embodying this invention;
FIG. 2 is an enlarged fragmentary longitudinal sectional view of the cutter head shown in FIG. 1, the head being shown somewhat schematically in FIG. 1;
FIG. 3 is a sectional view taken on line 3--3 of FIG. 2;
FIG. 4 is an enlarged fragmentary sectional view taken substantially on line 4--4 of FIG. 2; and
FIG. 5 is an end view of the cutter head shown in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, there is shown diagrammatically the usual suction dredge ladder 10 which carries on its underside the usual suction pipe 12 leading to a dredge pump (not shown). The forward end of the ladder 10 carries a downwardly and rearwardly inclined circular flat plate 14 pierced by the semi-circular suction mouth 16 of the suction pipe 12. Adjacent the mouth 16, the pipe 12 is channeled, as at 18, along its upper side for accommodation of a drive shaft 20 extending through the plate 14, for a cutter head 22. The shaft 20 is driven through appropriate reduction gearing 24 by an appropriate motor 26 which may be mounted on the ladder 10, as shown, or on the dredge hull, not shown. The forward end of the shaft 20 is journalled in a bearing (not shown) supported on the ladder 10 and projects beyond the suction mouth 16. Secured on the end of the shaft 20 is the hub 28 of the cutter head 22 from which spiral divergently rearwardly a plurality of angularly spaced somewhat flattened ribs 30 equipped on their forward edges with projecting teeth 32. At their rearward end, the ribs 30 are secured to a ring member 33 which surrounds the plate 14. For reasons later evident, that section of the shaft 20 extending between the plate 14 and the hub 28 preferably is enclosed in a protective sleeve 34 secured to the plate 14. The head 22 may be driven in a clockwise direction, as shown by the arrow in FIG. 5. The ribs 30 are shown only schematically in FIG. 2 with no spiral configuration and with the teeth 32 being omitted for simplification. As shown in FIG. 4, however, the ribs 30 are somewhat curved in transverse section with their trailing edges 36 nearer their axis of rotation than their leading edges 38.
In operation, the ladder 10 is lowered to urge the head 22 against the marine bottom, the shaft 20 is driven by the motor 26 and the dredge pump is driven by a prime mover (not shown) on the dredge hull to suck water and solids, i.e., cutter rubble or debris, through the mouth 16 of the suction pipe 12 for conveyance through a discharge line (not shown) to any desired location.
When the cutter head 22 is operating in sand or muck, the solids or cutter debris are no problem. On the other hand, when the cutter head 22 is operating in hard lumpy clay, sandstone, coral or other fossil or rock formations, large hard lumps of cuttings or rubble are produced which pass between the ribs 30 of the cutter head 22 and into the mouth 16 of the suction pipe 12. Such large hard lumps are apt not only to clog the suction pipe 12 but also to clog or damage the dredge pump. Moreover, such lumps may damage the suction pipe 12 and also damage or clog the discharge line if they pass undiminished in size through the dredge pump. In any event, the passage of such large hard lumps into the suction pipe 12 is not to be desired, and this invention provides means for crushing such large hard lumps into smaller non-damaging and non-clogging pieces before passage into the suction pipe.
For this purpose, there is provided within the cutter head 22 a crusher 40 of open-work construction secured at its rearward end, as by welding, to the plate 14. The forward end of the crusher 40 may be of planar circular plate-like construction, as at 42, having a central aperture 44 receiving the sleeve 34. Extending rearwardly from the periphery of the plate 42 is a crusher grid of frusto-conical construction having interconnected longitudinal and cicumferential strong sturdy steel bars 46 and 48, respectively, having openings therebetween. The rear end of the crusher 40 is formed by a ring member 50 that is secured, as by welding, to the plate 14. The openings in the crusher grid are sized to pass lumps or chunks of hard material of only a predetermined maximum size. For example, it has been found that lumps of 4" maximum cross-sectional dimension will pass readily through the pump and lines of a 14" dredge, i.e., having a 14" pump and 14" lines. Hence, for a 14" dredge, the openings should be no larger than 4" maximum dimension.
In transverse section, as shown in FIGS. 3 and 4, the crusher 40 is substantially circular or annular throughout appropriately at least a 180° sector, preferably a 270° sector, but is substantially flat, i.e., chordal, throughout the remaining 180°, or preferably 90°, sector. In front view, for a cutter head which rotates clockwise, the less than 180° chordal sector of the crusher is in the northwest quadrant, as shown in FIGS. 3 and 4. For a counterclockwise rotating head, the less than 180° chordal sector would be in the northeast quadrant. The radial spacing between the circular sector of the crusher 40 and the inner or trailing edges 36 of the ribs 30 is desirably maintained substantially constant and for a 14" dredge is restricted to, for example, no more than about 5 inches, i.e., a little larger than the maximum dimension of the grid openings. For this purpose, the ribs 30 are built up, on their inner sides, with thick strong steel plates 52, 54 secured to the ribs and to each other as by welding. One plate 52 rectangular in transverse section, as shown in FIG. 4, inclines radially inwardly rearwardly of its leading edge, which is set back from the leading edge 38 of the rib 30. At its trailing edge, the plate 52 is secured to the plate 54 which extends radially inwardly from the trailing edge 36 of the rib 30, somewhat beyond the plate 52, and terminates in a bulbous abrasion-resistant edge 56. It is the radial distance between this edge 56 and the crusher 40 which is restricted as described above. Preferably, the plates 52, 54 are reinforced by a number of gusset plates 58 positioned normal to the ribs 30 and the plates 52, 54, in the space encompassed thereby, and welded thereto.
In operation the ladder 10 is lowered or inclined downwardly until the cutter head 22 engages and digs into the marine bottom. As the ribs 30 and teeth 32 dig, grab, and break the material of the marine bottom, should large hard lumps be produced they normally will pass between the ribs 30 into the cutter head 22 at the lower part thereof, i.e. the southeast and southwest quadrants. Any lumps too large to be sucked and passed through the openings in the crusher grid 46, 48 are trapped between the crusher grid and the ribs 30 and carried and driven by the latter clockwise, as viewed in FIGS. 3 and 4. The spiral configuration of the ribs 30 produces a shearing and crushing action on large lumps engaged against the lontitudinal and circumferential bars 46, 48 of the crusher grid. If not sufficiently reduced in size by such action, when such over-size lumps reach the northwest quadrant, they tumble into the area between the ribs 30 and the chordal sector of the crusher 40. There the lumps are crushed further by the cam-wedge action between the plates 52, 54 on the ribs 30 and the chordal sector of the crusher 40. Any over-size lumps which might survive this action will be shattered by the wedge-like crushing action of the bulbous edge 56 of the plate 54 against the chordal sector of the crusher 40. Once such over-size lumps are so crushed, the fragments pass readily through the open spaces in the crusher grid 46, 48 and thence into the suction pipe 12.
The construction of the crusher 40 is such that it can be installed in a conventional cutter head with only minor modifications to the head, i.e. the build up of the plates 52, 54 on the inner side of the ribs 30. In actual practice, it has been found that the combination of the crusher 40 with the cutter head 22 greatly reduces vibration on the dredge and in the dredge pumping system, apparently by minimizing or eliminating the passage therethrough of large lumps of hard material. It further has been found that the crusher 40 increases the percentage of pumpable solids, thus increasing production. Even further, the crusher 40 reduces down time for cleaning clogged lines and repairing the dredge pump with resultingly increased operating time and efficiency.
It thus will be seen that the objects and advantages of this invention have been fully and effectively achieved. It will be realized, however, that the foregoing specific embodiment has been disclosed only for the purpose of illustrating the principles of this invention and is susceptible of modification without departing from such principles. Accordingly, the invention includes all embodiments encompassed within the spirit and scope of the following claims. | The rotatable cutter head of a suction dredge which is of rearwardly-divergent spiral toothed-rib construction has a crusher of open-work construction fixedly mounted therewithin and cooperating therewith to crush and reduce the size of hard lumps dug by the head to reduce damage to and clogging of the suction and discharge lines and the dredge pump. Preferably, the crusher is a frusto-conical grid having a flat sector which further cooperates with inner surface portions on the cutter head ribs that incline inwardly from the leading to the trailing edges of such portions. | 4 |
FIELD OF THE INVENTION
The present invention relates to an improved method and system for performing various machining, turning, milling or other required operations on the ends of parts or workpieces in mass production applications.
BACKGROUND OF THE INVENTION
Various devices for use in mass production applications are not new. In the device described in German Patent Number DE 1,264,927, for example, various chucks or chucking devices, which rotate around their axes, are mounted equal distances apart on a turntable. In this particular invention, all of the chucking devices are mechanically coupled by a common central shaft consisting of a universal joint propeller shaft and bevel gear drive. All of the chucking devices are, therefore, driven at the same speed, and the speed at which the devices rotate is synchronized with the speed of an automatic lathe installed opposite the turntable. After one end of the part or workpiece has been machined, the workpiece or part chucked in the automatic lathe is picked off. After the turntable has been advanced a step, it is possible to machine the opposite end of the workpiece at the same rotational speed as a workpiece which is chucked at two subsequent machining stations. To remove the workpieces from the automatic lathe, a slide, carrying the turntable, moves it to the correct position. Because all of the chucking devices are driven at the same speed, however, during the time it takes to move the turntable back and forth, it is not possible to machine workpieces in the other machining stations. In addition to this particular disadvantage, moving the entire turntable and slide assembly is a relatively clumsy and, therefore, a complicated process. In addition to this disadvantage, because all of the workpieces in the chucking devices on the turntable rotate at the speed of the automatic lathe, the unfinished ends of these parts can only be machined while the part is rotating. No other machining processes can be performed on these rapidly rotating parts.
The device disclosed in German Patent Number DE 936,176 is also of interest. This patent discloses workpiece chucking devices mounted on a turntable in such a way that the devices may slide in the radial direction but do not rotate around their axes. As a consequence, machining operations can only be carried out while each individual workpiece is stationary. To machine the unfinished end of a workpiece, a second turntable, which can be advanced in steps, is required to perform the necessary operations. This makes the overall device quite complicated.
Given the limitations discussed above, the art would be improved by a method and system designed to allow desired machining processes to fabricate the ends of workpieces both when the workpieces are rotating as well as when they are stationary with a minimum loss of machining time. This would simplify the manufacturing process.
To address the limitations of the prior art, the present invention utilizes a plurality of chucking devices designed as spindle motors. The spindle motors are mounted equidistant from each other on the circumference of a turntable. The invention also provides a means for reversing each workpiece to permit operations on both ends. Lastly, the invention provides a means for coordinating the speed of each chucking device with a lathe to allow for machining operations both when the workpiece or part is rotating and as well as when it is stationary.
SUMMARY OF THE INVENTION
The objects of the present invention, i.e, the improvements over the prior art, are accomplished as follows:
The workpiece chucking devices are designed as pick-off spindle motors which can slide in the radial direction of the turntable. Each individual pick-off spindle motor is adaptively controlled, and when these motors are used together with an automatic lathe, the rotational speed of each motor may be synchronized with that of the lathe. The rotational speed of the chucking devices at each workstation can be adjusted to the machining process to be performed at that station. The chucking devices may be kept stationary if necessary. Thus, the limitations of the prior art are overcome in an extremely simple manner.
The claims are directed towards several preferred embodiments of the invention. One preferred embodiment, shown in the drawings and described in greater detail, permits one end of a workpiece to be subjected to machining operations outside the axis of rotation, such as drilling, transverse drilling, milling, or thread-cutting, while the workpiece is stationary. By means of another preferred embodiment, also described in detail, a part reversing station allows the turned end of a workpiece to be machined on the turntable while the workpiece is stationary. This operation can be accomplished without turning off the automatic lathe and waiting for it to come to a complete stop.
The device according to the invention offers the following advantages over the state of the art:
1. By advancing the synchronized pick-off spindle motor located opposite the automatic lathe, a turned part, which has been machined on the lathe in a very short time (about 3 seconds), may be removed in the correct position for subsequent operations. The opposite end of the part may be machined in many different ways in at least one, or preferably several, e.g., three to eight or even more, workstations which are located around the turntable.
2. An extremely short turned part removal cycle is achieved by utilizing a pick-off spindle motor, which is moved forward or backward in an axial direction in a very short period of time by hydraulic, pneumatic, or electrical means. The ultra-fast turned part pick-off process makes it possible for the unfinished end of the turned part to be machined very rapidly.
3. Each of the sliding, synchronized spindle motors, which can be indexed on the turntable, functions in turn as pick-off spindle motor, depending on which of the various positions it occupies on the advanceable turntable. Thus, in addition to machining spindle motors on the turntable, there will always be a parts ejector spindle motor and a pick-off spindle motor on the turntable as well.
4. The machining cycle time depends upon the time required to machine the turned parts, the spindle motor pick-off time, and the turntable indexing time (forward feed time). The total part cycle time always depends on the longest machining cycle.
5. By using spindle motor pick-off devices, the turned parts may be removed in very short unit machining times (about 3 seconds) in their proper position for additional operations. Thus, even very small quantities of parts can be machined completely at low cost.
6. As a result of the speed-controlled spindle motors, which can be indexed on the turntable, it is possible to complete even complicated machining processes on the unfinished end of turned parts simply by providing the various workstations with appropriate tools.
7. The spindle motor pick-off device turning center can be built as a low-cost, station device to manufacture simple turned parts, which are machined at the unturned end, and also as complicated, multi-station, complete machining/turning centers with a relatively large number of workstations set up around the turntable.
8. Utilizing the pick-off spindle motor to remove the turned part effectively readies each part for additional operations to be performed on the cut end of the turned part. Mounting a part reversing station on the turntable avoids the need to stop the automatic lathe spindle when a previously turned part is subjected to machining processes which can only be carried out when the turned part is stationary, e.g., operations such as drilling at points outside the center of the rotational axis, transverse drilling, milling, thread-cutting, etc.
9. The time required for indexing or advancing the turned part can be exploited to slide the pick-off spindle motor back and then forward again to the next workstation or to the part ejection station. This permits each workpiece or part to be rapidly advanced to the next workstation.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects of the present invention, together with the various features of the system and its operations, are hereinafter more fully set forth with reference to the accompanying drawings where:
FIG. 1 is a schematic diagram of the side of one preferred embodiment of the invention showing the slide which permits the turntable to accommodate long workpieces;
FIG. 2 is an overhead view of the invention shown in FIG. 1 showing the chucking devices mounted on the turntable at equal distances from each other, a lathe, two workstations, and a part ejection station;
FIG. 3 is another overhead view, generally corresponding to that of FIG. 2, showing chucking devices arrayed on the turntable, several workstations, the part ejection station, the coordinated control system, and the part reversing station;
FIG. 4 is a schematic diagram showing the side of the part reversing station shown in FIG. 3 with a part or workpiece in place; and
FIG. 5 is the part reversing station illustrated in FIG. 4 with the part or workpiece rotated 180° from the position shown in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, a turntable (3) is mounted on turntable base (4) which in turn is mounted on a sliding mechanism allowing the turntable to move a certain adjustment distance (8) towards and away from the automatic lathe (1). The sliding feature permits the turntable to move a certain distance (6) towards and away from the automatic lathe to accommodate long workpieces. FIG. 1 also shows the spindle motor (16) for the automatic lathe, the automatic lathe (1) and the toolholder (15), which holds the appropriate tools to turn stock material and cut it to proper length. Also shown in FIG. 1 are roller guideways (5) to carry spindle motor (13) towards and away from the workstations.
FIG. 2 shows four spindle motors (13), which hold the workpieces during the machining operations, and roller guideways (5) mounted on turntable (3). The spindle motors are mounted on the turntable at equal distances from each other, so that separate machining operations can be performed at various workstations simultaneously. In addition, FIG. 2 shows several workstations (7) and (9) for performing operations such as grinding or drilling the unturned end of the workpiece, and part ejection station (12) where finished parts are ejected into a container or similar collecting apparatus (11).
FIG. 3 shows turntable (3) and the same turning and workstations as FIG. 1. FIG. 3 also shows electronic control units (22) and (23), a coordinating control unit (24), and part reversing station (20).
The system as shown in FIGS. 1 and 2 works the following way:
Stock material is inserted into automatic lathe (1) which fabricates a turned part (not shown) or workpiece in the lathe barrel (17) by means of tools attached to tool holder (15). It takes only about three seconds for a part or workpiece to be turned, at which point the part is cut off. Spindle motor (13), the rotational speed of which is synchronized with that of automatic lathe spindle motor (16), is located at pick-off spindle location (10) to remove the part or workpiece from the lathe. The pick-off spindle position is in precise linear alignment with the axial center (2) of the automatic lathe. Spindle motor (13) in pick-off position (10) is pushed hydraulically, pneumatically, or electrically over the turned part produced on automatic lathe (1) by a certain distance (6). A chucking device (collet chuck) holds the turned part in spindle motor (13). After the turned part has been subjected to the cut-off operation in automatic lathe (1), spindle motor (13), together with the turned part in the chucking device, is retracted by a certain distance (6) back to its starting position near the center of turntable (3) and, simultaneously with that, to save time, turntable (3) is rotated to the first workstation (9) to machine the unturned end as needed. This brings an empty speed synchronized pick-off spindle motor opposite automatic lathe (1) into pick-off position (10) to accept another turned part from automatic lathe (1).
While a second part is being turned on automatic lathe (1), the first part, previously turned on the lathe and then rotated to the first workstation (9), may be machined while spindle motor (13) is stopped.
When the part pick-off process for the second turned part in position (10) has been completed, turntable (3) is again advanced by one station bringing the first turned part to the second machining station (7) for additional machining operations, and the second turned part to the first workstation (9). Spindle motors (13) are thus sequentially advanced from automatic lathe (1) to the first workstation (9), and thereafter to the second workstation (7) for completion of additional machining operations on the unturned end of each part or workpiece.
After a third turned part has been finished on automatic lathe (1) and picked off by the spindle motor at pick-off station (10), turntable (3) is again advanced by one station. The first turned part or workpiece is now in finished part ejection position (12) where it is ejected into finished part container (11) or a similar collection apparatus and the second and third parts are in workstations (7) and (9). The spindle motor (13) at part ejection station (12) is now empty, and, shortly after a fourth turned part is brought by turntable (3) back into pick-off spindle position (10), the turntable is advanced once again in forward-advance direction (14) and the sequence of operations described above begins again and continues in an endless cycle.
The spindle motors (13) are mounted in roller guideways (5) on turntable (3) so that each can be moved with precision and low resistance, and thus with extreme speed, over pick-off distance (6). It should be noted that, in FIG. 1, workstation (9) has been omitted for the sake of clarity. To machine extremely short or long turned parts, the entire turntable unit can be shifted along adjustment distance (8) on the longitudinal axis of the lathe.
The preferred embodiment illustrated in FIG. 3 differs from the embodiment shown in FIGS. 1 and 2 in that, in addition to workstations (9) and (7), and finished part ejection station (12), which are visible in FIG. 2, part reversing station (20) and workstation (21) are shown on turntable (3), spaced at uniform angular distances of 60°. In each station, spindle motor (13) is supported in the same manner described above.
Part reversing station (20) is provided when a transverse machining operation on the turned end of a part or workpiece is required. In such a case, it is not necessary to stop spindle motor (13) of automatic lathe (16). At spindle position (18), the workpiece is removed from spindle motor (13) and inserted in part reversing device (20). After part reversing device (20) is rotated 180°, the part or workpiece (not shown) is inserted back in spindle motor (13) in spindle position (18). The next time turntable (3) is advanced a step, the part or workpiece, thus reversed, together with its pick-off spindle motor (13), arrives at workstation (21). In this position, the turned end of the part of workpiece can be machined, e.g., drilled, milled, turned, etc.
In the preferred embodiments according to FIGS. 1, 2 and 3, the speed of automatic lathe spindle (16) is synchronized with that of pick-off spindle motor (13) in position (10), by means of an electronic control unit coordinator (24), which synchronizes electronic control unit (22) for pick-off spindle motor (13), with electronic control unit (23) for automatic lathe spindle motor (16).
The means by which part reversing station (20) functions can be derived from FIGS. 4 and 5. Twin-jaw gripper (30) removes workpiece or turned part (31) from collet chuck (29) of spindle motor (13), in a manner not shown in detail, over pick-off distance (25). Twin-jaw gripper (30) is pivoted 180° in the direction of double arrow (28) into the position shown in FIG. 5. In this position, turned end (27) of workpiece (31) faces away from collet chuck (29), and machined end (26) of workpiece (31) is ready for axial insertion into collet chuck (29) over insertion distance (25). After workpiece (31) has been inserted with the machined end (26) in collet chuck (29), twin-jaw gripper (30) is removed from workpiece (31). Turntable (3) advances another step bringing workpiece (31) to workstation (21), where turned end (27) of workpiece (31) can be machined. Twin-jaw gripper (30) can be moved in a direction perpendicular to the longitudinal axis of the workpiece by pneumatic devices (not shown). The part reversing station (20) is designed to be rotatable and axially movable.
The entire sequence of machining operations of the embodiments illustrated in FIGS. 3-5 is as follows:
Turned end (27) of workpiece (31) is machined at pick-off station (10). At workstations (9) and (7), various operations are performed successively on the machined end (26) of workpiece (31), preferably while spindle motor (13) is stationary. In spindle position (18), the above-described 180° reversal of workpiece (31) is executed at part reversing station (20). At workstation (19), a last machining operation is performed on turned end (27) of the workpiece. In a final step, the finished workpiece arrives at part ejection position (12) and is ejected into a finished part container (11) or similar collection apparatus. The entire machining cycle begins again at pick-off spindle position (10), where the spindle speed of pick-off spindle motor (13) is synchronized with the speed of automatic lathe spindle (16). | A system for performing machining operations on different portions of workpieces comprising a plurality of workstations including a lathe disposed along a predetermined path, in the present instance, a circular path. A turntable supports a plurality of workpiece chucking devices equi-spaced circumferentially around the turntable. The turntable rotates relative to the workstations to position a workpiece chucking device at each workstation permitting different machining operations to be performed on workpieces simultaneously. The chucking devices are moveable on the turntable in a radial direction to present the workpieces to the various tools at the workstations. The workpiece chucking devices include spindle motors and means for synchronizing the speeds of the spindle motors of the chucking devices with the lathe motor. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to arrow fletchers of the type having a frame, a shaft support, a nock receiver and a clamp for holding a fletching adjacent the arrow shaft. More particularly, the present invention is addressed to an arrow fletcher capable of securely holding arrow shafts of different diameters, having an indexing head for locating fletchings at desired angular relationships about the shaft, and having a base quickly detachable from a mounting bracket coupled to a supporting surface.
2. Description of the Prior Art
Archery is receiving ever increasing popularity as a sport. The recent development of new technology in the fields of bows, sighting instruments and arrow supports has increased the accuracy of archers and lowered the cost of participation in the sport. At the same time, the fletching of arrows as both a hobby and a vocation has experienced significant growth. Fletching involves the attachment of the feathers or vanes to the arrow to stabilize its flight.
While many archers are content to purchase standard arrows already fletched from the factory, many have developed an interest in fletching their own arrows. At one time, this could be accomplished with only a limited degree of precision, as the bows and sights of that time correspondingly could only take limited advantage of any precision and consistency in the arrow.
One area of archery technology which has expanded the options of the fletcher is the arrow rest. From arrow rests which initially accommodated only a standard 120° fletching interval with the cock or index fletch extending horizontally, arrow rests now include springs, rollers, trailing arms and other instruments which permit a number of different angular relationships between the fletchings. For example, arrows may now include four fletchings instead of three, or even six fletchings in some applications. Moreover, the precise placement of the fletchings has become more critical as technology has provided for ever more accurate bows and sights. The fletcher receives arrow shafts which are straighter and more evenly balanced, and the fletchings or vanes (fletchings being generally used herein to encompass both feather fletchings as well as solid plastic vanes) are precisely ground and trimmed to provide uniformity.
As a result, a number of arrow fletchers have been developed for holding a fletching in fixed relationship to the shaft. Some of these arrow fletchers hold the shaft on a frame and receive an arrow nock therein with clamps which allow for attaching fletchings individually, while others are jigs which provide a compound clamp for attaching three fletchings at once. In most instances, an opening is provided for holding the shaft. In some instances, a rotatable index head is provided with indexing stops corresponding to pre-determined, non-adjustable fletching locations relative to the shaft. However, to change the fletching set up to provide different spacings, additional fletchings, or to accommodate helical fletchings has proven impossible or required expensive and elaborate conversion kits which were time consuming to install. In addition, there has been an absence of arrow fletchers which provide complete flexibility to the user in choosing his own set up and being able to consistently replicate that set up. Another disadvantage of prior art fletchers has been their difficulty in accurately and securely holding arrow shafts of different diameters in place. An archer may desire shafts of different dimensions for different shooting situations, different bow weights, or other factors of personal preference. Certain "universal" arrow fletchers have a diverging notch which supports the shaft according to its diameter. However, these shaped diverging notches require that the clamp mount be adjusted for each differently sized shaft to properly center the fletching on the shaft.
These diverging notch type fletchers also result in an occasional tendency of the shaft to slide up and out of the notch, resulting in an improper fletch. While some fletchers have a self-centering feature, these are jigs which clamp 3 fletches at the same time and the pre-set clamp angles are fixed. Further, separate, precisely positioned alternate openings are not provided to securely clamp a number of sizes of different arrow shafts. Many of the frame type prior art fletchers are configured to mount directly to a bench or other supporting surface. This provides a degree of rigid support and makes the fletcher easier to use. This is because most fletchers will tip over with a full length shaft and a hunting or practice point. Thus, most arrow fletchers have mounting holes for receiving screws to mount them to a work table or bench. In many cases, the mounting holes are difficult to access, and many users do not want to permanently mount the arrow fletcher to a work bench in order to free the space for alternative use.
SUMMARY OF THE INVENTION
These and other problems have largely been solved by the present invention. That is to say, the arrow fletcher hereof is fully adaptable to mount multiple fletchings on an arrow easily and with precision; to securely hold a variety of different shaft sizes; and quickly attaches and dismounts to a mounting bracket, freeing a work bench for a variety of alternative uses. The present invention is easy to use, allows the desired angle between the nock and the fletchings to be quickly changed, and furthermore permits both helical and straight fletchings to be mounted either straight or at an angle on the shaft. The fletcher broadly includes a frame, a shaft support, an indexing head having a nock receiver, and a clamp for holding a fletching adjacent the shaft of the arrow. The shaft support preferably includes a number of separate openings therein sized to receive arrow shafts of different diameters. The openings are specifically sized so that arrows corresponding to each size of hole can be quickly and securely positioned. Moreover, the shaft support is preferably rotatably mounted so that different openings can be readily placed in alignment with the nock receiver and held there by a detente mechanism between the frame and the rotatable shaft support.
The indexing head hereof is also preferably rotatably mounted to the frame whereby the shaft can be rotated to place the desired portion of the arrow adjacent the clamping mechanism. Advantageously, the indexing head includes a number of selectively positionable pointers which can be adjusted to a broad range of fletching locations. Additionally, the location of the nock of the arrow can be changed relative to the fletching pointers so that different arrow fletching configurations can be readily accommodated. The pointers are preferably mounted around the circumferential outer surface of the indexing head for engagement with a catch mounted on the frame, the catch serving to hold the pointers in position while the fletching is glued onto the shaft. The indexing head further provides indicia thereon so that the user can readily identify the particular fletching configuration. While in accordance with the intent of the present invention a large number of pointers could be accommodated, the present invention includes pointers and attachment couplings sufficient to accommodate up to six fletchings, with their relative position on the head being adjustable. The indexing head is held by a screw or other clamping device to a nock location indicator which is normally rotatable with the indexing head but may be adjusted relative to the indexing head for determining the angle of the fletching points to the nock of the arrow.
The arrow fletcher is preferably provided with a base and a mounting bracket. The mounting bracket is small and unobtrusive, and may be permanently attached to the worktable or other supporting surface by screws or the like. The mounting bracket and the base are alternately provided with a cooperatively configured recess and projection so that the base can be quickly and removably mounted to the bracket during use and then removed for storage, freeing the work surface for other tasks. The base is thus provided with a means of rigidly mounting to the supporting surface which enables it to be mounted and removed without the use of tools.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the arrow fletcher of the present invention showing a fletching clamp exploded away from the frame to show the mounting magnet therefore, and an arrow shown in phantom;
FIG. 2 is an enlarged fragmentary elevation view of the indexing head of the arrow fletcher showing the nock indicator and numerical indicia on the face of the indexing head;
FIG. 3 is an enlarged fragmentary elevation view of the shaft support showing the openings therein sized for receiving differently sized shafts;
FIG. 4 is a left side perspective view showing the arrow fletcher with a fletched arrow being removed therefrom;
FIG. 5 is a vertical cross-sectional view of the shaft support with a detente associated with the frame in engagement with depression corresponding to an opening on the shaft support;
FIG. 6 is a vertical cross-sectional view similar to FIG. 5, showing the shaft support being rotated to bring a different opening into position;
FIG. 7 is a vertical cross-sectional view of the indexing head showing the circumferentially extending slot for receiving the pointers therein.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, an arrow fletcher 10 broadly includes a frame 12, a shaft support 14, an index head 16, a fletching clamp 18, a base 20 and a mounting bracket 22. As may be seen in FIG. 4, the arrow fletcher 10 is designed to be mounted onto a supporting surface 24 so that the user is free to employ both hands during the fletching operation.
In greater detail, frame 12 broadly includes a curved supporting bar 26 which is routed through holes 28 and 30 of base 20, and a magnet support beam 32 which extends generally parallel to a shaft 34 of an arrow 36 to be fletched. The magnet support beam 32 is fixed relative to the supporting bar 26 by upper housing 38 and index head housing 40. Thus, support bar 26 is curved and is preferably higher at upper housing 38 in order to present shaft 34 at an angle when received in the arrow fletcher 10.
As seen in FIG. 4, magnet support beam 32 adjustably carries a magnet bar 42 thereon. The magnet support beam 32 is provided with two threaded holes for receiving thumb screws 44 which extend through transversely extending slots provided in magnet bar 42. Both upper housing 38 and index head housing 40 are provided with centering lines 46 and 48 respectively inscribed thereon, while magnet bar 42 is provided with graduation markings 50 at the upper end 52 and the lower end 54 thereon. Magnet bar 42 is thus able to shift laterally relative to magnet support beam 32, the degree of displacement being determinable by the relative alignment between centering lines 46 and 48 and graduation markings 50. Magnet bar 42 carries a permanent magnet 56 between thumb screws 44, the permanent magnet 56 being secured to the magnet bar 42 so that movement of the magnet bar 42 causes corresponding movement of the permanent magnet 56.
Upper housing 38 receives screw 58 for connecting to magnet support beam 52. As may be seen in FIGS. 3, 5 and 6, upper housing 38 rotatably mounts shaft support 14 thereon. Shaft support 14 is connected to upper housing 38 by bolt 60 which extends through an opening in upper housing 38 and is secured by a nut 62 holding a spring 64 in compression. Housing 38 includes a detente 66 which is positioned for engagement with a corresponding recess 68 in shaft support 14 as may be seen in FIGS. 5 and 6. A plurality of recesses 68 are provided in circumferentially spaced relationship around shaft support 14, one recess 68 being provided for each opening 70 spaced circumferentially around the shaft support 14. As shown in FIG. 3, the openings 70 are each sized differently to receive an arrow shaft 34 of a different diameter. For example, opening 70A has a width of 14 mm. and thus receives an arrow shaft 34 of a 14 mm. diameter, while opening 70B has a width of 20 mm., and thus is designed to receive an arrow shaft 34 having a diameter of 20 mm. As shown in FIG. 3, indicia 72 are preferably molded into the synthetic resin shaft support 14 whereby the user can readily determine the diameter of each opening 70. A cap 74 is force-fitted over lip 76 in shaft support 14 to cover nut 62 and spring 64; however, cap 74 can be removed to provide access to these components.
Index head housing 48 receives index head 16 for rotation therein. Index head 16 includes a nock receiver 78 including a cross-member 80 which spans the cavity 82 for receiving a nock 84 located on the shaft 34. The nock includes a notch into which cross-member 80 projects and holds the nock 84 (and thus the shaft 34) against rotation relative to the nock receiver. An indicator 86 is provided with a pair of tits 88 which engage corresponding hollows 90 defined in nock receiver 78 so that indicator 86 is rotatably engaged with nock receiver 78. Nock receiver 78 is internally threaded for receiving screw 92 to hold indicator 86 against nock receiver 78.
Index head 16 also includes index body 94 which is held in position against nock receiver 78 by the force applied by screw 92. Index body is provided in two pieces held together by screws 96. A circumscribing slot 96 is defined by index body 94, slot 96 including a channel 98 which loosely receives a plurality of square nuts 100 therewithin. Square nuts 100 are thus shiftable within channel 98 and oriented to threadably receive fletch locator bolt 102, the latter extending through fletch locator 104. Advantageously, fletch locator bolt 102 is provided with a round head 106 for purposes as will be described hereinafter.
Fletch locator 104 includes a pointer 108, best seen in FIG. 1. Locator receiver 110 is positioned adjacent index head 16 whereby a round head 106 of a fletch locator bolt 102 may be received between pins 112 and 114 as shown in FIG. 2. Locator receiver 110 is maintained in position relative to index head housing 40 by screw 116 threaded into index head housing 40. Spring 118 resiliently biases locator receiver 110 against index head housing 40, but permits locator receiver 110 to yield so that round head 106 is releasably held between locator pins 112 and 114.
As may be seen in FIG. 2, index body 94 presents a circular appearance when viewed from the end and includes numerical indicia 120 with corresponding angle markings 122 preferably molded or inscribed therein. Index body 94 is rotatably mounted relative to index head housing 40. Thus, fletch locator bolts 102 may be tightened relative square nuts 100 so that the fletch locator bolts 102 are clamped relative to index head 16 for rotation therewith and do not become dislodged upon engaging locator pins 112 and 114. The pointers 108 are directed toward numerical indicia 120 and angle markings 122 to reflect the relative positioning of fletch locators 104 around index head 16. In addition, indicator 86 is provided with a director 124 molded thereon or inscribed therein which similarly points toward numerical indicia 120 and angle markings 122. In addition, for convenience, nibs 126 may be molded at fixed, desired locations around index head 16 for indicating pre-selected fletching spacings.
Clamp 18 is of conventional design and includes graspable tabs 128 and 130 which may be pinched together by the operator's thumb and forefinger to open separable jaws 132 and 134. Jaws 132 and 134 are held together by spring clamps 136 and 138. Additionally, a ferromagnetic surface such as an iron band is affixed to jaw 134 for securing fletching clamp 18 to permanent magnet 56 located on magnet bar 42. Jaws 132 and 134 can be configured for providing either a straight, right-hand or left-hand fletching 140, as shown in phantom in FIGS. 1 and 7.
Base 20 is preferably not secured to supporting surface 24. Instead, it is provided with structure defining a recess 142 complementarily configured to a corresponding projection 144 of mounting bracket 22. Mounting bracket 22 is preferably provided with passages 146 and 148 to receive corresponding mounting screws 150 and 152 therethrough to secure the mounting bracket 22 to the supporting surface 24. Base 20 is provided with suitable grooves to carry a nock-receiver wrench 154 and additional fletch locators 104 therein.
In operation, the user initially positions the rotatable index head 16 relative to the index head housing 40 by locating cock fletch reference mark 160 on index head 16 between centering marks 162 on index head housing 40. The user then selects a shaft 34 of an arrow 36 to be fletched, placing the nock 84 into the nock receiver 78 whereby the nock is prevented from rotating by the cross-member 80. The user has selected a shaft of a particular diameter, and thus pulls outwardly on cap 74 as indicated in FIGS. 4 and 6 to place a correspondingly sized opening 70 in alignment with nock receiver 78. The detente 66 is then seated in a recess 68 to hold the shaft support 14 against undesired rotational movement. The shaft of the arrow is then placed into the selected opening 70 as shown in FIG. 1.
In order to attach a fletching 140 to the shaft 34, the fletching is first clamped by fletching clamp 18. The fletching clamp 18 is then magnetically secured to permanent magnet 56 and preferably, for consistency of alignment, the rearmost end 156 of fletching clamp 18 is moved rearwardly into engagement with nock receiver 78 of index head 16. As may be seen in FIG. 1, fletching clamp 18 is preferably provided with fletch alignment indicia 158 so that the fletchings are consistently positioned in a fore and aft direction along shaft 34.
The operator also loosens fletch locator bolts 102 by inserting an allen wrench into round head 106 to loosen the gripping engagement on index body 94 and move square nut 100, fletch locator bolt 102, and fletch locator 104 circumferentially around index body 94 to the appropriate location evidenced by numerical indicia 120 and angle markings 122. The number and location of the fletch locators 104 may be varied as desired by the user. For example, if the operator desires to utilize a 60° by 120° pattern using four fletches, the fletch locators 104 are set so that their pointers 108 point to the 0°, 120°, 180° and 300° numerical indicia 120 on index head 16. For this pattern, the user would then loosen screw 92 and shift indicator 86 relative to index body 94 so that director 124 points to the proper location for the desired fletching. For example, when a straight fletching is to be used, director 124 should point to the numerical indicia 120 indicating "90°", while if a left helical fletching clamp 18 is used, the director 124 should point toward the 205° numerical indicia 120. The following table illustrates a representative sample of fletching patterns which might be employed:
______________________________________ Set Director (124) to Numerical Indicia (120)No. of Fletch Set Pointers Right LeftFletches Angles To Straight Helical Helical______________________________________3 120° Cock 0°-120°-240° 0° 0° 0° Fletch Out3 120° Cock 0°-120°-240° 90° 90° 90° Fletch Down4 75° × 105° The 4 Nibs 90° 90° 90° (126)4 60° × 120° 0°-120°-180°- 0° 300°4 90° × 90° 0°-90°-180°- 45° 45° 45° Cock 270° Fletch 45°5 5 Fletch - 0°-72°-144°- 90° Cock 216°-288° Fletch Down6 FLU FLU 0°-60°-120°- 0° 180°-240°-300°______________________________________
In order to change the angle of the cross-member 80 (and thus the nock 84 of the arrow 36) relative to the index head 16 (and thus the fletching 140), wrench 154 having a slot therein is placed in the cavity 82 of the nock receiver 78 and a screwdriver is used to loosen the screw 92 one-half turn, thereby enabling the user to rotate the nock receiver 78 relative to the index body 94 so that the director 124 is repositioned to point to the desired number of degrees of the angle markings 122 and numerical indicia 120. The user then retightens screw 92, making sure the director 124 does not move during relative to the index body 94 during the retightening process.
To change the angle of the fletching, fletch locator bolts 102 are loosened so that fletch locator bolts 102 together with the square nuts 100 and the fletch locators 104 may slide circumferentially around slot 96 until the pointer 108 is set at the desired degree and then tightened using the allen wrench until the fletch locator 104 is snug against the index body 104. In the embodiment shown, up to six fletch locators may be employed around index head 16 by adding additional fletch locators 104 stored in base 20, although it is to be understood that the scope of the invention is not so limited.
With the fletch locators in place, the user rotates index head 16 until round head 106 is lodged between locator pins 112 and 114 as shown in FIG. 2. This thus places the shaft in position for receiving a first fletching 140 thereon. The user makes a trial alignment of the fletching 140 to be installed by placing the fletching clamp 18 holding a fletching 140 therein adjacent the shaft 34. If the clamp is not properly aligned on the arrow shaft, thumb screws 44 may be loosened and magnet bar 42 shifted until the proper alignment is achieved. Thumb screws 44 are the retightened and then fletching clamp 18 is removed. The user then applies a thin line of glue along the fletching 140 to be applied and repositions the fletching clamp 18 on the permanent magnet 56 until the glue is dry. The user then removes the fletching clamp 18, rotates the index head 16 until the round head 106 of the next fletch locator bolt 102 and fletch locator 104 clicks into position between the locator pins 112 and 114. The gluing process is repeated until all fletchings have been applied.
Although preferred forms of the invention have been described above, it is to be recognized that such disclosure is by way of illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.
The inventor hereby states his intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of his invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set out in the following claims. | An arrow fletcher for use in supporting an arrow shaft having a nock and holding a fletching proximate the shaft is provided which includes a frame, an shaft support and an indexing head including a nock receiver. The shaft support may include a plurality of discretely sized openings therein for receiving any one of a plurality of differently sized arrow shafts in alignment with the nock receiver. Preferably, the shaft support is rotatably mounted to the frame so that differently sized openings may be brought into position by rotating the shaft support. The indexing head includes a plurality of selectively positionable pointers and indicia located on the body of the indexing head for identifying the angular relationship between the nock of the arrow and the fletching placements. The nock receiver is preferably adjustable relative to the indexing head body whereby the angular relationship between the nock and the fletchings may be changed. The frame may be coupled to a base for supporting on a supporting surface, and a mounting bracket may be coupled to the base for permitting the base to be readily removed from the supporting surface but securely held in position when coupled to the mounting bracket. | 5 |
BACKGROUND OF THE INVENTION
The need to turn to coal as a principal energy source has provided an impetus for examining various methods of burning the fuel in an environmentally acceptable manner. Among the methods in which interest has been rekindled is that of burning the coal in a fluidized bed. In a fluidized-bed arrangement, coal and air are reacted in a bed of particulate matter that is agitated by the flow of the air to the extent that it attains a quasi-liquid state. The advantages of this mode of burning coal lie in the ability of the bed to burn the coal in a comparatively small volume, to conduct heat relatively rapidly to heating surfaces placed in the bed, and to absorb the sulfur in the coal if the fluidized medium includes material that reacts with the oxidized sulfur.
The relatively rapid conduction of the heat to the heating surfaces results from the high thermal conductivity that characterizes the quasi-liquid mass of particles in the bed. Unfortunately, the high conductivity of the bed in the fluidized state makes stable operation at low firing rates difficult. A fluidized bed that liberates 1×10 6 Btu/Hr--and which therefore has associated with it heat-conduction surfaces that absorb heat at that rate--may only have 4×10 4 Btu associated with it at a temperature of 1500° F. (820° C.). Consequently, a small imbalance between the rate of heat liberation and the rate of heat removal can cause the bed temperature to fall by a relatively large amount. Such an imbalance, caused, for instance, by a momentary reduction in fuel-supply rate, can use the bed temperature to fall below the ignition temperature of the fuel, particularly when the average firing rate, and thus the bed temperature, is already relatively low. Since the ignition of fuel in a fluidized-bed boiler is dependent predominantly upon bed temperature, the almost unavoidable heat-flow imbalances in the system can cause the bed to be extinguished at low loads.
SUMMARY OF THE INVENTION
The present invention is therefore a method and apparatus for facilitating operation of a fluidized-bed furnace, particularly at low load.
A fluidized-bed cell according to the present invention comprises a combustion region with a static bed positioned in it, a fluidized bed positioned above and immediately adjacent to the static bed, and a means for feeding it with fuel particles. The static bed comprises inert heat-storage particles, and means are provided for blowing air up through the static bed into the combustion region in such a manner as to fluidize the fuel particles but not the heat-storage particles. Means are also provided for igniting the fuel particles supplied to the combustion region.
According to the preferred embodiment, the feeding means is a means for feeding fuel particles to the combustion region through the static bed.
BRIEF DESCRIPTION OF THE DRAWINGS
These and further features and advantages of the present invention will be described with reference to the attached drawings, in which:
FIG. 1 is a partly sectional vertical elevation of a cell in a fluidized-bed boiler constructed according to the teachings of the present invention; and
FIG. 2 is a more detailed vertical section of the ignitor housing and part of the coal pipe shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a single cell of a fluidized-bed boiler. It is thought beneficial to divide a fluidized-bed boiler into several segments, or cells, for efficient operation and control. Since some designers prefer that bed-level heat-transfer surfaces be provided as water-cooled walls as well as tubes embedded in the fluidizing region, the segmented arrangement has the further advantage that it increases wall, and therefore heat-transfer, area. Thus, though the arrangement in FIG. 1 could in principle be the entire combustion area of a boiler, it would be more typical for it to be a single cell in a multi-cell boiler.
The combustion region is bounded on the sides by horizontal waterwalls 40 and on the bottom by the upper surface of an air duct, or windbox 20. The windbox is a horizontal duct that is positioned parallel to the floor 12 of the structure, the space between the windbox 20 and the floor 12 defining an access space 14. A static-bed support 34 is positioned above the windbox 20 and extends across the entire area of the cell. It is somewhat dish-shaped, being deeper in the center than on the sides, and it contains inert heat-storage particles, such as heavy ores, in a static-bed region 36. The static-bed support 34 has appropriate openings for allowing air, but not heat-storage particles, to pass through it.
Above and immediately adjacent to the static bed is a fluidizing region 44, which is shown in the drawing as being occupied by a fluidized mass of particles. This suggests the normal operation of the bed, in which the fluidization creates a quasi-liquid mass having a more or less definite upper boundary above which the so-called freeboard region 46 extends. The freeboard region, whose purpose is to provide a region in which particles thrown from the bed can execute a complete trajectory and fall back into the bed without being drawn out with the exhaust gases, is not shown surrounded by a waterwall. This is because the cell shown in FIG. 1 is merely one segment of a larger boiler, and it may be permissible for particles thrown from the bed to be returned to an adjacent bed. Of course, the waterwalls could be extended up to enclose the freeboard region.
A coal pipe 18 is led horizontally along the access space 14 and bent upward to proceed vertically, penetrating the windbox 20 and extending up into the static bed 36, terminating in a coal distributor 32 that houses an ignitor and is located in the static bed. The upper surface of the windbox 20 has a circular opening 28 concentric with the coal pipe 18. A damper 24, whose purpose is to regulate the flow of air from the interior of windbox 20 through the opening 28, is positioned in opening 28. The damper 24 has a lower plate 22 that prevents air from entering the damper 24 from the bottom. The damper also includes blades 26 that are adjustable for controlling the amount of air admitted to the damper 24 and through the opening 28. Between the opening 28 and the static bed support 34 is provided a baffle plate 30, which is also concentric with the pipe 18. Since the function of the baffle plate 30 is to distribute properly the air entering through the opening 28, it is appropriately shaped or perforated for this purpose.
The coal pipe 18 and the distributor 32 are shown in more detail in FIG. 2. A section of the coal pipe 18 and the distributor 32 and a vertical elevation of the gas pipes 16 and 50 and the helical swirl plate 48 are displayed. The first gas pipe 16 is positioned interior to and concentric with the coal pipe 18, and a helical swirl plate 48 is coiled around it. A second gas pipe 50 is positioned horizontally in the interior of the ignitor housing 32, and it communicates with the vertical gas pipe 16 to allow gas to flow from the vertical pipe 16 to the horizontal pipe 50. Though only one horizontal pipe 50 is shown in the drawing, it would be typical for a second horizontal pipe, also in communication with the vertical pipe 16, to be provided at right angles with the horizontal pipe shown. The second horizontal pipe would also have holes in both ends similar to the openings 51 that occupy either end of the horizontal gas pipe 50. The openings 51 are positioned in registration with coal-distribution holes 52, which, along with other holes 54, are spaced around the circumference of the distributor 32.
Though pipes 16 and 50 have been referred to as gas pipes, any other suitable ignitor fuel could be supplied through these pipes. Ignitor fuel entering through these pipes is sprayed out of the distributor 32 through the holes 52 that register with the openings 51 and the horizontal gas pipe 50. This ignitor fuel is lighted by any appropriate means to create a flame whose purpose is to ignite coal supplied through the coal pipe 18. As an inspection of the apparatus will reveal, a coal-air mixture entering through the coal pipe 18 will be caused to follow a helical path by the helical swirl plate 48, and centrifugal force will cause the coal to be propelled out of the distributor through holes 52 and 54.
Operation of the fluidized bed is initiated by feeding ignitor fuel through gas pipes 16 and 50. The ignitor fuel is lighted at the openings 51 by appropriate means not shown in the drawings, and the resulting combustion begins to heat the particles in the static bed 36. To a lesser extent, the heat-transfer surfaces 40 and 42 and the particles in the remainder of the combustion area are also heated. After the static bed has reached a temperature that is high enough to support ignition of the coal, coal feed is initiated through the coal pipe 18, which conducts it to the interior of the ignitor housing 32. Centrifugal force resulting from the helical path that the coal is forced to take propels it out of openings 52 and 54, sending it through the space between the particles in the static bed 36 and distributing it evenly over the cell area. As the coal leaves the ignitor housing 32, it is ignited by the gas flame or by heat from coal already burning in the static inert-particle bed 36. Much of the fuel is blown into the fluidized-bed region 44, but this fuel is not fluidized at first, because the air-flow rate is initially relatively low.
The coal feed is gradually increased to full capacity, and since the combustion is self-sustaining, the flow of auxiliary fuel is discontinued. This mode is maintained until the bed temperature reaches, say, 1500° F. When this temperature is reached, steady-state operation is begun by opening the damper 24 far enough to permit a fluidizing flow of air and turning down the coal feed to the desired rate.
During this normal mode of operation, the characteristic feature of the fluidized bed, its high thermal conductivity, manifests itself, so a small imbalance between heat liberation and heat absorption in the bed can cause a significant change in bed temperature. As the firing rate is lowered in response to changes in load, the normal temperature in the bed is reduced, so a significant temperature drop could well result in a bed temperature that is below the ignition point of the fuel. It is under such conditions that the advantages of the bed constructed according to the teachings of the present invention become apparent.
In prior art designs, if an imbalance between heat liberation and absorption were great enough to reduce the temperature in the fluidized bed to below that required for ignition, the bed would be extinguished and the load dropped. In a boiler built according to the present invention, the imbalance may well act to reduce the fluidized-bed temperature to below the ignition point, but the lower thermal conductivity of the static bed would enable the temperature of the static bed to remain above that required for ignition until restoration of the proper heat-flow balance. As a result, fuel flowing to the fluidized-bed region 44 is ignited by the high temperature in the static-bed region 36, so the bed is rekindled and bed operation continues. The use of fluidized-bed boilers constructed with cells built according to teachings of the present invention can therefore afford reliable fluidized-bed operation even at relatively low loads. | An individual cell of a fluidized bed includes a static bed disposed immediately below the fluidization region. The static bed contains heavy ores or other suitable dense material that can be heated to a temperature above the ignition temperature of the fuel used in the fluid bed. Should the fluidized-bed temperature fall below the ignition temperature of the fuel, the lower thermal conductivity of the static bed permits it to maintain the ignition temperature and to ignite the fuel until the fluidized bed has been rekindled. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/901,142, filed on Feb. 14, 2007. The disclosure of the above application is incorporated herein by reference.
FIELD
The present disclosure relates to a safety mechanism for a door structure, and more particularly to a safety enclosure mechanism for a door frame.
BACKGROUND
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Inherent with standard door designs is the relative movement between hard and relatively sharp fixed surfaces. These surfaces often pose hazards to the fingers of children. As such, there is a need to reduce the risk to children caused by the moving surfaces of the door.
SUMMARY
To overcome the deficiencies of standard door system, a safety system is provided. The safety system includes a louvered covering for the door jamb. One side of the louvered cover is coupled to the door, while the second side of the cover is coupled to the door frame.
In one embodiment, a louvered door jamb cover is provided. Each of the members of the louvers are coupled together using a pin and slot system. In this regard, the pins of a first louver member are configured to be slidably received within slots of a second louvered member. It is envisioned that the pins and slots can take a variety of different configurations.
In another embodiment, a pendulum is rotatably coupled to a front or rear face of the door. The pendulum is positioned so as the rotation of the pendulum positions a portion of the pendulum between the door and the door's jamb. A spring biases the pendulum into the location between the door and the door jamb. A user can retract the pendulum to allow the door to close.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
FIG. 1 represents a standard door system;
FIG. 2 represents a door safety device according to one embodiment of the teachings;
FIG. 3 represents a top view of the system shown in FIG. 2 ;
FIGS. 4 and 5 represent cross-sectional views of the louvered system according to the teachings herein; and
FIG. 6-10 represent an alternate embodiment of the invention.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
The safe door hinge system disclosed herein is configured to eliminate the danger to fingers or other anatomy created by a door and door jamb coming together at the hinged edge of the door when being closed. In the current design, used almost universally, a pinch point is created when the door and door jamb come together as the door is closed. Current door hinge design consists of two metal plates of equal size joined at one edge by a pivoting joint allowing the plates to open and close leaving no gap between them in the closed position.
A finger guard device 26 is proposed to protect fingers or other anatomy from being injured by the forces produced by a door and door jamb 24 coming together at the hinged edge of a door 22 when being closed. The finger guard 26 covers the gap created between the door and the door jamb when a door is opened, thereby preventing fingers or other anatomy from being inserted and subsequently crushed or pinched when the door is closed. The finger guard 26 retrofits easily to existing doors and be easily removable, using Velcro as one possible means of attachment. The finger guard 26 can be formed of a plurality of polymer elongated curved or flat panels ( 40 , 42 , 44 ) ( FIG. 3 ) running vertically the entire height of the door jamb up to the lintel 46 positioned in layers that would expand and contract horizontally to cover the gap between the door 22 and the jamb 24 as the door is opened or closed.
It is envisioned the panels ( 40 , 42 , 44 ) can be curved or flat and are configured to slide parallel to and behind one another when the door is closed, and expand as the door is opened.
The panels are connected to each other at any number of points along their height by horizontal fastening tracks consisting of a combination of pins and slots, rails and channels, hooks and rods, wheels and tracks, or any other fastening combination that would attach the panels together securely front to back, limit and control the gaps between the panels, and allow the panels to slide back and forth horizontally. The back of the top panel would be attached to the front of the second panel 42 and the back of the second panel would be attached to the front of the last panel 40 . The first and last panels would be connected pivotally to the door and the door jamb respectively 54 , 56 which would cause the entire device to expand and contract as the door is opened or closed.
A finger guard device 26 is proposed to protect fingers or other anatomy from being injured by the forces produced by a door and door jamb coming together at the hinged edge of a door when being closed. The finger guard 26 covers the gap created between the door and the door jamb when a door is opened thereby preventing fingers or other anatomy from being inserted and subsequently crushed or pinched when the door is closed. The finger guard would retrofit easily to existing doors and be easily removable using Velcro as one possible means of attachment. The finger guard would consist of any number of elongated panels 40 , 42 , 44 running vertically the entire height of the door jamb up to the lintel 46 positioned in layers that would expand and contract horizontally to cover the gap between the door 50 and the jamb 48 as the door is opened or closed. A portion of the elongated panels nest when the door is in an open position.
As shown in FIGS. 4 and 5 , the panels can be coupled together using a pin and slot configuration. In this regard, it is envisioned that a first elongated panel 40 has a plurality of pins 30 which are slidably received within a slot defined within the second member 42 . As shown in FIG. 5 , the pins can be free floating within the slot 34 or can be coupled directly to an adjacent member. It is envisioned that the pins can have a plurality of head configurations of with either flat or curved interface surfaces. In this regard, the surfaces of the slots can be angled to interface with flat or curved surfaces of the pin or pin head.
It is envisioned that the system 26 can be coupled to the door or frame using fasteners such as screws nails or adhesives. The elongated members can be directly coupled to the frame and door, using a flange which is fixed to the elongated member. This flange can be pivotably or rigidly fixed to one elongated members.
FIGS. 6-10 represent another embodiment which can be used with the system described above. The safe door stop 62 is configured to prevent injury to hands and fingers caused by contact with a door while being closed. As shown in FIG. 6 , the safe door stop 62 is designed to prevent injuries occurring between the door 50 and the jamb 48 at the door knob edge of the door.
The safe door stop prevents injury by placing a soft barrier between the door and the door jamb automatically whenever the door is opened. Removing the barrier requires a user closing the door to pause and complete the final few inches of closing the door slowly with both hands. The necessity of using two hands requires that the closer face the door thereby increasing visibility and therefore safety. In addition the necessity of pausing and completing the final few inches slowly when closing a door gives anyone in close proximity to the door more time to see the door being closed, and move hands or fingers out of harms way. The safe door stop also prevents a door from being slammed or closed from behind.
The safe door stop 62 can consist of a soft stopper 63 coupled to a member to form a pendulum. As shown in FIGS. 8-10 , a spring operated extension arm consisting of two hinged plates, a door face plate 64 and a door edge plate 68 , and a holding bracket to secure the safe door stop to the door. It is envisioned the extension arm could also be of one piece design. The safe door stop operates automatically whenever a door is opened. As the door opens, door faces plate 64 is brought into full contact and held on the door face. As the door continues to open, door edge plate 66 with attached soft stopper 62 (FIG. 6 ) is brought into full contact and held on the edge of the door. To close the door, a handle 70 can be used to assist in holding the safe door stop away from the edge of the door when pushing the door closed, and a spring operated pusher 72 would be mounted on the opposite side of the door to push and hold the safe door stop away while pulling the door closed. Optionally, a locking mechanism can be used to position the locking pendulum into a disengaged position which would allow the normal opening and closing of the door.
The soft stopper could be a variable size and density sufficient enough to stop a door from closing while leaving a gap large enough to prevent any part of the door from contacting hands or fingers that may be in the path of the door. The holding bracket would be attached to the door with Velcro™ or could be attached in any other secure manner such as a nail, screw, bolt or adhesive. | A safety system for a door-to-door jamb interface is provided. The safety interface uses several slidably joined members which are coupled to the door and its associated door jamb to prevent interaction between a user and the door-to-door jamb interface. | 4 |
FIELD OF THE INVENTION
This invention relates generally to electrical receptacle connectors, and is particularly directed to an electrical receptacle connector having an internal structural member disposed within an electrical cable coupled to the connector for providing the cable and connector combination with great strength.
BACKGROUND OF THE INVENTION
An electrical receptacle connector is a fitting connected to an electrical cable and adapted to receive a plug. The cable may carry electric power or may include one or more conductors carrying electrical signals. Sometimes the receptacle connector is attached to an electrical panel member. When employed in a harsh environment, large forces may be applied to the receptacle connector which may result in loosening or separation of the cable from the receptacle connector and loss of power or electrical signals. To deal with these large forces, some connectors are provided with high strength materials. One form that these high strength materials take is known as Kevlar. Kevlar as a para-aramid synthetic fiber having high strength. Kevlar is typically spun into ropes or fabric sheets, or it may be used as an ingredient in composite material components. Kevlar exhibits a high tensile strength-to-weight ratio and is said to be five times stronger than steel on an equal weight basis. However, on a space, or volume, basis, a substantially greater amount of Kevlar is required to provide the same strength as steel. Thus, where space is at a premium, such as in the area of electrical connectors and components, Kevlar's applications are somewhat limited. In addition, because Kevlar typically is comprised of a large number of individual strands of different lengths, the cumulative effect of all of the strands is not realized along the entire length of an elongated Kevlar member such as an electrical cable and connector assembly and the strength exhibited by Kevlar in this environment is limited. In addition, Kevlar strands are typically secured to another member by tying which is impractical in the small dimension environment of electrical connectors.
The present invention is intended to provide a high strength electrical receptacle connector capable of operating in harsh duty environments where tension values as high as 300 pounds may be encountered.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a high strength, compact electrical receptacle connector which is easily connected in a sealed manner and disconnected and may be either female or male in configuration.
It is another object of the present invention to provide an electrical receptacle connector adapted for use with multiple conductors in a single shielded cable which includes an elongated nonconductive insert for maintaining the conductors in fixed, spaced relation and for providing physical and electrical isolation between adjacent conductors within the receptacle connector.
A further object of the present invention is to provide a split washer in an electrical receptacle connector which is securely coupled to a high strength steel cable to provide the receptacle connector with high strength and which allows the receptacle connector to be easily assembled.
A still further object of the present invention is to provide an electrical receptacle connector comprised of an end-to-end threadably coupled bushing and shell combination and which is connected to a cable having plural conductors and a steel cable to provide high strength, wherein tightening of the threadably coupled bushing and shell places the steel cable under increased tension while simultaneously introducing slack in the electrical conductors.
The present invention contemplates an electrical receptacle connector adapted to receive an electrical cable having plural conductors, the electrical receptacle connector comprising: a bushing adapted to receive the electrical cable and having a first threaded end portion; a shell adapted to receive the electrical cable and having a second threaded end portion coupled to the first threaded end portion of the bushing; an elongated, thin strength member disposed in and extending along a portion of the length of the electrical cable; and a split washer connected to the strength member and having an open inner portion and a partially circular peripheral portion, wherein the plural conductors are disposed in and extend through the open inner portion of the split washer and the partially circular peripheral portion of the split washer is disposed in contact with the first threaded end portion of the bushing, and wherein tightening of the coupling between the bushing's first threaded end portion and the shell's second threaded end portion urges the split washer into tight fitting engagement with the shell applying increased tension upon the strength member while removing tension from the plural conductors.
The present invention further contemplates a multi-conductor electrical cable and receptacle connector arrangement comprising: a bushing adapted to receive the electrical cable and having a first threaded end portion; a shell adapted to receive the electrical cable and having a second threaded end portion coupled to the first threaded end portion of the bushing; an elongated, thin strength member disposed in and extending along a portion of the length of the electrical cable; a retaining member having an open inner portion and a partially circular peripheral portion, wherein the plural conductors and the strength member are disposed in and extend through the open inner portion of the retaining member and the partially circular peripheral portion of the retaining member is disposed in contact with the first threaded end portion of the bushing for increasing the strength of the electrical cable receptacle and connector arrangement; and an elongated centering and isolating member disposed within and along at least a portion of the length of the cable, wherein the centering and isolating member is disposed about the strength member and intermediate adjacent conductors for centering the strength member within the cable and isolating the conductors from the strength member while maintaining the conductors in equally spaced relation from one another.
BRIEF DESCRIPTION OF THE DRAWINGS
The appended claims set forth those novel features which characterize the invention. However, the invention itself, as well as further objects and advantages thereof, will best be understood by reference to the following detailed description of a preferred embodiment taken in conjunction with the accompanying drawings, where like reference characters identify like elements throughout the various figures, in which:
FIG. 1 is a side elevation view of a harsh duty receptacle connector in accordance with the principles of the present invention;
FIG. 2 is a longitudinal sectional view of the inventive harsh duty receptacle connector;
FIG. 3 is an exploded perspective view of a portion of the inventive harsh duty receptacle connector;
FIG. 4 is another exploded perspective view of the inventive harsh duty receptacle connector illustrating additional details of the invention;
FIG. 5 is a sectional view illustrating internal details of the inventive harsh duty receptacle connector; and
FIG. 6 is a sectional view of a multi-conductor cable with which the harsh duty receptacle connector of the present invention is adapted for use.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 , there is shown a side elevation view of a harsh duty receptacle connector 10 in accordance with the principles of the present invention. A longitudinal sectional view of the inventive receptacle connector 10 is shown in FIG. 2 . FIGS. 3 and 4 are exploded perspective views illustrating additional details of the inventive receptacle connector 10 .
Receptacle connector 10 includes a receptacle bushing 12 and a receptacle shell 14 . Bushing 12 and shell 14 are generally cylindrical in shape, are preferably comprised of a high strength metal such as steel, and include respective center slots extending therethrough for receiving a shielded electrical cable 18 .
Cable 18 includes plural spaced electrical conductors 16 a - 16 d extending along the length thereof. Disposed within cable 18 and between the individual conductors 16 a - 16 d is an elongated, nonconductive centering/isolating member 46 preferably comprised of a non-rigid plastic as shown in the sectional view of FIG. 6 . Centering/isolating member 46 extends along the length of cable 18 and includes four spaced members 46 a - 46 d . each extending radially outward from a center portion 46 e of the center/isolating member. Each of the four radially extending spaced members 46 a - 46 d is preferably integrally formed with the center portion 46 e of the centering/isolating member 46 . First spaced member 46 a is disposed between first and second electrical conductors 16 a . 16 b . while second spaced member 46 b is disposed between the second and third electrical conductors 16 b . 16 c . Similarly, the third spaced member 46 c is disposed between the third and fourth electrical conductors 16 c . 16 d while the fourth spaced member 46 d is disposed between the fourth and first electrical conductors 16 d . 16 a . Adjacent spaced members of centering/isolating member 46 maintain each electrical conductor in fixed position during electrical conductor 18 manufacture and provide electrical isolation between adjacent electrical conductors.
Extending along the length and disposed within the center portion 46 e of the centering/isolating member 46 is a strength member 20 , as also shown in FIG. 6 . Strength member 20 could take on various forms, but in a preferred embodiment is a multi-strand steel aircraft cable which provides high strength for the harsh duty receptacle connector 10 as described in detail below. Centering/isolating member 46 also ensures that high strength member 20 is centered in cable 18 and provides physical isolation of the four conductors 46 a - 46 d from strength members 20 .
Receptacle bushing 12 includes an external threaded end portion 12 a which is adapted for engagement with an internal threaded end portion 14 a of receptacle shell 14 . Receptacle shell 14 further includes a second outer threaded portion 14 c and an intermediate enlarged shoulder portion 14 b disposed between the receptacle shell's inner threaded portion 14 a and its aforementioned outer threaded portion. The outer periphery of the receptacle shell's enlarged shoulder portion 14 b is provided with plural flat portions 14 d as shown in FIG. 1 to facilitate engagement of the receptacle shell 14 by a wrench (not shown) for attaching the receptacle shell to a nut 28 for securely mounting the inventive receptacle connector 10 to a structural member such as flat panel 27 as shown in FIG. 2 . The outer threaded portion 14 c of receptacle shell 14 is also provided with a keyway 14 e , also as shown in FIG. 1 , which is received by a matched portion in a cut-out (not shown) within the panel 27 to eliminate rotation of shell 14 during installation of nut 28 . Finally, the outer peripheral surface of receptacle bushing 12 is also provided with plural spaced flat portions 12 c as shown in FIGS. 3 , 4 and 5 to facilitate manipulating the receptacle bushing by means of a tool such as a wrench.
Adjacent ends of each of the first through fourth conductors 16 a - 16 d are adapted to receive respective electrical contacts 26 a - 26 d as shown in FIG. 3 . Each of the electrical contacts 26 a - 26 d is adapted for insertion through a respective slot within a cylindrical insulator 29 . Cylindrical insulator 29 , which includes four slots 38 as shown in FIG. 3 , is inserted into a circular slot extending through receptacle shell 14 . An end 29 b of the slotted cylindrical insulator 29 and the ends of the four electrical contacts 26 a - 26 d extend outward from the end of receptacle shell 14 . The four electrical contacts 26 a - 26 d are adapted for mating electrical connection to respective electrical contacts of a complementary connector, which is not shown in the figures for simplicity. In addition, while the four electrical contacts 26 a - 26 d are shown recessed within one of respective slots 38 in the slotted cylindrical insulator 29 for receiving complementary male contacts, the present invention also contemplates the use of the four electrical contacts in a male, or projecting, configuration for mating electrical engagement with four female contacts in the complementary electrical connector which is not shown in the figures for simplicity. Finally, an elongated slot 29 a in a lateral portion of cylindrical insulator 29 forms a keyway for permitting mating contact of the distal end of the insulator and its associated four electrical contacts 26 a - 26 d with a complementary configured connector.
Receptacle connector 10 further includes a drain wire attachment 30 attached to cable 18 and including a drain wire 30 a which extends along the length of shielded cable 18 . Drain wire attachment 30 is in electrical contact with receptacle bushing 12 which is maintained at ground potential because receptacle bushing is connected to receptacle shell 14 which is in contact with structural member 27 which is at ground potential. The combination of drain wire attachment 30 and its drain wire 30 a maintains the cable's inner conductive sheath at the same potential along the entire length of cable 18 to provide effective electromagnetic interference (EMI) shielding for the cable. A first O-ring 34 is positioned between an inner portion of receptacle shell 14 and structural member 27 in a sealed manner. A small bead 44 of UV potting material is deposited on an outer peripheral surface of insulator 36 so as to form a seal with an inner surface of receptacle shell 14 .
With the four conductors 16 a - 16 d disposed within and along the length of cable 18 and maintained in fixed position therein by means of a centering/isolating member 46 , the end of strength member 20 , which is disposed within centering/isolating member, is inserted through a slot 22 a within a split washer 22 . A stop sleeve 24 comprised of a conductive material such as copper is crimped to the end of strength member 20 for securely attaching the stop sleeve to the strength member as shown in FIG. 3 . There are various other approaches available for securely attaching a stop member to the end of the strength member 20 to prevent disconnection of the strength member from split washer 22 , with the crimping arrangement shown in the figures being the preferred way to securely attach these two components of the receptacle connector 10 of the present invention.
With cable 18 disposed within and extending through receptacle bushing 12 and with the four conductors 16 a - 16 d and the strength member 20 extending through an open inner portion 22 c of split washer 22 , the exterior threaded portion 12 a of receptacle bushing 12 is positioned in contact with the internal threaded portion 14 a of receptacle shell 14 . Rotation of one or both of the receptacle bushing 12 and receptacle shell 14 relative to the other results in secure engagement between these two receptacle connector components. During tightening of the threaded engagement between the receptacle bushing 12 and receptacle shell 14 , the outer peripheral portion of split washer 22 is positioned in contact with the end portion 12 b of receptacle bushing 12 adjacent its exterior threaded portion 12 a as shown in the sectional view of FIG. 5 . Continued tightening of the threaded engagement between receptacle bushing 12 and receptacle shell 14 causes tension to be applied to strength member 20 . When the receptacle connector 10 is tightly assembled and in use, this tension is maintained on strength member 20 which removes all tension from the four conductors 16 a - 16 d . resulting in slack in all of these conductors. The slack in each of the first through fourth conductors 16 a - 16 d is shown in FIGS. 2 , 3 and 4 as bent portions of each of these conductors. This reduces the likelihood of detachment of any of the conductors from its associated end contact upon the application of a large axial force to the receptacle connector 10 . In a preferred embodiment, strength member 20 is in the form of an aircraft cable capable of withstanding an axial tension of 300 pounds. Also in a preferred embodiment, the outer surface of receptacle bushing 12 , and its juncture with cable 18 , is covered with a thin layer of shrink tubing 42 .
Once the inventive receptacle connector 10 is assembled, an inert semi-rigid potting compound having a high durameter rating is injected via a first slot 32 into the receptacle bushing 12 . The potting compound, which is typically comprised of a polymer such as epoxy or polyurethane, encapsulates and fixes in position and configuration the electrical conductors 16 a - 16 d therein. A second slot 33 within receptacle bushing 12 allows for the escape of air from the bushing as the potting compound is injected into the bushing.
While particular embodiments of the present invention have been described, it will be obvious to those skilled in the relevant arts that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim in the appended claims is to cover all such changes and modifications that fall within the true spirit and scope of the invention. The matters set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art. | A sealed electrical receptacle connector, either male or female, includes, in combination, a bushing and a shell threadably coupled together in an end-to-end manner. The bushing is adapted to receive a cable having plural conductors arranged in a spaced manner and separated from another along their respective lengths by an elongated nonconductive insert having plural radially extending spaced members, each disposed between a pair of adjacent conductors. A split washer is disposed between and in abutting contact with adjacent inner end portions of the receptacle and the shell and includes a slot extending therethrough. The split washer facilitates receptacle connector assembly and its slot is adapted to receive the plural conductors and an elongated axial strength member, such as a multi-strand steel cable, disposed within and along the length of the nonconductive insert to provide the receptacle connector and cable combination with high strength. | 7 |
This is a divisional of copending application Ser. No. 08/786,388, filed on Jan. 16, 1997.
TECHNOLOGICAL FIELD
The present invention pertains to a soldering process suitable for use with inexpensive polymer substrates having low heat distortion temperatures without distortion or other thermally induced damage.
DESCRIPTION OF THE RELATED ART
At one time, virtually all electronic devices, ranging from computers to radios, televisions, radar and other consumer, industry, and military electronics, were assembled from discrete components on a metal chassis. Electrical connections were made by hand soldering using a soldering iron or soldering gun. With the advent of the transistor and attendant miniaturization, the metal chassis as a means to support individual components gave way to use of printed circuit boards. The latter were generally fiberglass or paper impregnated with phenolic or epoxy resins, with a relatively thick copper layer plated onto or laminated to one or both sides, the copper layer(s) etched to form the necessary conductive paths and device mounting pads. In most cases, the printed circuit boards were mounted in metal frames, or attached to other support structures using insulative spacers and traditional fasteners. As familiarity with printed circuit boards grew, and as product volumes increased, new soldering methods began to replace hand soldering.
In reflow soldering, solder (such as solder paste) is applied (e.g. printed) onto the circuit board and at a later stage following placement of electronic components on the board, heat is applied to melt or "reflow" the solder. Heat may be applied locally, but for volume production, ovens, through which conveyors carrying component-loaded boards pass, are used.
A further mass production technique is wave soldering. In wave soldering, a tank of molten solder is maintained, and a pump drives solder over a dam forming a wave of uniform height across the width of the tank. Printed circuit boards, with the electronic components mounted on top and the leads emanating from the lower surface of the board, and/or with surface mount devices (SMD) attached (for example, with adhesives) on the bottom surface of the board, are conveyed across the top of the tank such that the crest of the wave contacts the lower surface of the board, electrically and mechanically joining the electronic devices to the circuit by soldering the component leads or end termination to the exposed copper conductors (i.e. the pad area). Areas of the board which are not desired to obtain solder are coated with a temperature resistant solder mask.
While reflow soldering and wave soldering offer a tremendous increase in throughput and quality relative to hand soldering, and are well suited to use both with epoxy or phenolic laminate circuit boards as well as circuit boards or flexible films of high temperature thermoplastics such as polysulfones, polyarylene sulfides, polyimides, polyetherimides, and the like, such techniques are highly unsuitable for use with common, inexpensive thermoplastics having relatively low heat distortion temperatures (HDT) and melting points. Examples of such thermoplastics are polyvinylchloride, polypropylene, ABS, polyurethane, polystyrene, and other thermoplastics which constitute the majority of polymers used in consumer goods. These materials will be greatly distorted by heat, have their mechanical properties adversely altered, or sustain cosmetic surface damage due to the heat generated in reflow and wave soldering. Factually, the high distortion and low melting temperatures of these polymers has been taken advantage of to facilitate component interconnection in both reflow and wave soldering techniques.
For example, in U.S. Pat. No. 3,501,832, a polymer component having electrical connections plated thereon or embedded therein is forced under pressure on top of a device requiring electrical interconnections on varying planes, one or both of the polymer component or device component having a solder coating. Heating the device to melt the solder also heats the polymer beyond its heat distortion temperature, deforming the polymer, e.g. polyethylene, during the soldering process so as to allow connections at various heights. The deformed thermoplastic may remain to serve as a protective cover over the components. In U.S. Pat. No. 4,254,448, thermoplastic pins are inserted into a circuit board, electronic components mounted, and the thermoplastic pins heated and deformed to secure the various leads in the correct positions for reflow soldering. The now-redundant pins, if not already melted away, may be removed by melting or other means.
The inability to use mass production soldering techniques such as reflow soldering and wave soldering with low cost, low HDT thermoplastic substrates renders the use of the latter impractical, and raises the cost of electronic assemblies. This detriment was recognized in U.S. Pat. No. 4,774,126 which disclosed use of low HDT thermoplastics by forming a sandwich structure with a low HDT thermoplastic core flanked by high performance thermoplastic exterior surfaces of thickness suitable to absorb the heat generated by wave or reflow soldering. However, this technique still requires use of expensive thermoplastics as the sandwich exterior, and requires manufacture of unique sandwich structure devices. Thus, the cost improvement is marginal at best.
The inability to utilize low cost thermoplastics as electronic substrates affects more than the cost of printed circuit boards alone. For example, in the manufacture of devices such as computers and televisions, the cases are generally constructed of low cost thermoplastics, and in automobiles, easily moldable, low cost thermoplastics are used for such components as center consoles, dashboards, and the like. It is totally impractical, and in many cases, impossible, to employ high HDT thermoplastics such as polyamide or polyetherimide for these components.
Hence, if components such as those previously described are to include electronic elements requiring interconnection, it is necessary to utilize separate circuit boards and then mount these boards to the case or automotive component. Such methods are inherently redundant, increasing both component weight and cost, and in addition necessitate increased assembly time, further increasing costs. For example, in automotive dashboards, large printed circuit boards or several smaller boards with wiring harness or ribbon conductor interconnects may be required, together with necessary mounting pedestals, mounting hardware, and the like. Inability to directly attach and interconnect electronic components on low cost, low HDT thermoplastics has become a limiting factor in system integration, for example, vehicle instrument panel integration.
It would be desirable to provide a process for the interconnection of electronic components which maintains the mass production throughput of techniques such as reflow and wave soldering and yet which may be used with inexpensive thermoplastics having low HDT. It would be further desirable to provide a process where a load bearing and/or aesthetic component of low HDT thermoplastic may be used as a substrate for the mounting and interconnection of electronic devices without the redundancy of separate circuit boards and mounting devices. It would further be desirable to provide a high volume efficient production process suitable for use with low HDT substrates. It would further be desirable to implement a process whereby physical and functional integration of complex structures constructed of low HDT thermoplastics with other polymers/metals that make up the product is facilitated.
SUMMARY OF THE INVENTION
A method of soldering components onto low HDT thermoplastic substrates has been developed which allows for high throughput similar to that exhibited by reflow and wave soldering techniques; and which surprisingly allows even large complex structures of low HDT thermoplastics to be used directly as a substrate for electronic components without melting or distortion, thus eliminating one barrier to using low cost materials in consumer and transportation components. The method comprises providing a substrate of a low HDT thermoplastic having applied thereon a low temperature solder such as solder preform onto the circuit conductor pad; preheating the substrate to a temperature below the melting point of the solder and below the HDT of the substrate; preheating components to be soldered to a temperature above the melting point of the solder such that the thermal energy stored in the component is sufficient to cause the solder to melt and flow upon contacting of the component and the solder; and contacting the component and its respective solder on the pad for a time sufficient for the solder to melt, flow, and establish a metallurgically and electrically sound joint. The ability to avoid high temperatures allows low HDT substrates to be used.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the use of the subject process for integration of an automotive component;
FIGS. 2a and 2b illustrate one embodiment of the subject process; and
FIG. 3 illustrates integration of a consumer electronics product made possible through use of the subject process.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The subject process requires providing a substrate of low heat distortion temperature thermoplastic having applied thereon the desired solder on the pad of the interconnecting traces. The entire substrate may be of low HDT thermoplastics or only a portion thereof. Suitable low HDT thermoplastics generally have heat distortion temperatures below 350° F. (177° C.) with most being in the range of 190° F. (88° C.) to 250° F. (121° C.) and are commercially available. These include by example, but not by way of limitation, polyethylene, polypropylene, polybutylene, other polyalkylene polymers and copolymers, polyvinylchloride, thermoplastic polyurethane, ABS (acrylonitrile/butadiene/ styrene copolymer), SAN (styrene/acrylonitrile copolymer) polystyrene, and the like. The solder on the pad may be provided by numerous techniques, e.g. electroplating, electroless plating, metal spraying, lithographic techniques, printing/dispensing solder paste followed by reflow, metal foil lamination, etc. The various techniques are well known to those skilled in the art. Specifically, solder may be delivered using solder preforms.
Low melting solders may be chosen from among numerous commercially available solder alloys known to those skilled in the art. The various physical properties of such alloys, e.g. their fatigue resistance, corrosion resistance, tensile strength, etc., are well known, as are their melting points. Melting points advantageously range from about 100° C. to about 170° C., although solders of both higher and lower melting points may be used as required. However, if the melting point of the solder is too high, the electronic component to be soldered may not be of sufficient mass and/or be capable of being heated to a temperature sufficient to supply enough heat to melt the solder. Integrated circuits, for example, should in general not be heated substantially above 220° C., although components such as ceramic resistors, ceramic capacitors, and the like, are frequently able to withstand higher temperatures.
Examples of a variety of suitable solders is presented in Table 1 below. Many others are, of course available. Solders containing cadmium are not listed, as cadmium is toxic and current thought is that its use should be limited. However, such solders are also usable with the subject invention, and are candidates especially for limited numbers of interconnects where strength or other factors outweigh use of a limited amount of cadmium-containing solders.
TABLE 1______________________________________Solder Composition, weight percent m.p. (°C.)Low Temperature SoldersComposition (wt %) M.P. (°C.)______________________________________58Bi/28Pb/22Sn 10046Bi/34Sn/20Pb 10054.5Bi/39.5Pb/6Sn 102-10867Bi/33In 10952.98Bi/42.49Pb/4.53Sn 103-11752In/48Sn 12050In/50Sn 118-12540In/40Sn/20Pb 121-13057.42Bi/41.58Sn/1Pb 13558Bi/42Sn 13897In/3Ag 14358Sn/42In 118-14599.3In/0.7Ga 15048Sn/36Pb/16Bi 140-162100In 15760Sn/40Bi 138-170______________________________________
In general, it is preferable to apply a solder of limited thickness on the conductor pad on the substrate, following which a solder preform supplies the majority of the solder used to form the soldered connection. The solder preform alloys, some examples of which are shown in Table 1, need not be the same as those on the pads. Moreover, either or both of the solder preforms or solder on the pads may be coated with a flux, preferably a rosin-type or adipic acid-type flux, to ensure a metallurgically sound joint. Solder preforms, as is well known, are generally stamped or cut from a thin foil in a shape and thickness appropriate for the particular joint to be formed. Photochemical machining may also be used to manufacture solder preforms. In general, the preform thickness may range from about 100 μm to 300 μm, although both thicker and thinner preforms may also be used. Preforms are adhered to the pads by traditional techniques.
The components to be soldered encompass a wide variety of electrical devices, including simple wire or multiple-wire ribbon-type interconnects; resistors, capacitors, transistors, diodes, integrated circuits, LEDs, incandescent light sockets, relays, flashers, induction coils, and the like. There is no particular limitation on the nature and/or size of the particular electrical component, except that the component must be capable of withstanding a temperature which is higher than the melting temperature of the solder and high enough such that a sufficient quantity of heat may be transferred to the solder to enable melting and flow/reflow to form a metallurgically sound and electrically conductive bond. In this respect, components which are large may require heating to a lower temperature than small components. However, in general, most components will be of at least reasonably similar size, and will usually be heated to the same temperature.
The substrate is preferably heated to a temperature which is about 5° C. to 30° C., preferably about 10° C. to 20° C. below the melting point of the solder and which is less than the heat distortion temperature of the thermoplastic. These two requirements will facilitate selection of a particular solder. For example, if the heat distortion temperature of a particular thermoplastic is 130° C. and a solder melts at 170° C., then this combination is not likely to provide acceptable results, unless the electrical components can withstand higher temperatures such that the required temperature differential between the allowable substrate temperature (c.a. 120° C. in this case) and solder melting point (170° C.) can be overcome. In the case of 130° C. HDT thermoplastic, it would be preferable to employ a low melting solder, e.g. one with a melting point of 120° C. or less. The selection of a particular solder is a common sense decision well within the knowledge of one skilled in the art.
The electrical component temperature is similarly easily determined by one skilled in the art. The temperature must be below temperatures which would cause component damage. Discrete devices such as ceramic resistors and capacitors, etc., can usually withstand temperatures in excess of 250° C. Other packaged components such as relays, coils, etc., however, are usually more limited in their ability to withstand temperature excursions. Most such devices can withstand temperatures of c.a. 200-220° C., which is generally sufficient for operation in the subject process. The maximum temperature which may be safely utilized can usually be obtained from the device manufacturer, or may be easily determined from device failure rates obtained from devices subject to a given processing protocol.
While it may be important to know the maximum temperature which a given device can withstand, it is also generally important to choose a temperature such that heat in excess of the minimum amount required to melt and reflow the joint is present, but the excess amount is such that the joint rapidly solidifies due to heat being transferred away from the joint through the substrate or surrounding air/atmosphere, or is at most such that minimal time is required in a cooler environment to allow the joint to solidify. While the exact amount may be determined by simple experiments, it is also possible to calculate the temperature based on amount of heat required by the joint, i.e. its geometry, the heat of fusion of the solder, the solder pad/preform surface and edge areas, the thermal conductivity of the substrate, the mass and heat capacity of the component and component leads, etc. Preferably, the components are heated to temperatures in the range of 180° to 350° C., more preferably 190° C. to 250° C., and most preferably about 200° C. to 220° C. The component should not be heated to a temperature such that excess heat damages the substrate.
In many instances, a flux is desired for removing oxides and thereby obtaining a sound metallurgical joint. Fluxes may be incorporated on or in the solder pads, solder preforms, or pre-tinned leads, or may be separately supplied as a spray, coating, foam, and/or by dipping, liquid immersion, dispensing, etc. Lithographic techniques may be used as well. Plasma or other methods may also be used for oxide removal. Following soldering, residual flux may be left on the substrate or may be removed by conventional techniques such as solvent washing, etc. Following such techniques, the now-soldered substrate and component assembly may be encapsulated with a protective coating to protect the solder joints from oxidation and other adverse effects. Where necessary, additional means of providing thermal energy to facilitate soldering one or more joints may also be used, either on all the joints on the substrate or only on selected joints. Such additional energy may be in the form of laser energy, electron beam, focused infrared, microwave, ultrasonic, etc, and/or carried through heated tools that are used to place the electronic components on the circuit.
FIG. 1 illustrates the use of the subject invention to integrate electronic circuitry on a non-parasitic, low HDT structure. The structural member 1 of low HDT thermoplastic provides both structural support as well as a mounting surface for the electronic components. Hence, there is no "parasitic" load, or "redundancy" common when a circuit board is mounted to a structural member. Because the structural low HDT polymer member is not distorted by mounting of components in accordance with the subject invention, it may have a shape dictated by both function and aesthetics as well as serving as the mounting surface for the electronic components.
At 3 in FIG. 1 are located edge card interconnections while at 5 and 7 are shown male and female pin-type connector devices. Conductive traces 9 connect active devices 11, passive devices 13, and the respective connectors 3, 5, and 7. The traces are preferably located directly on the surface of the low HDT plastic. Shown at 15 are solder pads to which the devices have been soldered by heating the structural member, traces, and solder pads to a temperature somewhat lower than the solder melting point and applying to the solder pads the various connectors, devices, etc., heated to a temperature higher than the solder temperature.
FIG. 2a illustrates one embodiment of the process of the subject invention. A substrate of low HDT (150° C.) thermoplastic 21 has applied thereon circuit conductor pads 23, onto which is applied solder (such as solder preforms 25) having a melting point of 125° C. The substrate, solder pads, and solder preforms are heated to about 115-120° C., for example on a conveyor belt in a low temperature oven. Electronic components, in this case chip resistor 27, and semiconductor diode 29 are secured by reusable clamps 26 secured to metal or polymeric (such as high HDT thermoplastic) carrier 28. The carrier, components, and clamps are heated to about 200° C. to 220° C., the carrier and substrate approach each other, contacting electrical component leads or end termination 24 with their respective solder pads/preforms. Contact is maintained until a metallurgically sound solder joint is formed by solder flow followed by solidification, and carrier removed, resulting in FIG. 2b, a completed electronic circuit on an undistorted, low HDT thermoplastic substrate.
In FIG. 3 is shown an example of the type of electronics/plastics integration which may be achieved with the subject invention for a consumer electronics product. A polystyrene computer monitor case 31 is shown without the CRT and without power transformer and video transformer. In conventional computer monitors, the interior circuitry is created on separate printed circuit boards. Power transistors and diodes on such circuit boards are frequently mounted to metal heat radiators (sinks). The circuit boards are then mounted to the case by employing a separate metal frame or by bolting the individual circuit boards to molded-in standoffs, the boards being connected by multiple conductor ribbons and in-line connectors.
In FIG. 3, circuitry equivalent to two separate circuit boards is mounted directly to the polystyrene case itself, without any separate circuit boards, standoffs, or connecting hardware. In addition, the connections between the two circuit boards requires no wires or multiple conductor ribbon connectors. Within the area on the case inside bottom bounded by dotted lines 33 are soldered, to respective solder pads/preforms (not labeled for clarity) and copper connecting traces 34, integrated circuits 35. Within the area on the case inside side wall 39 is found the equivalent of a second circuit board, having its integrated circuit components 35 and discrete components 37 soldered to solder pads located directly on the low HDT case itself. Rather than use wires or a multiple-conductor ribbon connector to make the electrical connections between the circuit components in areas 33 and 39, the copper conductor traces 41 are plated/printed/laminated directly around the interior walls of the case. By contrast to conventional assemblies, in many designs, component heat may be dissipated directly through the case, eliminating the need for separate and relatively expensive heat sinks. The case may be constructed of heat conductive filled low HDT thermoplastic for greater heat transfer, e.g., polystyrene incorporating metallized metal particles or metal flakes.
Thus, the subject invention pertains to a method for soldering and interconnecting electronic components on a low heat distortion substrate, this method comprising selecting a substrate of low heat distortion temperature thermoplastic; providing solder pads as part of the electrical conductor traces on at least one surface of the substrate; and providing solder such as solder preforms onto one or more of the solder pads, the solder having a relatively low melting temperature. One or more electronic components having electronic component leads or end termination to be soldered to respective solder pads are then provided; the substrate heated to a first temperature lower than the solder melting temperature and lower than the heat distortion temperature of the thermoplastic, and the electronic component(s) heated to a second temperature higher than the melting temperature of the solder. The electronic component leads/end termination are then contacted with the respective solder pads for a time sufficient to melt the solder and form a solder joint between the solder pads and the electrical component leads or end termination, the first and second temperatures such that sufficient heat transfers from the electronic components to the solder to cause the solder to melt and flow to form a plurality of the solder joints.
The subject invention further pertains to an integrated electronic component-containing construction comprising a substrate of low heat distortion temperature thermoplastic, said construction having structural, functional, and/or aesthetic surfaces, at least one of the said functional surfaces having mounted directly thereto a plurality of solder pads as part of the electrical conductor traces, said pads having applied thereto solder such as solder preforms, and having soldered to the solder pads a plurality of electronic component leads/end termination, wherein a low melting solder adheres to the solder pad and the leads/end terminations forming a solder joint therebetween.
By the term "non-integrated circuit board" as used herein is meant a separate circuit board which must be mounted onto a substrate by conventional fastening means and is not comprised of a low HDT thermoplastic having components soldered directly to solder supplied thereon. By "mounted directly thereto" is meant that the solder pads, and ultimately the electronic components, are mounted directly on the low HDT thermoplastic without the intervention of any high HDT thermoplastic of sufficient thickness so as to preclude damage to the low HDT thermoplastic. Preferably, the solder pads, electrical conductor traces, etc., are plated directly onto the substrate, or adhesively bonded thereto by a thin layer of thermoplastic or thermoset adhesive. The term "mounted directly thereto" excludes sandwich type structures which are prepared in sandwich form and have an appreciably thick high HDT thermoplastic exterior as shown in U.S. Pat. No. 4,774,126, but does not exclude the addition of a thin, essentially non- functional layer of high HDT thermoplastic, i.e., Mylar™, Kapton™, or Ultem™. By "non-functional" is meant that the construction could be prepared without distortion by the process of the invention without the use of the particular film, i.e. the film serves no purpose in protecting the substrate from heat induced damage/distortion.
Having now fully described the invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the invention as set forth herein. | A soldering process is suitable for use with low cost, low heat distortion temperature thermoplastic substrates without distortion or damage to the substrate yet having the mass production capability exhibited by wave and reflow soldering techniques. The process allows integration of consumer products and, in particular, vehicle components such as integrated instrument panel or other such assemblies, without the redundancy of separate printed circuit boards. | 7 |
This application is a continuation, of application Ser. No. 968,657, filed Dec. 11, 1978 now abandoned which itself is a continuation of Ser. No. 785,794, filed Apr. 8, 1977, now abandoned.
BACKGROUND OF THE INVENTION
It is known to use bandaging material impregnated with plaster of Paris for making stiff bandages. These plaster of Paris bandages are too heavy and insufficiently permeable to air and once set they rapidly lose their strength when moist, for example when brought into contact with water. Furthermore, owing to their capacity to absorb and scatter X-rays, they affect the diagnostic results of X-ray photographs and, owing to their inadequate resistance to water, they often give rise to skin irritation brought about by bacterial or mold growth in the bandage.
There have, therefore, been many attempts to provide bandaging materials which are free from these disadvantages. It has for example been attempted to impregnate bandaging material with polymer solutions which harden under exposure to UV light and then to harden the impregnated bandage by irradiation with UV lamp. (Chemical Orthopaedics and Related Research 103, 109-117 (1974)).
The UV lamps required for this purpose are difficult to handle, and moreover, the UV light only reaches the upper layers of the bandage so that the deeper layers harden only after a considerable time if at all. Another serious disadvantage of this method is that while the bandage is being hardened by UV light, the fracture under the bandage cannot be observed by X-rays.
A bandaging material which is capable of stiffening has been described in German Offenlegungsschrift No. 2,353,212. It consists of a flexible basic material treated with substances which contain oxycarbonyl isocyanate groups. The bandaging material described in German Offenlegungsschrift No. 2,353,212 was not successful in practice, partly because practically insurmountable difficulties were encountered in the manufacture of the bandaging material owing to the extremely high reactivity of oxycarbonyl isocyanates and partly because casts or supporting bandages made from these materials were not strong enough for the purposes required. Furthermore, the high reactivity of oxycarbonyl isocyanates rendered the impregnated bandaging material extremely unstable in storage since the prepolymers with oxycarbonyl isocyanate and urethane groups used according to German Offenlegungsschrift No. 2,353,212 rapidly harden even in the absence of atmospheric moisture.
The process described in German Offenlegungsschrift No. 2,357,931 for producing hardened bandages is also generally unsuitable for medical or surgical purposes because the process of hardening by the action of atmospheric moisture described in that Offenlegungsschrift takes too long.
The present invention provides a novel process for producing supporting bandages for surgical and veterinary surgical use which is substantially free from the disadvantages of the above mentioned processes known in the art. The process according to the invention described below is distinguished in particular by the following advantages:
1. The material is highly permeable to X-rays so that X-ray photographs can be taken through the bandage without any shadow
2. the bandages required for producing a given supporting effect are much lighter than the known plaster of Paris bandages providing the same effect, the saving in weight being up to about 80%;
3. the bandages are resistant to water;
4. the bandages attain weight bearing strength after only about 10 to 15 minutes;
5. the heat of reaction produced during hardening of the bandage is slight compared with that of conventional plaster of Paris bandages;
6. both application of the bandages and their removal after completion of the healing process are extremely simple and clean;
7. the risk of skin irritation due to bacteria or molds is much smaller than in known plaster of Paris bandages;
8. no apparatus is required for applying the bandage;
9. the bandages according to the invention have excellent permeability to air and hence breathing activity.
SUMMARY OF THE INVENTION
The present invention relates to a process for producing a supporting bandage for surgical or veterinary surgical use comprising covering the part of the body which is required to be supported with an air-permeable dressing and then applying a self-hardening bandage over this dressing, characterized in that the self-hardening bandage comprises strips of air-permeable, flexible fabric impregnated or coated with about 50 to 300% by weight, based on the uncoated fabric, of an isocyanate prepolymer which contains free isocyanate groups and is based on aromatic polyisocyanates and polyols containing tertiary amino nitrogen, the prepolymer having an isocyanate content of about 5 to about 30% by weight and a tertiary amine nitrogen content of about 0.05 to 2.5% by weight, the impregnated and/or coated fabric being soaked with water immediately before it is applied. Even the impregnation time is not critical, kneading water for 3 to 5 seconds is sufficient. Due to the short hardening time storage in water preferably should not exceed 2 minutes.
The present invention also relates to lengths of bandaging material which comprise pieces of flexible, airpermeable fabric coated and/or impregnated with about 50 to 300% by weight, based on uncoated fabric, of an isocyanate prepolymer which contains free isocyanate groups and is based on aromatic polyisocyanates and polyols containing tertiary amino nitrogen atoms, the isocyanate polymer having an isocyanate group content of about 5 to 30% by weight and a tertiary amino nitrogen content of about 0.05 to 2.5% by weight.
DETAILED DESCRIPTION OF THE INVENTION
To carry out the process according to the invention, the part of the body which is required to be supported is first covered with an air permeable, unimpregnated dressing. Suitable materials for this dressing include, for example, porous paper, non-woven webs or textile fabrics. The materials used for this dressing preferably have only a limited hydrophilic character. Non-woven polyester or polypropylene fabrics, for example, are therefore particularly suitable.
When the affected part of the body has been covered with the unimpregnated dressing, a bandage according to the invention which has previously been saturated with water is wound over it. This saturation with water of the bandaging material used according to the invention is carried out immediately before application of the bandage, for example, by immersing it in water.
The bandaging materials according to the invention are flexible, air-permeable fabrics having a weight per unit area of from about 20 to 1000 g/m 2 , preferably about 30 to 500 g/m 2 , which are impregnated with certain isocyanate prepolymers. The basic fabric of the bandaging material is preferably a textile. Suitable fabrics for this purpose include, for example, the following:
(1) Woven, knitted or warp knitted textile fabrics having a weight of about 20 to 200 g/m 2 , preferably about 40 to 100 g/m 2 and a thread count of preferably about 2 to 20 threads per centimeter in the longitudinal and transverse direction. The woven or knitted textile fabric may be produced from any natural or synthetic yarn, but it is preferred to use fabrics made of mixed yarns containing both hydrophobic filaments or fibers with a high elastic modulus (for example polyester) and hydrophilic natural or synthetic filaments or fibers (for example cotton or polyamide).
(2) Woven, knitted or warp knitted glass fiber fabrics weighing from about 60 to 500 g/m 2 , preferably about 100 to 400 g/m 2 and having a thread count of preferably about 2 to 20 per centimeter in the longitudinal and transverse direction. Glass fiber fabrics which have been treated with a hydrophilic sizing agent are preferred.
(3) Bonded or non-bonded or stitched non wovens based on inorganic and preferably organic fibers and having a weight of about 30 to 400 g/m 2 preferably about 50 to 200 g/m 2 .
For producing stiff bandages according to the invention in the form of shells or splints, it is also suitable to use textile materials (preferably non-wovens) of the kind mentioned above weighing up to about 1000 g/m 2 .
The woven, knitted or warp knitted fabrics mentioned under paragraph (1) above are particularly preferred.
Isocyanate prepolymers suitable for impregnating the flexible fabrics mentioned above as examples include in particular those which have from about 5 to 30% by weight, preferably about 10 to 25% by weight, of aromatically bound isocyanate groups and about 0.05 to 2.5% by weight, preferably about 0.1 to 1.5% by weight, of tertiary amino nitrogen atoms. Furthermore, suitable choice of the viscosity of the starting materials used for preparing the isocyanate prepolymers ensures that the prepolymers have a viscosity of from about 5000 to 50,000 cP at 25° C., preferably about 10,000 to 30,000 cP at 25° C.
The preparation of the isocyanate prepolymers is carried out in known manner by reacting excess quantities of aromatic polyisocyanates with polyols which contain tertiary amino nitrogen atoms, preferably at an NCO/OH-ratio of between 2:1 and 15:1.
The aromatic polyisocyanates used may be any of the aromatic polyisocyanates known in polyurethane chemistry which have been described, for example, in "Polyurethanes, Chemistry and Technology", Part I, Interscience Publishers (1962) or in "Kunststoff-Handbuch", Volume VII, Polyurethane, Carl Hanser Verlag, Munich (1966). The following are preferred: 2,4-diisocyanatotoluene or 2,6-diisocyanatotoluene or isomeric mixtures thereof; 4,4'-diisocyanatodiphenylmethane and 2,4'-diisocyanatodiphenylmethane and mixtures of these isomers which may contain small quantities of 2,2'-diisocyanatodiphenylmethane, or any mixtures of the above mentioned polyisocyanates or polyisocyanate mixtures which can be obtained by the phosgenation of aniline-formaldehyde condensates and which contain higher nuclear diphenylmethane polyisocyanates in addition to 2,2'- 2,4'- and 4,4'-diisocyanatodiphenylmethane. The last mentioned diphenylmethane polyisocyanate mixtures are particularly preferred.
The following are examples of suitable polyols containing tertiary amino nitrogen atoms:
(1) Low molecular weight polyols having a molecular weight of from about 105 to 300 which contain tertiary nitrogen atoms and are free from ether groups, e.g. N-methyl-diethanolamine, N-ethyldiethanolamine, N-methyl-dipropanolamine, triethanolamine or tripropanolamine;
(2) polyester polyols having a molecular weight of from about 300 to 2000, preferably about 800 to 1500, containing tertiary nitrogen atoms, which polyester polyols can be obtained by the reaction of polybasic acids with amino alcohols of the kind mentioned in (1) above as examples, if desired together with polyhydric alcohols which are free from nitrogen. Suitable polybasic acids include, for example, adipic acid, phthalic acid and hexahydrophthalic acid. Suitable nitrogen free polyhydric alcohols for the preparation of the polyesters include, for example, ethylene glycol, tetramethylene glycol, hexamethylene glycol and trimethylolpropane.
(3) Polyether polyols with tertiary amino nitrogen atoms having a molecular weight of from about 300 to 2000, preferably about 800 to 1500, which can be obtained in known manner by the alkoxylation of nitrogen containing starting compounds. Suitable starting compounds of this kind include, for example, ammonia, the amino alcohols mentioned in (1) above as examples and amines containing at least two-NH-bonds, e.g. ethylene diamine, aniline and hexamethylenediamine. Suitable alkylene oxides for the preparation of the polyethers include, for example, ethylene oxide and propylene oxide. Propoxylation products of the above mentioned nitrogen containing starting materials are particularly preferred.
Any method may be used for coating and/or impregnating the bandaging materials used in the process according to the invention with the above mentioned isocyanate prepolymers. Conventional apparatus or devices may be used, for example the bandages may be coated by means of doctor coat wipers or impregnated and subsequently squeezed off on rollers or centrifuged or they may be sprayed with the isocyanate prepolymer.
The prepolymer may be used either solvent-free or as a solution. In the case of a solution, the preferred solvents are volatile solvents such as methylene chloride, acetone, methyl ethyl ketone, chloroform, THF, ethyl acetate, chlorobenzene and DMF.
Preferably the weight per unit area, density of mesh of the flexible support and quantity of isocyanate prepolymer applied within the ranges specified above are chosen so that only the fibers of the fabric become coated with the impregnating agent while gaps between the fibers are preserved to ensure the necessary porosity to air.
If auxiliary solvents have been used, the impregnated substrate is subsequently freed from them, for example, by a vacuum treatment. After impregnation, the resulting bandaging materials according to the invention may be stored in sealed containers in the absence of moisture. They are preferably stored as rolls or folded flat in airtight metal containers, for example aluminum containers. Sealed bags made of polyethylene coated aluminum foils or moisture sealed aluminum tins are particularly suitable for storing the bandages according to the invention.
One of the advantages of the bandaging materials according to the invention, compared with the bandaging materials according to German Offenlegungsschrift No. 2,353,212 is that when packed airtight as described above they can be stored under normal conditions.
Whenever the bandaging materials are required for the process according to the invention, they can be removed from the container and impregnated with water. The thickness of the supporting bandage (e.g. splint or cast) formed by the process according to the invention depends on the surgical requirements and is generally between about 3 and 10 mm. The bandaging materials according to the invention may be used in the process according to the invention both for forming supporting bandages or casts by winding the strips of material around the parts of the body which require support or they may be used as flat folded bandages for forming shells or splints.
The bandaging materials may be colored, for example, by the addition of pigments or dyes to the isocyanate prepolymers. To increase the rigidity of the supporting bandages formed according to the invention, inorganic additives which may be chemically inert or capable of hardening under the action of water may be added to the isocyanate prepolymers used for impregnating the bandaging materials, but the use of such additives is generally unnecessary due to the excellent mechanical properties of the supporting bandages obtained by the process according to the invention. Suitable additives would be, for example, chalk, glass fibers or plaster of Paris.
The invention is further illustrated, but is not intended to be limited by the following examples in which all parts and percentages are by weight unless otherwise specified.
EXAMPLES
Example 1
A strip of bandage gauze made of bleached cotton 12 cm in width and 4 m in length and having a weight of 31 g/m 2 and a thread count of 11 threads per cm in the longitudinal direction and 8 threads per cm in the transverse direction of the woven fabric is impregnated with 24 g of an isocyanate prepolymer obtained from (a) a phosgenation product of an aniline-formaldehyde condensate having an isocyanate group content of about 30% by weight and a viscosity of 200 cP at 25° C. and (b) a trihydroxypolyether obtained by propoxylation of triethanolamine and having an OH number of 146 and a viscosity of 1200 cP/25° C. in a ratio by weight of a:b=3:1 (tertiary N: 0.3% by weight; free isocyanate group content: 18.7% by weight; viscosity: 21,300 cP at 25° C.) on impregnating rollers with stringent exclusion of atmospheric moisture (dew point below -50° C.), and the impregnated guaze is wound on a core of polyethylene and sealed into a bag made of a three-layered laminate of polyester, aluminum and polyethylene equipped with a sealing edge.
When it has been stored for one week at about 25° C., the impregnated bandaging material is removed from its package, dipped in water at about 25° C. for 3 to 5 seconds and lightly kneaded. It is then wound within 3 minutes around a tubular body having an internal diameter of 42 mm and a length of about 12 cm.
The supporting bandage hardens within a further 5 minutes with slight evolution of heat (maximum surface temperature 35° C.) to form a stable, solid structure which is capable of bearing loads and has excellent bonding between the layers.
Example 2
30 impregnated strips of bandaging material are prepared by the process described in Example 1 and tested for use after storage at about 25° C. for 3, 6 and 9 months. In the bending test (width of unsupported material 40 mm, maximum bending load 50 kp), the test samples obtained as described in Example 1 show a maximum deviation of the deformation due to load of ±10%, which is within the range of deviations due to manufacture found in such hand finished test samples. No fracture of the test samples under load occurred up to the maximum load.
Example 3
The process described in Example 1 was repeated but instead of the 4 m long strip of bandage gauze, a 2 m long strip of warp knitted fabric (width 10 cm) made of a mixed yarn of 67% polyester fibers and 33% cotton fibers and having a weight of 97 g/m 2 and a thread count of 4 threads per cm in the longitudinal direction and 10 threads per cm in the transverse direction was used. The ratio by weight of the isocyanate prepolymer described in Example 1 to the weight of fabric was 1.4:1. A sample prepared by the process according to Example 1 hardened within 6 to 7 minutes and in the mechanical test it showed the same rigidity as a sample produced from twice the length of fabric by the method described in Example 1.
Example 4
A strip of bandage guaze 12 cm in width produced from a mixed yarn of 40% cotton and 60% viscose and weighing 30 g/m 2 and having a thread count of 12 threads per cm in the warp and 8 threads per cm in the weft is impregnated with 25 g of the isocyanate prepolymer described in Example 1 in the form of a solution in methylene chloride (ratio by weight of prepolymer/solvent=1/1) under moisture free conditions, and the solvent was removed by an oil pump vacuum. The resin impregnated bandaging material was packaged as in Example 1 and stored for about one month at about 25° C. The package was opened at the end of this time and a test sample is produced as in Example 1. The setting time and strength of the sample are similar to those of the sample obtained in Example 1.
Example 5
45 strips of bandaging material were prepared and packaged as in Example 4. Over a period of three months, the strips were used in clinical tests for preparing surgical supporting bandages or casts on the upper and lower extremities of patients with fractures of the long bones. The dressing used under the bandages was a polyester fleece or cotton wadding about 0.4 cm in thickness. The bandages hardened within a maximum of 10 minutes and were load bearing after only one hour.
The supporting bandages could be applied without soiling the surgery and could be exactly modelled. There was no need to remove the bandages for X-ray examination of the fracture since they caused no shadow on X-ray films. They were radiologically practically invisible.
The bandages were removed with the aid of the usual tools used for plaster casts (plaster shears, oscillating saw). The bandages without exception produced very little dust compared with plaster casts. All the patients found the very low weight of the bandages and the porosity to air extremely pleasant.
The condition of the skin areas which had been covered by the bandages was extremely satisfactory in all cases. No allergic reactions were observed.
Example 6
Strips of woven glass fiber fabric 1 m in length and about 10 cm in width and weighing 285 g/m 2 and having a thread count of 20 threads per cm in the warp and 6 threads per cm in the weft were impregnated with the isocyanate prepolymer described in Example 1 by the process according to Example 4. The quantity of prepolymer applied was 150 g/m 2 . Tubular test samples having the dimensions described in Example 1 were prepared by hand as in Example 1 and tested for bending. No fracture could be produced under a load of 50 kp. The maximum sagging obtained under the test conditions of Example 2 was 4 mm.
Example 7
A strip of glass silk fabric 2.3 m in length and 10 cm in width and having a thread count of 20 threads per cm in the warp and 6 threads per cm in the weft and weighing 290 g/m 2 was impregnated by the process described in Example 4 with 69 g of the prepolymer described in Example 1. The impregnated length of fabric was then folded to a length of about 8 cm and packed airtightly into a tin under exclusion of moisture. When the packaging material was removed from its package after several months of storage, it showed no signs of change. It was placed in water at a temperature of 20° C. for about 2 minutes and then spread out on a polyethylene foil to form six layers of equal length placed above one another. After about 3 minutes, the viscosity of the PU resin applied to the fabric increased sharply with moderate rise in temperature. While in this condition, the stack of bandaging material was applied to the forearm of a patient to form a supporting half shell for the wrist and forearm. The hardening reaction was substantially completed after a further two minutes. The dimensionally stable half shell was then placed inside a circular stiffening bandage for added rigidity.
Example 8
Strips of a stitched non-woven of polyester fibers measuring 10×25 cm in width and length and about 4 mm in height and weighing 820 g/m 2 were impregnated with 240% by weight, based on the weight of the textile, of the PU prepolymer described in Example 1 by the method of solution impregnation described in Example 4. The impregnated strips were dipped in water at a temperature of about 40° C. for about one minute and used immediately for modelling a half shell on a human forearm after the usual application of a dressing to the skin. The bandage had hardened substantially completely after about 5 minutes.
The case obtained in this way was perforated mechanically to make it permeable to air and used as surgical forearm splint.
Example 9
The strips of bandaging material specified in Example 3 were impregnated by the method of solution impregnation described in Example 4 with an isocyanate groups containing prepolymer obtained from (a) a phosgenation product of an aniline-formaldehyde condensate having an isocyanate group content of about 30% by weight and a viscosity of 100 cP at 25° C. and (b) a polyether obtained by propoxylation of ethylene diamine and having a molecular weight of 1140 and an OH number of 196, in proportions by weight of a:b=4:1 (viscosity of the prepolymer 15,400 cP at 25° C.; free isocyanate content 20.4% by weight, tertiary nitrogen: 0.24% by weight).
When the bandaging material was made up into test samples as described in Example 1, they hardened within about 8 minutes. In the mechanical tests, the samples were found to have exceptionally high impact strengths.
Example 10
Numerous strips of bandaging material were prepared for use as stiffening bandages by the process according to Example 4 and made up into test samples. The samples were stored in groups of 4 (length of fabric 4 m, width of fabric 10 cm) in 1 liter of twice distilled water for 4 hours at 23° C. and 2 hours at 50° C., and the aqueous extracts were examined for their carbon content after filtration. The carbon content was found to be between about 0.002 and 0.007% by weight, showing that the hardened bandages release practically no organic material when moist.
Example 11
Strips of bandaging material conforming to the specifications given in claim 1 were prepared by the process according to Example 1 and made up into test samples as described. Some of the test samples were tested for their flexural strength and breaking strength after about 24 hours. Another portion of the test samples were stored in water at about 20° C. for 2 hours, dried and then tested under loads of up to a maximum of 50 kp for comparison with the test samples mentioned above. The decrease in strength after storage in water was insignificant within the limits of statistical error. This indicates that showers or baths can be taken when wearing the supporting bandage according to the invention.
Example 12
A cotton bandage gauze 12 cm in width conforming to the specifications given in Example 1 was impregnated by the process described in Example 4 with an isocyanate prepolymer obtained from a mixture of 4,4'-diphenylmethane diisocyanate and 2,4'-diphenylmethane diisocyanate (proportions by weight 1:1.5) and a propoxylated triethanolamine having a molecular weight of about 1200 and an OH number of 146 in proportions by weight of the diisocyanates to the propoxylated triethanolamine of 1.25:1, in a manner analogous to the process of Example 1. The prepolymer contained about 12% of free isocyanate groups and had a viscosity of 19,000 cP at 25° C.
Test samples prepared in a manner analogous to Example 1 were completely hardened after only 5 minutes, had sufficient mechanical strength for surgical use and were highly permeable to air and moisture.
Example 13
A strip of bandaging fabric 10 cm in width and 4 m in length manufactured from a mixed yarn of 65% polyester and 35% cotton and having a weight of 60 g/m 2 and a thread count of 12 threads per cm in the warp and 8 double threads per cm in the weft was impregnated with about 160% by weight, based on the weight of the textile, of the isocyanate prepolymer described in Example 12, and sealed into a polyethylene coated aluminum bag with sealed edge. After 9 months in storage at an average temperature of 23° C., the bandaging fabric was used for preparing a test sample as in Example 1. When the impregnated fabric was made up into a test sample and mechanically tested, no significant differences in properties were found between test samples of freshly prepared bandaging material and the above described test samples.
Example 14
Strips of tubular knitted fabric 50 cm in length and 10.5 cm in width when laid out flat made of untextured polyacrylonitrile yarn and having an open mesh of about 1 mm 2 and a weight of 238 g/m 2 (when double) were impregnated each with 12 g of the prepolymer described in Example 1 by the method according to Example 4 and made up into test samples of the kind described in Example 1, using the tubes as double layered bandaging fabric. The hardening time was approximately 7 minutes. The test samples had good breathing activity and excellent bonding between the layers so that the hardened bandages could not be unwound without destroying the textile structure.
Example 15
Numerous strips of bandaging fabric 4 m in length conforming to the specifications given in Example 13 were impregnated with the PU prepolymer described in Example 1 by the method according to Example 4. The quantities of prepolymer applied were 104, 156 and 208% by weight, based on the weight of the dry, unimpregnated fabric.
The base of a transparent tube 30 cm in length and 0.9 cm in diameter was glued to the test samples and the outflow time of a water column 10 cm in height was measured.
The outflow time through fabrics which had been impregnated with 104% by weight and 156% by weight was approximately 3 seconds; when the fabrics were impregnated with 208% by weight, the outflow time increased to approximately 10 minutes.
This test demonstrates the excellent breathing activity of bandaging fabrics which have been impregnated with the optimum amount of 150 to 160% by weight. In the case of the least impregnated fabric (104%), the test sample was destroyed in the bending test under a load of only 35 kp while more highly impregnated test samples remained completely intact under a load of 50 kp and were deformed by only about 2 mm.
Example 16
(Comparison Example)
Numerous strips of bandage gauze described in Example 4 were impregnated each with 25 g of trimeric hexamethylene diisocyanate by the method indicated in Example 4. The impregnated bandaging fabrics were kneaded for 10 seconds in water at 20° C. and made up into tubular test samples having a length of about 12 cm and an internal diameter of 42 mm. The time required for complete hardening at about 23° C. was about 48 hours.
In another test series, 0.3% by weight of tertiary nitrogen in the form of N,N-dimethylaniline was added as activator to the polyisocyanate. The test samples obtained in this series showed no significant reduction in the hardening time but had an unpleasant odor due to free amine.
In another test series, N,N'-dimethylaminoethane was used as activator instead of N,N-dimethylaniline. Test samples prepared from the bandaging fabrics in this series did not harden significantly more rapidly than the starting material. These were also found to have an unpleasant odor.
EXAMPLE 17
(Comparison Example)
Strips of bandage gauze confirming to the specification given in Example 4 were impregnated with an isocyanate prepolymer of (a) a phosgenation product of an aniline-formaldehyde condensate having an isocyanate group content of about 30% by weight and a viscosity of 100 cP at 25° C. and (b) a polypropylene glycol polyether which had been started with moist glycerol and had an OH number of 159, a molecular weight of 920 and a functionality of 2.62 by the method described in Example 4. The ratio by weight of a:b was 3:1. The prepolymer was found to have a viscosity of 12,600 cP at 25° C. and to contain 20.4% by weight of free isocyanate groups.
After storage in sealed polyethylene-aluminium-polyester bags, the strips of bandaging fabric were made up into test samples by the method described in Example 1 and their hardening time was determined. This was in all cases more than 45 minutes, which indicated that the prepolymer system free from activator was unsuitable for use as surgical supporting bandage or cast.
Although the invention has been described in detail for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | The present invention relates to a process for producing a supporting bandage for surgical or veterinary surgical use comprising covering the part of the body which is required to be supported with an air-permeable dressing and then applying a self-hardening bandage over this dressing, characterized in that the self-hardening bandage comprise strips of air-permeable, flexible fabric coated and/or impregnated with about 50 to 300% by weight, based on the uncoated fabric, of an isocyanate prepolymer which contains free isocyanate groups and is based on aromatic polyisocyanates and polyols containing tertiary amino nitrogen atoms, the prepolymer having an isocyanate content of about 5 to 30% by weight and a tertiary amino nitrogen content of about 0.05 to 2.5% by weight, the coated fabric being soaked with water immediately before it is applied. The present invention also relates to lengths of bandaging material which comprise pieces of flexible, air-permeable fabric coated with about 50 to 300% by weight, based on the uncoated fabric, of an isocyanate prepolymer based on aromatic polyisocyanates and polyols containing tertiary amino nitrogen atoms, the isocyanate prepolymer having an isocyanate group content of about 5 to 30% by weight and a tertiary amino nitrogen content of about 0.05 to 2.5% by weight. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of P.C.T. application PCT/EP01/15153, filed Dec. 20, 2001 by inventor Hans Kragl, titled, “Coupling Arrangement for Optically Coupling an Optical Waveguide Comprising an Electro-optical or Opto-electrical Semiconductor Converter,” and claims priority to German application DE 100 65 624.2, filed Dec. 29, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The communications industry's conversion from electrical to optical communications engineering has accelerated the demand for and the requirements of optical transceiver modules in all fields of data transmission. Both high-rate optical transmission technology on long-distance lines via glass fibers, as well as optical transmission technology with comparatively lower data rates via relatively “thick” polymer fibers or hybrid glass/polymer fibers (so-called HCS fibers), are increasingly used. In the former case, hundreds of kilometers are typical, whereas only some 10 to 100 m are transmitted at data rates of a maximum of some 100 MB/s in the latter case. Systems of this second type are used within mobile means (motor vehicles, railway, airplanes) or for the so-called in-house linkage, i.e., within a building, such as for the data connection of all multi-media devices existing in a house (TV, internet, video recorder, audio devices, PCs, etc.). For cost reasons these networks do often not operate with laser diodes but instead are operated using simple surface light emitting light diodes (LEDs). For coupling such an LED to a relatively thick optical waveguide, a very inexpensive structure may be used, although significant precision is still required. An electro-optical module that contains the coupling point from the LED transmitter to the waveguide or from the photo diode receiver to the optical waveguide, is called optical transceiver.
2. Technical Background of the Invention
For a coupling of a surface-emitting LED and a relatively thick polymer fiber optical waveguide, generally two constructions exist, namely constructions without beam formation and constructions with beam formation. It is noted by way of non-limiting example that typical dimensions may be 250×250 μm 2 for the LED and 1000 μm diameter for the polymer fibers. Beam formation means that some or all of the light rays emitted by the LED are changed in their propagation through lenses or curved mirrors so that a higher light portion can be coupled into the optical waveguide compared to a case where such measures are not taken. In any case, the alignment of the optical waveguide to the LED requires a high precision in view of the relevant dimensions, such as those given by example above.
One approach for this type of coupling is presented by the MicroMID technology which has recently become known. An example of this technology is described in DE 198 51 265 A1. Here, a micro-structured plastic support is used, the shape of the support being capable of being designed very flexibly. The manufacture of a reflector for the LED while simultaneously manufacturing an electronic circuit on the substrate is possible. An adjustment of the optical waveguide is implemented by means of a three-dimensional structure formed on the substrate. However, the high equipment costs of this technology are disadvantageous so that only the manufacture of large numbers of pieces justifies their use. Finally, since in the MicroMID technology the electronic circuit of the transceiver must be imaged in conformity with the injection molding tool, the technology is cumbersome in attempting to adapt to client-specific variants of the circuit. An adjustment is implemented between LED and optical waveguide in a structure ordered from LED to micro-structured printed circuit board to fiber plate to optical waveguide. Publications with respect to the MicroMID process can be found in Kragl, H. et. al.: “MICROMID: A low cost fabrication technology for polymer fiber transceiver modules”, POF Conference 2000, Boston, and in Kragl, H. et. al.: “Microstructured three-dimensional printed circuit boards: a novel fabrication technology for optical transceiver modules”, Proc. MicroTec 2000 Conference, Hannover.
For coupling an optical fiber and an LED, a coupling device where the LED optically opposes the end face of the fiber is known from DE 38 34 395 C2. The LED is fixedly connected to a support and is electrically connected by a bond wire to a conductor formed on the support. A coupling element is connected to the support and receives the end portion of the optical fiber. The LED is directly arranged on a planar electrode, namely a so-called lead frame. The coupling element receives the end of an optical fiber, the optical fiber having a free end face to be opposed to the LED, the coupling element having a type of a column which comprises sections matching with the conductors of the lead frame, so that these conductors are received in the sections. The LED is attached on the one conductor, whereas the other conductor is connected to the LED through a bond wire. In order to attach the LED on the lead frame in a highly precise manner, an optical pattern detection process is required, which proceeds so slowly that a use in mass production must be ruled out. If, however, the placing of the semiconductor element is left to a mass die bonder, a tolerance in the range of 50 μm to 70 μm must be accepted. When attaching the coupling element to the lead frame, there is some likelihood that the lead frame will be damaged, and the bond wire can be damaged even more easily. If this is to be avoided, additional tolerances must be taken into consideration so that, in the case of mass production, an overall tolerance of 200 μm must be taken into consideration.
A coupling arrangement for coupling an optical waveguide to an opto-electronic device, e.g. a light emitting diode or a photo diode, is known from EP 0 611 975 A1. This coupling arrangement uses a cuboid base member made of a silicon monocrystal and a cuboid cover member also made of a silicon monocrystal, the cover member planarly lying thereon. A V-shaped groove for receiving the uncovered end of an optical waveguide is formed in the base member, the groove ending in a reflecting, oblique surface inclined by 45°. On the end of the groove opposite to the oblique surface, this groove opens into a V-shaped groove of a larger cross section, which provides for the accommodation of the covered section of the optical waveguide and which extends up to an edge of the base member. In the area over the oblique surface, the opto-electronic device is attached on the base member. The cover member comprises on its side facing the base member a V-shaped groove whose cross section corresponds to the larger cross section of the V-shaped groove in the base member. In the area in which the semiconductor component is located, the cover member has a recess, which offers space for the accommodation of the opto-electronic device. The orientation of the base member and the cover member on each other is carried out by means of two spheres, which are received in matching pyramid-shaped recesses formed in the base member and in the cover member. The cover member has two openings through which a casting compound can be filled into the area of the electro-optical device and the covered optical waveguide. This publication does not provide any clue regarding how the opto-electronic device is aligned on the reflecting oblique surface to obtain the desired accuracy that is defined by +/−1 μm.
A laser-glass fiber coupling and a method of establishing such a coupling connection is known from DE 33 39 189 A1. In this coupling arrangement, the coupling point is encapsuled with a curing resin mass to obtain optically favorable relations and to obtain a device for coupling a semiconductor and a fiber optical waveguide that is insensitive against environmental influences.
An optical coupling between an optical semiconductor and a fiber optical waveguide is known from U.S. Pat. No. 6,004,046. This arrangement uses a paraboloid mirror, not only bundling the light rays emitted by the optical semiconductor, but also at the same time deflecting them by 90°.
SUMMARY OF THE INVENTION
An object of the invention is to provide a coupling arrangement for optically coupling an end of an optical waveguide with at least one electro-optical or opto-electrical element and a method suitable for the manufacture thereof, so that a light-emitting and/or light-receiving semiconductor component may be aligned in a highly precise alignment achieved in a technically simple manner.
According to an aspect of the invention, an optical coupler for optically coupling an optical waveguide, having an end portion, with at least one electro-optical or opto-electrical semiconductor element that optically opposes an end face of the end portion, the optical waveguide being insertable into the optical coupler, includes: a support having at least one conductor formed thereon; at least one semiconductor element disposed to optically oppose the end face of the waveguide, the semiconductor element being fixedly connected to the support; a bond wire electrically connecting the semiconductor element to the conductor; a coupling element connected to the support and adapted to receive the end portion of the optical waveguide; a submount having a top and bottom side, the submount being fixed at its bottom side to the support, the submount having on its top side an adjustment structure in the form of a recess adapted for precise adjustment of the semiconductor element; and a transparent adhesive, wherein the semiconductor element is fixed in a thermally conductive manner to the submount, the coupling element is positively aligned on the submount, at least that conductor of the support onto which the bond wire is connected is electrically isolated from the submount, and wherein a space, between the semiconductor element and the end face of an optical waveguide to be inserted, is adapted to be filled by the transparent adhesive.
According to another aspect of the present invention, a coupling arrangement includes: a waveguide having an end portion including an end face; a support having at least one conductor formed thereon; at least one semiconductor element, the semiconductor element being one of an electro-optical type and an opto-electrical type, the semiconductor element being disposed to optically oppose the end face of the waveguide, the semiconductor element being fixedly connected to the support; a bond wire electrically connecting the semiconductor element to the conductor; a coupling element connected to the support and adapted to receive the end portion of the waveguide; a submount having a top and bottom side, the submount being fixed at its bottom side to the support, the submount having on its top side an adjustment structure in the form of a recess adapted for precise adjustment of the semiconductor element; and a transparent adhesive, wherein the semiconductor element is fixed in a thermally conductive manner to the submount, the coupling element is positively aligned on the submount, at least that conductor of the support onto which the bond wire is connected is electrically isolated from the submount, and wherein a space between the semiconductor element and the end face of the waveguide is filled by the transparent adhesive.
In various embodiments of the invention, the coupling arrangement may be adapted so that the end portion of the waveguide is able to be inserted into the recess of the submount without tolerance. An optical path may be defined for the semiconductor element, and the coupling arrangement may include a beam-forming metallic reflector surrounding the optical path of the semiconductor element, the beam-forming metallic reflector being arranged between the semiconductor element and the end face of the waveguide. The reflector may include a metal layer disposed on surfaces of the submount surrounding the semiconductor element. The reflector may include a metal layer formed on a wall of the coupling element between the end face of the waveguide and an end portion of the coupling element adjoining the semiconductor element. The reflector may include a metal layer formed on a wall of the coupling element between the end face of the waveguide and an end portion of the coupling element adjoining the semiconductor element. The coupling arrangement may also include at least one cutout for accommodating at least one bond wire extending from the semiconductor element, the cutout being formed in at least one of the coupling element and the submount. In an optical coupling arrangement, the optical path may be further defined as being between the semiconductor element and the end face of the waveguide, and the reflector may be formed to deflect the optical path by 90°. The waveguide may include a glass fiber. The end portion of the waveguide may be inserted so that it adjoins the semiconductor element, and the end portion may be adapted to be held by a highly precise ferrule receivably disposed in the recess formed in the submount. The submount may be electrically conductive, the semiconductor element may be electrically connected to the submount, and the bottom side of the submount may be electrically connected to the support. These exemplary embodiments, those discussed below, and others may be employed for obtaining various advantages.
In various additional exemplary embodiments, the invention provides an arrangement for optically coupling an optical semiconductor element, e.g. a transmission diode, to an optical waveguide having a submount on which the semiconductor element is positioned. The submount and the coupling element may contain beam-forming reflectors. The submount may be directly set onto a support, which may, for example, be a conventional printed circuit board, a TO housing, a lead frame, or a Molded Interconnect Device (MID) support. At least one bond wire is guided from the semiconductor element onto the support, which, if it is not conductive itself, is provided with a conductor to which the bond wire can be connected. An adjustment of the optical waveguide with respect to the semiconductor element may be implemented by adjusting the optical waveguide at the submount, either directly or by means of a separate coupling element, which in turn may be aligned precisely onto the semiconductor element by interlocking connection with the submount.
The submount may be made of a metal or of plastic with a surface metallization and it may directly establish the electrical connection between the support and an electrode of the semiconductor component. It may also be made of an insulating material, such as microstructured ceramics. In any case, is it favorable if the submount is heat-conductive in order to favorably discharge the heat emitted by the semiconductor component. It is evident that if the submount does not serve for the electrical connection to one of the electrodes of the semiconductor component, the semiconductor component may alternately be electrically connected by means of at least two bond wires.
The coupling element may be particularly used for coupling fiber conductors and in that case preferably consists of a thermoplastically-made plastic body with a cylindrical bore in an upper, first segment, which may taper in a second, lower segment in the form similar to a paraboloid of rotation. In such a case, the inner wall of the paraboloid may then advantageously be coated in a reflecting way, e.g., by coating with a thin silver layer. As an alternative, the coupling element may be formed as a massive metal member, e.g., made of silver, aluminum or copper, the latter preferably being formed with a reflecting coating made by deep drawing. In the case of higher volume manufacturing runs, the deep drawing of parts of soft metals may be more inexpensive than the injection molding of such parts.
Regarding the above-mentioned exemplary embodiment having a paraboloid form, a recess may be formed on the base point of the paraboloid, the edge contour of the recess being substantially congruent with the outer contour of the submount. Such a structure may be used to positively accommodate the submount and to thereby align the coupling element at the submount. Moreover, it may have at least one recess for receiving one or several bond wires, the latter being used, for example, when the submount is used for insulating as noted above.
In another exemplary aspect of the present invention, an assembly of a coupling device may include the following steps. A first step may include attaching a submount on a support having a surface suitable for wire bonding at a position provided for this purpose. The submount, for example, may be soldered or adhered-on with conductive adhesive. An attachment may be made by use of a projection (e.g., a pin) formed on the submount on the side opposing the semiconductor component, the projection being seated and secured in a recess or hole. The semiconductor element may be attached onto the submount by use of die bonding where, depending on the required precision, an adjustment structure arranged in the submount may be used. A second step may include electrically connecting the semiconductor component to a conductor on the support by wire bonding starting out from the semiconductor component. When using a coupling element, the coupling element may be set onto the submount and aligned in a manner that allows the semiconductor component to look through an opening of the coupling element provided for this purpose. The coupling element may have an adjustment structure allowing it to be precisely fit onto the submount, thereby exactly positioning the semiconductor component. Of course, damage of the bond wire or the bond wires must not occur during adjustment. In order to avoid the danger of a bond wire damage, the submount may also have a lateral bond wire protection or any other suitable manner of protection. In a preferred embodiment, when the coupling element is correctly seated on the support, it is non-detachable and is preferably impervious to fluids that may be present in this position, such as fluids used for manufacturing the support and the submount, e.g., by adhesion. A third step may include inserting a transparent adhesive into the submount, such as by filling. This may be achieved, for example, by filling the submount the fiber guide hole of the coupling element, the adhesive also flowing into the section in which the bond wire extends, thereby also enclosing the bond wire there. A fourth step may include inserting the optical waveguide so that its end is brought into contact with the adhesive whereby it is adhered to the adhesive that is still soft. If a coupling element is missing, the optical waveguide directly aligns at the submount. If a coupling element is used, the alignment at the submount may be carried out by use of the coupling element. As an alternative, it is also possible to use a plug of a non-adhesive material instead of using the optical waveguide, such a plug staying at its position until the adhesive has cured and being then replaced by the optical waveguide. This alternative allows the optical waveguide to be exchanged at a later time.
In a preferred method of assembly, if a suitable projection is being provided in the coupling element or at the submount (for example, when an annular shoulder is provided in the coupling element) where the end face of the optical waveguide abuts when being inserted, a significant improvement may be achieved in assembly, since the exact, axial position of the optical waveguide no longer need to be observed. This also represents a substantial improvement compared to the MicroMID technology, which does not provide a passive, axial adjustment for the optical waveguide. When inserting the optical waveguide or the plug, excessive adhesive may escape past the optical waveguide or plug. As an alternative, a vent hole or other means suitable from the field of casting technology may be provided, which takes up excessive adhesive that is displaced from the optical waveguide or plug when the optical waveguide or plug is inserted.
The submount and/or the coupling element may be provided with optical reflectors by suitable shaping and coating.
A circuit arrangement used for operating the semiconductor element (e.g., LED and/or a photo detector to be mounted in the same manner) may directly be attached in direct proximity of the semiconductor component on the support, which may for instance be a double-sided printed circuit board. For example, the circuit arrangement may be attached on the back side of the printed circuit board. Thus, for example, a pre-amplifier for a photo diode (PD) may be located only 1 mm away from the PD. EMC problems therefore may be prevented. Since the printed circuit board is typically manufactured in a conventional standard industrial process, the wiring provided thereon may be implemented in any complex manner. High-quality printed circuit boards, such as those made using ceramics or printed circuit boards made of Teflon, particularly necessary for extremely high-frequency applications, may be used.
In order to obtain a complete transceiver system, a coupling element with a flexible printed circuit board may be fit into an electric plug system and the optical waveguide ends may be connected via a splice or plug system. Alternatively, the coupling element with a rigid printed circuit board may be directly inserted into a female plug, wherein the plug contacts are realized (e.g., by contacts on the printed circuit board).
The present inventor has achieved improvements in optical coupling arrangements. Contrary to the known MicroMID process, the optical waveguide of the present invention is not adjusted at the support (e.g., printed circuit board) but at the submount carrying the semiconductor element, this being done directly or by use of the above-mentioned coupling element. If the submount is a metallic or metallized body, it typically does not have the power guidance demanded from a support (e.g., printed circuit board) for both electrical terminal conductors, but only for one of them. On the other hand, by adjusting via a submount, advantages result compared to the MicroMID technology.
As a result of the present invention, a printed circuit board to be newly designed for a given product application does not have to be realized in the expensive MicroMID process having high equipment costs. In addition, the adaptation of the outer electronic connection on a standard printed circuit board requires substantially shorter development times and is less expensive.
By galvanically applying a copper layer having a thickness of 25 to 50 μm on the MicroMID printed circuit board, the micro-structured plastic surface of the MicroMID substrate substantially loses precision. By comparison, a micro-structured submount according to the invention may have highly precise adjustment structures on its surface and may include a massive or sheet-like metal or metallized plastic element. The invention thus may provide for a significantly higher precision compared to MicroMID.
The structures on the micro-structured submount that can be used for adjusting the optical semiconductor element do not necessarily have to be formed with significant de-formation bevels, since they are not required to be manufactured in a multi imaging process in metal and plastics. Thus, vertical structures are also possible. If a micro-structured submount in the shape of a sheet having thickness of approximately 100 μm is used, the opening for the semiconductor element can easily be expanded by bending the sheet so that the semiconductor element can be inserted. Subsequently, the fine centering of the semiconductor element may take place during the relief phase.
On a metallic, micro-structured submount, the electro-optical semiconductor element may also be soldered instead of only being adhered as in MicroMID. This leads to a thermally and electrically improved connection between the semiconductor component and the submount, which is particularly important when the semiconductor component is a LED having a bad efficiency, whose lost heat must be dissipated.
In MicroMID technology and in the classic lead frame technology, the entire metal surface of the substrate or of the lead frame may be wire bonded. A surface coating suitable for this purpose is expensive (e.g., palladium support) and particularly has the disadvantage that the optical reflection behavior of the layer is not optimal. A non-bondable silver layer would have a better reflection factor for many applications but it cannot typically be used for the above-mentioned reason. Since, however, it is generally not necessary in the present invention to wire-bond on the submount, this submount can be provided with an ideally reflecting coating, which does not have to take bondability into consideration.
If the substrate of the semiconductor element is non-conductive, so that a direct electrical contacting of the same at the submount is not possible, an electrical connection between the semiconductor component and the support may be implemented, while the other electrical connection between the semiconductor component and the support may be implemented directly on the support by means of wire bonding.
In additional embodiments of the invention, a number of variants are possible and sensible, and may have an advantageous effect independent of the required precision and/or independent of the irradiation properties of the transmitting diode.
The following non-limiting examples illustrate variations for a coupling arrangement according to the invention. For example, a waveguide layer may be formed of a planar plate and a curved plate, a waveguide layer may be formed as a tube, a plurality of semiconductor elements may be optically coupled to the waveguide layer, semiconductor elements may be transmission diodes of different light emission wavelengths, a semiconductor element may be electrically connected to the submount by a use of die bonding, a beam-forming metallic reflector may be formed to surround the optical path and may be arranged between the semiconductor element and the end face of the optical waveguide, the reflector may be formed as a metal layer on the surfaces of the submount surrounding the semiconductor element, the reflector may be formed as a metal layer on a wall of the coupling element between the end face of the optical waveguide and an end portion of the coupling element adjoining the semiconductor element, at least one recess for accommodating a bond wire connecting the semiconductor element with a circuit may be formed in the coupling element, at lest one recess for receiving a bond wire connecting the semiconductor element with a circuit may be formed on the submount, the reflector may be formed to deflect the optical path between the semiconductor element and the end face of the optical waveguide by 90°, the submount (1) may be a lathe work, the submount may be a punched member, the coupling element may be a deep drawn member made of a soft metal, the optical waveguide may be a glass fiber having its end portion adjoining the semiconductor element held by a highly precise ferrule, the ferrule may be adapted to be inserted into the coupling element, the ferrule may form the coupling element and an end of the ferrule may be received by a recess formed in the submount, and an electro-optical transmission converter and an opto-electrical receiver converter may be attached on the submount so that they are shielded from each other and so that the converters optically oppose the same optical waveguide.
Many variations may likewise be used in forming a coupling arrangement according to the present invention. Some non-limiting examples of methods that may be used in forming the coupling arrangement include: manufacturing the submount by a micro-structuring method that includes applying a thin conductive coating on the surface of a micro-structured plastic body, removing projecting sections from this coating by surface polishing, applying metal on the remaining conductive coated surfaces by use of galvanization, and removing this metal structure from the plastic body; a method of manufacturing a coupling arrangement, for optically coupling an end of an optical waveguide with at least one electro-optical or opto-electrical semiconductor element that optically opposes the end face of the optical waveguide, may include the steps of (1) using a two-piece tool to form a cavity that images the coupling element receiving the end portion of the optical fiber, the tool having one part formed as a negative image (e.g., impression) of a submount receiving the semiconductor converter, (2) forming a molded body by injecting a plastic material into the cavity, the molded body being shaped later, (3) metallizing an entire surface of the molded body on its side negatively imaging the submount, (4) removing the metallization by brushing on all projecting portions; (5) increasing the remaining metallization by galvanic metal deposition, (6) separating the metal structure formed on the molded body from the molded body, (7) providing the resulting molded body with a light inlet opening on the bottom of a recess that is determined for receiving the optical waveguide, and setting the molded body onto the submount formed as a coupling element receiving an optical waveguide; a method as just described for forming a coupling arrangement, the method including removing ridges from the metal structure after the galvanizing, and optionally including metallizing the recess, determined for receiving the optical waveguide, in its area adjoining the bottom; a method, for optically coupling a fiber optical waveguide with an electro-optical or opto-electrical semiconductor component mounted on a submount, may include aligning the submount with a coupling element having a bore aligned onto the semiconductor component, filling the space above the semiconductor component and above part of the bore with a transparent adhesive, then inserting the fiber optical waveguide into the bore and curing the adhesive in contact with the end face of the fiber optical waveguide; and, a method of optically coupling the end of a fiber optical waveguide to an electro-optical or opto-electrical semiconductor component mounted on a submount, at which a coupling element is aligned, the method including aligning a bore of the coupling element with the semiconductor component, filling a space above the semiconductor component and part of the bore with a transparent adhesive, then inserting a plug of a non-adhesive material into the bore and curing the adhesive in contact with the end face of the plug, removing the plug from the bore, and then inserting the end of the fiber optical waveguide into the bore.
Any reference herein to a LED or transmission diode as being a semiconductor element shall not be understood in a restrictive way but only as an example, since the present invention may also be used in a same or similar manner in connection with light-receiving semiconductors such as photo diodes, photo transistors or photo resistors.
The foregoing summary is non-limiting. The scope of the present invention is defined only by the appended claims. A preferred embodiment of the present invention will now be described in detail with reference to the drawing figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIGS. 1A and 1B respectively show in a longitudinal section and in top plan view a structure with a parabolic mirror in the coupling element in a first exemplary embodiment of the present invention.
FIGS. 2A and 2B respectively show in a longitudinal section and in top plan view a submount with a parabolic mirror and a milled slot for receiving a bond wire in a second exemplary embodiment of the present invention.
FIGS. 3A and 3B respectively show in a longitudinal section and in top plan view a submount with a parabolic mirror and a bore for receiving a bond wire as an exemplary alternative to the second exemplary embodiment shown in FIGS. 2A and 2B.
FIG. 4 shows in a longitudinal section the second exemplary embodiment according to FIGS. 2A and 2B with a submount with a coupling element adjusted thereon.
FIG. 5 shows in a longitudinal section a submount without a reflector and a coupling element with a reflector adjusted at the submount, in a third exemplary embodiment of the present invention.
FIGS. 6A-6C respectively show in a top plan view and in longitudinal sections a submount formed in micro structure technology in different assembly steps;
FIG. 6D shows in a longitudinal section the arrangement according to FIG. 6C, and FIG. 6E shows a coupling element adapted thereto, in a fourth exemplary embodiment of the present invention.
FIGS. 7A-7E show an injection molding tool and different stages in the manufacturing process of a submount formed in micro structure, according to the fourth exemplary embodiment of the present invention.
FIG. 8 shows the irradiation diagrams of different types of light-emitting semiconductors.
FIGS. 9A and 9B respectively show in a longitudinal section and in top plan view a printed circuit board with several submounts and a common coupling element including the features of the fourth exemplary embodiment of the present invention.
FIG. 10 shows in top plan view a submount formed in micro structure technology for two optical semiconductor chips according to FIGS. 9A and 9B.
FIG. 11 shows a coupling element with a deflection mirror on a micro-structured submount.
FIG. 12 shows a coupling element with a 90° deflection obtained by use of a flexible printed circuit board.
FIG. 13 shows a glass fiber adjustment obtained by use of a highly precise ferrule in a fifth exemplary embodiment of the present invention.
FIG. 14 shows a ferrule receiving a glass fiber and forming the coupling element itself in a sixth exemplary embodiment of the present invntion.
FIGS. 15A and 15B respectively show in longitudinal section and in top plan view a submount that carries a transmission and receiving diode with a common optical waveguide, according to a seventh exemplary embodiment of the present invention.
FIG. 16 schematically shows in longitudinal section the manufacture of a fit of coupling element and fiber support complying with high precision demands.
FIG. 17 shows a construction similar to FIG. 15 a with a coupling element made of a transparent plastic material.
FIG. 18 shows a construction with 90° deflection and a coupling element made of a transparent plastic material, in an eighth exemplary embodiment of the present invention.
FIG. 19 shows a submount fixed on a support by use of a pin, with a coupling element formed as a parabolic mirror, in a ninth exemplary embodiment of the present invention.
FIG. 20 shows a submount fixed on a support by use of a pin and formed integrally with a parabolic mirror aligning an optical waveguide, according to a tenth exemplary embodiment of the present invention.
FIG. 21 shows a top plan view onto a lead frame that is suitable for supporting the submount of the ninth and tenth embodiments.
FIG. 22 shows a diagrammatic view of an exemplary embodiment of the present invention with a layered, planar optical waveguide.
FIG. 23 shows a diagrammatic view of an exemplary embodiment of the present invention with a layered, tubular optical waveguide.
DETAILED DESCRIPTION
FIGS. 1A and 1B show an arrangement consisting of a submount 1 , a light emitting diode (hereinafter referred to as LED) 2 attached thereon, and a coupling element 3 , preferably made of plastics, adjusted at the submount 1 . In the present example the submount consists of metal and is attached on a printed circuit board 4 , preferably it is soldered on, and it electrically connects the one electrode of the LED to the electrical circuit comprised on the printed circuit board 4 . The other electrode of the LED is electrically connected to the circuit on the printed circuit board by means of a bond wire 5 . The bond wire 5 is received by a slot 6 in the section of the coupling element 3 surrounding the submount 1 and is thereby protected against damage.
A bore is formed in the coupling element 3 , said bore receiving an optical waveguide 7 , which in this example is an optical fiber. The bore has an annular shoulder 8 at a distance above its lower end at which the end face of the optical waveguide 7 is supported. Below this shoulder 8 , the bore is formed to be parabolic and has a metal coating 19 to reflect the light rays, emitted by the LED and impinging onto the bore wall, into the optical waveguide 7 .
As may be seen, the bore has a cross section in the coupling element 3 at its lower end, which is matched to the cross section of the submount 1 so that the coupling element 3 is centered at the submount 1 .
The space between the end face of the optical waveguide 7 and the LED 2 as well as the slot 6 are filled by a transparent adhesive K, which reaches up to the end of the optical waveguide and which improves the optical coupling between the LED 2 and the optical waveguide 7 . It is evident that when filling in the adhesive K, the slot 6 and the bore of the submount must be closed at the bottom, this being, for example, ensured by the support 4 , not shown in FIG. 4 or FIG. 5 .
As an alternative to the exemplary embodiment of FIG. 1, a plug (not shown) made of a non-adhesive material (e.g., POM, PTFE or a chrome-plated metal pin) may be inserted instead of the optical waveguide 7 into the bore of the coupling element 3 during the manufacture of the arrangement after filling in the transparent adhesive K, the pin then being pulled out of the bore after curing the adhesive K. The optical waveguide 7 can subsequently be plugged into the hole that was formed in this manner and it can optionally also be removed therefrom again.
FIGS. 2-4 show exemplary embodiments having a submount with a reflector (e.g., metal coating 19 ) as a lathe work with a slot 6 (FIG. 2) or bore (FIG. 3) for receiving a bond wire. A detailed explanation is not necessary, since the drawings speak for themselves.
FIG. 4 shows how the coupling element 3 is attached to a submount 1 (e.g., according to exemplary embodiments shown in FIGS. 2A-B and FIGS. 3 A-B), and how the optical waveguide 7 is adjusted. The fiber stop can be recognized as a small annular shoulder 8 on the submount 1 , since the upper edge of the reflector 19 formed thereon has a slightly smaller diameter than the optical waveguide 7 accommodated by the coupling element 3 . The end face of the optical waveguide therefore sits on this shoulder 8 for axially adjusting the fiber.
For certain applications (e.g., in the automotive industry) submounts produced by turning on a lathe may not be sufficiently inexpensive, so that it will be desired to manufacture the member shown in FIGS. 2A-4 by punching or deep drawing. In these processes, the submount 1 may be formed during one working step from a planar sheet in a manner that it obtains the required surface, and at the same time the opening for the bond wire may be punched out.
As an alternative, the reflector 19 may be formed in the coupling element 3 (e.g., FIG. 1 and FIG. 5 ), which is particularly advantageous if the reflector is formed axially with a length so long that it can no longer be formed within the submount in a technically sensible manner. Long reflectors, as shown by example in FIG. 5, are advantageous when using transmission diodes that are irradiating axially closely, such as RCLEDs.
By forming a recess (e.g., round, formed angularly, etc.) on the substrate at a position where the LED shall be positioned, it is possible to provide a passive adjustment device for the semiconductor chip.
In addition it must be noted that punching and deep drawing techniques are manufacturing methods most suitable for the mass production (scale of 1 million and more) for submounts, but the required precision must be ensured. Due to the opening in the submount required for the bond wire, two processing steps are used, which may possibly also be carried out simultaneously, namely shaping of the starting sheet or starting wire (in the case of deep drawing, it is advantageously operated with wire material as semi-finished product, as this does not lead to loss of material) to provide the reflector or the chip adjustment and the adjustment structure for the coupling element, and punching out the hole or slot for the bond wire passing. As an alternative, the hole or the slot may be manufactured by laser cutting. A material suitable for punched submounts may, for example, either be bronze with a high copper proportion (easily deformable, favorable heat conduction) or, in a use analogous to vehicular headlamps, a very pure aluminum alloy (99% Al), which can also easily be deformed, but also silver. A submount made of bronze must galvanically be coated before or after the punching process to obtain a highly gloss finished surface. A submount made of aluminum is subsequently electro-polished which, however, is usually only feasible in the case of very pure grades of aluminum.
The submounts shown in FIGS. 1 to 5 may also be manufactured of a plastic material by thermoplastic molding if this plastic body is subsequently prepared by a metallic coating process in a manner such that the lost heat of the transmission diode can be dissipated and that, if the submount shall contain a reflector, the metal surface is sufficiently reflecting. A coating with approximately 30 μm copper and a subsequent thin silver deposition usually fulfills this requirement. An advantage of this structure is the simple and still highly precise design possibility of the plastic submount.
It is also possible to make the submount of a micro-structured ceramic material, since this material can principally be injection molded.
It is also possible to provide the submount and/or the coupling element with reflectors.
A special advantage of the invention is that the bond wire from the transmission diode to the printed circuit board can be kept extremely short. For frequencies of around 100 MHz, a bond wire with a length of 1 mm is still uncritical. Higher frequencies of more than 1 GHz, as they typically occur in glass fiber lines, require shorter bond wires. The configuration shown in FIGS. 1 to 5 as well as solutions with punched or deep drawn submounts, however, may not meet with the demands on precision for applications in this frequency range. For these applications it is required to manufacture the submounts by use of methods of micro structure technology, which will now be explained with reference to FIGS. 6A-E.
FIG. 6A shows in a top plan view a possible structure for a micro-structured submount 1 . It may be formed of a U-shaped, flat object made of metal. Between the two long legs of the U, as close to the edge as possible, a recess 9 is located, in which the semiconductor element 2 , in the present case an LED, can precisely be accommodated. The micro-structured submount 1 according to FIGS. 6B-C may be adhered or soldered onto the printed circuit board 4 in a manner such that later a bond wire 5 from the LED 2 can be bonded onto the contact 10 of the printed circuit board 4 , this contact being located between the long legs of the U (FIG. 6 D).
Depending on the manufacturing method for the micro-structured submount, this submount may also be formed of a massive metal member (FIG. 6B) or of a sheet having a thickness that is constant at any position (FIG. 6 C). If such a large amount of metal is galvanically deposited onto a thin metal layer on its lower side so that the recesses existing there are filled, and this side is then leveled by brushing, a structure according to FIG. 6A may be obtained. If, however, a thin layer is galvanically deposited onto the metal layer, the result of FIG. 6C may be obtained.
Since the bond wire 5 is located below the outer, U-shaped elevation, it is protected against damage by lateral influence. If the micro-structured submount 1 is made of a thermally well conductive material, such as copper, it forms an excellent heat sink for the lost heat generated by the diode 2 .
FIG. 6E shows how the coupling element 3 can be adjusted at the microstructured submount 1 , when the coupling element 3 has on its rear side the surface structure inverse to the micro-structured submount 1 . However, the LED 2 in this exemplary embodiment cannot reach into the interior of the reflector in the coupling element 3 , since it is surrounded on all sides by the micro-structured submount 1 .
A exemplary method of manufacturing the micro-structured submount and the associated coupling element will now be explained with reference to FIGS. 7A-D.
FIG. 7A shows a two-piece injection molding tool for manufacturing the submount and the matching coupling element. The injection molding tool may include an upper part 11 and a lower part 12 , which are aligned with respect to each other by use of adjustment pins 13 and adjustment bores 14 and which encompass a cavity.
Except for the recess 9 used for the accommodation of the semiconductor chip, the precision of the surface structure of the tool is uncritical, since any ‘error’ is automatically integrated into the coupling element and the micro-structured submount. The main difficulty when making the tool is therefore the precise integration of a rectangular recess 9 (e.g., with a typical 250 μm×250 μm surface) into the lower part 12 of the injection molding tool. If for this purpose (e.g., for cost reasons) galvanic technology shall not be used, two more simple methods can alternatively be used, sink erosion with micro dimensions or precision drilling/milling drilling. The latter method is by far the most inexpensive method, if a forming of the vertical walls during the molding process does not lead to difficulties.
The upper tool member 11 must precisely be adjusted with respect to the lower tool member 12 , which can be accomplished by use of the adjust pins 13 and adjust bores 14 . Then, the enclosed cavity is spouted by plastics thereby forming a plastic body 15 , which may in turn be used as a lost molded core and which is shown in FIG. 7 B.
For the manufacture of the submount, the lower side of this plastic body 15 may be used. In providing this additional functionality for the manufacture of the coupling element, both sides of the plastic body 15 are used.
An exemplary embodiment for manufacturing of the submount is now explained. The entire lower side of the plastic body 15 (FIG. 7 B), manufactured by use of an injection mold, is provided with a thin, electrically conductive layer 16 formed by sputtering, evaporation, or by use of wet-chemical processes (FIG. 7 C). Subsequently, this side is brushed or polished. By this process, the thin metallization is removed on all projecting portions 17 and thus the micro-structure of the later submount is isolated (FIG. 7 D). This step allows the precise limitation of the submount at the “bond wire position”.
A galvanically or chemically depositable metal is applied in an arbitrary layer sequence onto the remaining metal layer 16 . The resultant structure is shown by reference number 16 a in FIG. 7 E. Aspects considered in the metal selection are thermal conductivity, mechanical stiffness, smoothness of the rear side (leveling), and the ability to be soldered and adhered (moistening). For example, nickel and copper are useful candidates. If the rear side is coated with tin, a soldering process of the submount on a printed circuit board is facilitated.
Depending on the leveling character of the galvanic bath used, metallic bulges may disturb the levelness of the rear side of the later submount. In this case, it is also useful to subject the galvanically structured layers on a plastic body to another grinding process and to thereby remove these ridges. If the quality requirements are not too high, a brush machine can also be used for this purpose.
Subsequently, the metal body formed in this way is separated from the plastic body 15 . For this purpose, all plastic-destroying procedures can basically be taken into consideration (e.g., thermal, chemical and with restrictions also mechanical procedures, since the metallic micro-structure may be more easily harmed by such a mechanical process). Preferably, a selective heating of the metallic micro-structures (e.g., by microwave irradiation, high power heating or eddy current heating) beyond the glass transition temperature of the plastic material and a subsequent plastic clearing in a bath of organic solvents, such as an NMP bath can be taken into consideration.
If the metallic micro-structure is to be wire-bondable, it must be coated again especially for this purpose. The micro-structured submount is then ready for being mounted onto a printed circuit board.
Now an exemplary manufacture of the coupling element exactly fitting to this submount will be explained. By use of the mentioned two-piece tool, a plastic body 15 is injection molded, as shown in FIG. 7 B. The recess 18 formed therein for receiving the optical waveguide is metallized in a lower, parabolic portion 19 , to be able to act as a reflector. A simple method for this purpose involves the use of a reductive silver coating with two-component spraying which is known from the manufacture of mirrors and from the jewelry industry. A subsequently applied transparent lacquer may prevent silver migration. For wavelengths in the more remote infrared, gold coating techniques may be applicable.
Two additional manufacturing steps are employed in order for the coupling element to be serviceable. A hole (e.g., FIG. 1) must be worked into the reflector portion 19 . This can be most easily be implemented if the demands on precision are not too high by use of a punching tool, which can precisely be positioned through the recess for the optical waveguide. As an alternative, drilling processes by use of a laser beam are possible.
Before the coupling element 3 can be set onto the micro-structured submount 1 , those portions 6 of the plastic body that are occupied by the electronic or electrical elements (e.g., LED, bond wire, circuit etc.) must roughly be removed. This may be implemented in the case of small numbers of pieces by drilling or milling. See in this respect the examples of FIGS. 1-5. In the case of larger numbers of pieces, the tool may be modified accordingly.
The submount and the coupling element, which are manufactured according to the above-mentioned method, fit onto each other with an extremely high precision. Their joining surfaces are perfectly inverse with respect to each other, since they originate from an identical reproducible geometric surface, i.e., the surface of the plastic body shown, for example, in FIG. 7 b.
A variety of different transmission diodes exist, wherein each diode emits a characteristic radiation into the steradian, depending on the operating current. FIG. 8 shows three typical steradian spectra, as they occur for VCSEL, RCLED and GaN-LEDs on sapphire substrates. Since the radiation of a VCSEL (Vertical Cavity Surface Emitting Laser diode) is normally fully in the acceptance angular range of a optical waveguide, beam forming measures are superfluous in this case. The coupling element according to the invention is typically used in this case only for the lateral adjustment between the diode and the optical waveguide. The radiation of a RCLED (Resonant Cavity Light Emitting Diode) takes a significantly larger steradian so that beam-forming measures are advantageous also when being coupled to optical waveguide with a high aperture. The RCLED radiation is, however, still basically concentrated to portions that are axially close so that a long parabolic reflector with a great distance from the LED should be used, relevant dimensions being calculated in a manner that allows the light impinging onto the reflector surface to be reflected into the optical waveguide. For an LED with a very broad angular spectrum and a characteristic possibly irradiating directly to the side, a short reflector is the most effective beam-forming measure. Here, the irradiation emerging from the diode chip to a significant extent into the lateral direction can be coupled into the optical waveguide.
If several electro-optical chips (arrays) are coupled on a printed circuit board to an optical waveguide in the manner according to the invention, the following problem may occur. If the submounts 1 are manufactured separately and set onto the printed circuit board for each transmission diode 2 , they do not fit to a coupling element 3 that consists of one piece. Two solutions are provided for this occurrence. A first solution is shown by way of example in FIGS. 9A-B. The LEDs 2 and the LED/submount units are bonded onto the printed circuit board 4 prior to the optical waveguide coupling. Mechanical tolerances naturally occur, which cannot be offset in the coupling element 3 , which is formed of one piece, for several optical waveguide 7 . In order to offset these tolerances, a flexible printed circuit board 4 may be used, which may also have a slot 20 to increase its flexibility. The simply movable tongues 21 of the printed circuit board 4 can easily be moved towards the position provided for them in the coupling element 3 .
An alternative solution is shown in FIG. 10 . Several receptacles 9 for semiconductor chips are arranged on one single submount 1 . This solution can generally only be applied in connection with micro-structured submounts. Since the micro-structured submount 1 can be manufactured at high precision, the distances between the semiconductor chips can be chosen such that the submount 1 can be inserted into the coupling element 3 that is manufactured with the same high precision. A tolerance compensation as in FIG. 9 is not required. To explain FIG. 10, reference is made to the explanation of FIG. 6 in order to avoid repetitions.
Configurations are known from the MicroMID technology, which operate with deflection reflectors for the 90° deflection of the light irradiated by the diode (see, e.g., DE 198 51 265 A1 at FIG. 11 ). These constructions have the advantage in many practical applications that the optical waveguide and the printed circuit board are on one plane and the housing around the transceiver arrangement can therefore be formed in a flatter way. For example, this is advantageous if the transceiver shall be located in the interior, such as on the inner layer of an electro-optical printed circuit board.
An application of this general idea to structures according to the invention is shown by way of non-limiting example in FIG. 11 . Contrary to DE 198 51 265 A1, the adjustment is not carried out by use of the printed circuit board 4 , but the adjustment is instead on the submount 1 .
The necessity for the 90° deflection between the optical waveguide and the printed circuit board via a deflection mirror 19 is only for limited special cases and some possible applications of the disclosed invention (e.g., electro-optical printed circuit board, coupling to integrated-optical circuit). Since the printed circuit board 4 onto which the submount 1 is set, can be made of a flexible material, the effect of saving overall height (as shown in FIG. 11) can also be achieved according to FIG. 12 by folding a flexible printed circuit board 4 . By this construction, the optical waveguide 7 perpendicularly set onto the printed circuit board is also brought on one plane with the printed circuit board 4 .
If transceivers are to be manufactured for glass fibers used as an optical waveguide with standard diameters of 125 μm, the manufacture of a coupling element with an axially long highly precise hole of a diameter of only 125 μm will become technically difficult. In that regard, it is offered according to FIG. 13 to hold the glass fiber 22 first of all by a highly precise ferrule 23 (tolerances below 1 μm) and then to adjust the ferrule 23 in the manner according to the invention by use of the coupling element 3 on the submount 1 . FIG. 13 shows this arrangement.
Even greater demands on the adjustment accuracy can be fulfilled if the ferrule 23 forms at the same time the coupling element according to the invention. FIG. 14 shows a submount 1 , which is formed on its surface in a manner that the ferrule 23 with the glass fiber held therein may directly be inserted and opposes the semiconductor chip in a centered manner.
The construction shown in FIGS. 15A-B enables the extremely inexpensive structure of transmission/receiver modules (transceivers), which at the same time (i.e. not in the time multiplex or duplex operation) enable the data reception and the data transmission. An LED 2 used as a transmitter and a photo diode 24 (PD) used as a receiver are arranged on a common submount 1 . Between these two components the submount 1 has a back 25 , which optically shields the two components against each other. An optical waveguide common to the two electronic components 2 and 24 is held in a coupling element 3 . The submount has two slots 6 for receiving the bond wires 5 leading from the components 2 and 24 to the printed circuit board (not shown). The back 25 at the same time serves for supporting the optical waveguide in the predetermined distance from the components 2 and 24 and therefore takes over the function that is provided by the shoulder 8 in the other embodiments.
It is advantageous compared to the prior art that the diodes 2 and 24 have no electric interaction, since the current of the transmission diode does not have to flow through the chip of the receiver diode.
An exemplary embodiment suitable for high precision demands is shown in FIG. 16 in the longitudinal section, in which the coupling element 3 is provided on the one side first of all with a blind hole, which is later opened mechanically from the rear side (e.g. by milling) whereby the area defined in FIG. 16 by the dotted line is removed on the surface of the coupling element 3 . In this manufacturing method, the tolerances are avoided that occur during the injection molding of the upper tool surface and the lower tool surface, since the matching parts are defined from the same side.
If the coupling element consists of a transparent plastic material and if the refractive index of the adhesive filled in is larger than the refractive index of the coupling element, an optical waveguide is produced in the coupling element, such optical waveguide being useable for the cross sectional adaptation between the fiber and the coupling position. In this way, an arbitrary amount of electro-optical chips can be coupled to one single fiber. An example for this is shown in FIG. 17 .
A different application results if the transceiver contains an integrated-optical 1×2 splitter for bi-directional operation on one single optical waveguide. By using a deflection reflector, an especially simple coupling from the transmission and receiver diodes to the integrated optical structure is possible. The light of the transmission diode is in this case not coupled into a fiber but into an integrated optical waveguide, as shown in FIG. 18 . Here, the coupling element also consists of a transparent plastic material and the adhesive filled in has a higher refractive index than the plastic material of the coupling element.
FIG. 19 shows another exemplary embodiment of the invention, in which the submount 1 is provided with a pin 26 on its side disposed opposite the semiconductor element 2 . The submount 1 comprises on its surface a parabolic recess which is provided with a metal coating 19 , comparable to the coating for the embodiment of FIG. 4 . Moreover, the FIG. 19 structure is provided on its surface with an annular step 27 at which a cylindrical coupling element 3 is centered, which has an axial bore, which is shaped parabolically and which is steplessly connected to the recess in the submount 1 . An optical waveguide 7 is set into the upper end of this bore. The gap between its end and its opposing semiconductor element 2 that is attached on the submount is filled by a transparent adhesive K.
The pin 26 of the submount is received by a breakthrough 28 in a first connection flap 29 of a support 4 , provided in this case as a lead frame, which is shown in sections in FIG. 21 in top plan view. Pressing hooks 30 integrally formed on the lead frame project into the breakthrough 28 , the pressing hooks resiliently contacting the pin 26 when pressing the pin 26 into the recess 28 and the tips thereof digging into the pin 26 so that the pin 26 and thus the entire submount 1 are secured at the lead frame 4 . Additionally, the lead frame 4 may be soldered with the connection flap 29 of the lead frame 4 , where it is solderable. The lead frame 4 further comprises a second connection flap 31 that is separated from the first one and at which second flap the bond wire 5 is connected.
For mechanically stabilizing the entire arrangement, the lead frame 4 is molded together with the submount 1 and the coupling element 3 in the lower portion of same with a plastic material 32 . This plastic material may be the same material that is filled into the bore and the submount 1 as adhesive K, wherein in this case the filling of the adhesive and the molding of the arrangement may be carried out by the aid of a mold in one single process. It is evident that webs 33 connecting the two connection flaps 29 and 31 of the lead frame 4 and all other parts of the lead frame, that are no longer required and that can be seen in FIG. 21, are being removed after molding the arrangement.
An alternative embodiment according to FIG. 20 differs from the embodiment according to FIG. 19 in that the submount and the coupling element are combined to form an integrated unit 3 . All remaining features resemble those of FIG. 19 so that a repetition of the explanation is not herein included.
FIG. 22 shows an arrangement of four LEDs, which are coupled in juxtaposition to an edge 35 of a common optical waveguide 7 which, for example, may be a flat, light-conducting plate 34 e.g. made of plastics. The light emitting diodes may be held in arrangements as they are, for example, shown in FIGS. 19 and 20, and their design is shown in FIG. 22 only schematically, i.e., without details. However, it is important that the coupling of a part of coupling elements 3 to the ends of parabolic mirrors 19 remote to the LEDs takes place. For this purpose, the coupling elements 3 may have corresponding cut-outs on their free end face, which receive the edge portion of the plate-shaped optical waveguide 34 . The light emitting diodes may have different colors so that the light colors in the optical waveguide 34 additively mix. In this manner the generation of the mixing color white is possible in the case of an appropriate matching of the color temperature and the light intensity of the light emitting diodes.
FIG. 23 shows an arrangement that is comparable to the arrangement of FIG. 22, except that for reasons of clarity the light emitting diodes and their coupling elements are not shown. The important feature compared to the embodiment according to FIG. 22 is that the optical waveguide 34 is formed as a tube at whose edge 35 a plurality of light emitting diodes are coupled, each with a coupling arrangement according to the invention, while the opposing edge serves as a light outlet direction. In this embodiment the light mix colors can also be generated.
It is evident that in the embodiments of FIGS. 22 and 23 all features described with reference to the preceding embodiments are preferably used to an extent possible. This particularly refers to the metal coating of all components participating in the light guidance, the filling of empty spaces with transparent adhesives, the alignment of optical waveguides through positive locking to the coupling elements and the attachment of the semiconductor components by means of submounts on their respective supports as well as the formation thereof.
The invention has been described in detail for purposes of understanding. The structure and capabilities of the present invention may be modified, however, to meet the demands of the particular application. Hence, reference herein to specific details of the illustrated embodiments is by way of example and not by way of limitation. It will be apparent to those skilled in the art that many additions, deletions and modifications to the illustrated embodiments of the invention may be made without departing from the spirit and scope of the invention as defined by the following claims. | For a precisely fitting alignment of an optical waveguide on an electro-optical component, the electro-optical component is attached onto a submount, which can be attached at any position on a support. For retaining the optical waveguide, a coupling element is selectively provided, the coupling element having a negative imaging of the contour of the submount. This element is positively attached at the submount and receives the end of the optical waveguide. The space between the electro-optical component and the optical waveguide is filled by a transparent adhesive. The submount can be formed in micro-structure technique. The coupling element can be eliminated if the optical waveguide is directly aligned on the submount. | 6 |
CROSS-REFERENCE TO OTHER APPLICATIONS
[0001] None.
FIELD OF THE INVENTION
[0002] This is an examinable patent application under Code Section 111(a) submitted for a formal filing receipt and examination. The present invention lies in the field of plastic materials mixing in continuous mixer assemblies.
BACKGROUND OF THE INVENTION
[0003] Materials mixing rotors with standard threads, configured as depicted in prior art FIG. 1 and 2 , were seen to be breaking down, and would not run for more than a few weeks, causing down time and requiring major rotor construction, if salvageable. Such prior art rotors were wrapping molten materials about their periphery, creating pinch points, that caused the elongate rotor pairs to deflect. Such repetitive deflection eventually caused rotor cracking, and operational breakdown. Thus, the standard threaded rotor was structurally weakened and gave only limited and costly operational longevity when using standard threads on flights throughout the mixing length.
[0004] According to the present invention, an alternative configuration for the peripheral threads was devised, whereby a second and distinct set (flight) of threads were provided by adding to the threads span, and by abutting the opposite helixes, so as to help the flow of material to the helix segments of the rotors. The second flight comprises a set of Lowenherz threads, adapted to make the rotors stronger, by adding a sloped radius to the threads of the added second flight. Such will also serve to cut and churn the multi-materials being fed to the materials mixer.
[0005] The dual flight rotors of the present invention have typically operated for extended periods, without rotor flexing and associated cracking, calling only for infrequent shutdowns to change the composition of the polymer materials being processed.
[0006] Accordingly, it is a principal object of the present invention to provide a rotor assembly that avoids jamming up from fluidized partial bottom feeds so as to extend the operational range for a given sealing means and paired rotor assembly.
[0007] Another object of the invention is to modify the standard flight configuration to include a separate flight of threads, each having a linear bevel on the upstream stage for one of the flights, whereby more uniform cutting and churning of the particulate feed materials is accomplished.
[0008] It is another object of the present invention to increase the root diameter of the mixing rotor significantly, which serves to increase its structural strength and obviates its flexing from materials binding with it during processing.
[0009] A still further object of the invention is to provide improved means for the interconnection of the drive shaft and mixing rotor by adding to the drive surface provided at each longitudinal end of the rotor itself with a special keying means.
[0010] Yet another of the invention is to preclude operational failures of the mixing assembly caused by deflection of the rotor under materials compression during the vigorous mixing phase.
BRIEF DESCRIPTION OF THE DRAWING
[0011] FIG. 1 is a side elevational view of a conventional compact processor for plastic particulate materials comprising a unitized particulate mixing and extrusion system, wherein particulate plastics are mixed, liquified, and the resultant molten materials are pelletized for later molding into useful articles;
[0012] FIG. 2 is a side elevational view of a prior art, single flight rotor, seen in isolation that is employable in the prior art compact processor of FIG. 1 ;
[0013] FIG. 3 is a side elevational view of one rotor of a preferred embodiment of the dual flight, rotor set of the present invention, having a representative number of the more effective flight profiles shown in each configuration;
[0014] FIG. 4 is an enlarged top plan view, like that of the processor of FIG. 1 , but now depicting a parallel set of material mixing, paired rotors, which rotors embody the dual flight features of the present invention first depicted in FIGS. 3 ;
[0015] FIG. 5 is a perspective view of one paired set of the dual flight rotors of FIG. 3 , as seen in isolation from its assembly mode, depicted for clarity of viewing;
[0016] FIG. 6 is an enlarged cameo (semi-encircled) of an adjacent set of a Lowenherz modified, and a standard thread flights, better depicting the outward bevel on the set of upstream flight.
[0017] FIG. 7 is an enlarged broken out view of a flight rotor with the drive shaft engagement (and alignment) at the upstream (and similarly so at the downstream) ends of the flight rotor; and,
[0018] FIGS. 8 and 9 , are elevational views of the keyed driving means for each of the elongate flight rotor of FIG. 3 , positioned at the upstream and downstream longitudinal ends thereof, respectively, of each of the modified flight rotor component of the present invention.
SUMMARY OF THE INVENTION
[0019] Fluid materials mixing rotors can be provided with a variety of vertical cross sectional configurations on the rotors, such as the American standard thread (depicted schematically in the prior art assembly of FIG. 2 ). We have concluded that the publicly described, Lowenherz thread can now be usefully adapted to concurrent and advantageous with the standard thread. This is done by providing a second thread flight having the Lowenherz profile, located upstream of the standard thread flight and being integral therewith, and also somewhat extending the linear span of the dual set of peripheral threads. The Lowenherz thread has flats at the top and bottom, the same as the U.S. standard form, but the depicted angle is 53 degrees 8 minutes. The depth equals 0.75×the pitch, and the width of the flats at the top and bottom is equal to 0.125×the pitch. This screw type thread is based on the metric system and is used for measuring instruments, especially in Germany.
[0020] According to the invention, there is provided a continuous mixer apparatus adapted for commingling particulate thermoplastic material of varying polymeric compositions, and having a mixer barrel, at least one main rotor with a helical profile body section at one longitudinal end thereof, a driven journal located at an opposite end, a drive end rotor plate, a drive end packing seal retainer, and a packing gland seal means at the drive end, the improvement in the main rotor external configuration which comprises: (a) a first upstream (leading) feed flight having a plurality of Lowenherz profile threads integral with the outer periphery of the main rotor; and, (b) a second downstream (trailing) feed flight, abutting the first flight, and having a plurality of screw-type, outer standard threads, also being integral with the periphery of the main rotor, which standard threads terminate at an abutting trailing helix flight. In a preferred embodiment, a complemental pair of modified thread rotors operate in concert, as will be shown.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] With reference to FIG. 1 , there is shown a prior art, compact processor 20 for plastic materials and comprising a unitized mixing and extrusion system that allows a user to customize mixing and extrusion of the plastic materials being processed. This unitized processor system comprises a two-rotor, continuous mixer 22 mounted on an upper level 23 of a framework 24 . Plastic materials, fillers, additives, colorants, and the like, namely various ingredients desired to be mixed with plastic materials, as desired by the user, are introduced into a feed entrance (sometimes called a “feed throat”) of the continuous mixer 22 , as indicated by an arrow 26 . The resulting molten plastic materials flow by gravity downward from the continuous mixer 22 , like a molten “rope”, descending within a vertical chute 28 , into a hot-feed extruder 30 . Standard screw type threads 29 ( FIG. 2 ) are used on rotor 31 . The molten output from the extruder 30 ( FIG. 1 ) issues through an extruder head 32 , which is adapted to have various types of configurations for an extrusion device 33 mounted thereon, as may be desired by the user.
[0022] For driving the two rotors of FIG. 2 ( 22 L/R) in the mixer 22 ( FIG. 1 ), there is shown a suitable drive system 34 , such as a d.c. drive motor 35 , arranged with suitable feedback speed and torque controls, as known in the art, for turning the mixer rotors preferably at predetermined constant speed. This motor 35 is coupled to a suitable speed-reducer 36 , for example, such as an all helical gear, speed-reducer with two output shafts coupled to two three-piece rotors for rotating the two rotors in opposite directions about their respective longitudinal axes. In this illustrative example, the two rotors are turned in opposite directions at the even/or ratio rates.
[0023] The mixer 22 includes a drive end frame 38 (also called a “drive bearing housing assembly”) for rotatably supporting a drive end journal (not seen in FIG. 1 ). This drive end frame 38 and its journal will be described in detail later. The mixer includes a driven end frame 39 “which may be called the “water end frame” and also may be called “driven bearing housing assembly”) for rotatably supporting a driven end journal (not seen in FIG. 1 ). Mounted between drive and driven end frames 38 , 39 is a mixer chamber barrel, or housing 40 , including an upper half (chamber) 41 and a lower half (chamber) 42 .
[0024] For driving an extruder molten feed screw 45 ( FIG. 6 ) in the hot-fed extruder 30 , there is shown an electric motor 46 mounted on a base 48 of vertical framework 24 . This motor 46 is coupled through a suitable speed-reducer transmission 50 linked to the extruder screw 44 .
[0025] The prior art rotor 31 of FIG. 1 is shown in isolation, in FIG. 2 , depicting that all peripheral threads flights are of like configuration, namely they are standard, screw-type threads for kneading and admixing the feeds in the type housing 40 of FIG. 1 .
[0026] In FIG. 3 , is depicted one of the rotor pair of FIG. 4 , which embraces the dual flight, set of threads of the present invention. Each of the modified rotors, like 50 R, has a first upstream (proximal the driven end feed flight, 54 L/R, have a plurality of Lowenherz vertical profiles 52 , (see FIG. 6 ), disposed on rotor shaft 53 , and being integral with the periphery 55 of the rotor 50 R ( FIG. 4 ).
[0027] A second downstream (distal the driven end) abuts the first flight of threads, but now presenting a standard set 54 ( FIG. 6 ) of screw-type threads, also being integral with rotor 50 R ( FIG. 4 ).
[0028] The first and second flights are continuous in the zone of transition, varying only from the older to the newer profile. As to fabricating, the main rotor, such as 50 R, is first machined with standard thread profiles, which are spaced substantially more closely, as depicted in FIGS. 3 and 5 . Certain of them are then subjected to follow-on machining to provide the novel flight periphery seen in FIG. 3 . It is well within the skill of the rotor shaping art to produce the depicted dual flight rotor configuration of FIG. 6 .
[0029] Looking to top plan view of FIG. 4 , with upper barrel half 41 ( FIG. 1 ) removed, there is shown a pair of parallel rotors ( 50 L/R), both positioned horizontally within housing 40 ( FIG. 1 ), and which are denominated the left and right side mixing rotors, respectively. The left-hand, longitudinal ends of the mixing rotors are mounted conventionally in journals at the drive end, frame 38 ( FIG. 4 ), while the drive ends each have a packing seal assembly, generally 56 L/R, respectively, to be described, in connection with FIGS. 4 , et seq. The other longitudinal ends of the paired rotors are mounted in driven ends of the housing frame, 39 1). It will be apparent that first flight of screws present the Lowenherz threads, while the abutting second flight of standard screw present the standard (squared) profile.
[0030] In the top plan view of the mixer 22 , cover removed, of FIG. 4 are seen the side-by-side pair of complemental rotors, 50 L/R. The feed materials (not seen) are introduced into the open section of the mixing assembly (see prior art FIG. 1 ), and are intimately mixed as they move rightwardly, until they reach vertical chute 28 , dropping therethrough into the conduit 30 containing extruder molten feed screw 44 .
[0031] In the perspective of FIG. 5 , are depicted dual flight rotor 50 R, each having a set of Loweriherz threads, 52 L/R, (three are exemplified), and an abutting downstream set, 54 L/R, of standard threads (four are exemplified). The connected helix segments 56 adjoins and functionally transitioning blends with the second set of screws 54 . The thoroughly mixed plastic component drops down to the extrusion stage just as depicted in FIGS. 1 , and the description related thereto. The flanged, longitudinal ends 58 L and 58 R, are mounted as described in connection with FIG. 4 .
[0032] In the broken out, enlarged view of FIG. 6 there is depicted a configuration of a standard thread with the abutting Lowenherz thread of the present invention. Standard thread 54 is on the right, and the Lowenherz thread 52 is on the left. As indicated earlier, a standard thread 54 is machined, by well-known machining methods, so as to provide the thread profile of the Lowenherz thread 52 .
[0033] In Table 1, there is provided the agreed specifications for the integral relationship of Lowenherz thread diameter, pitch of thread, and appropriate number of threads per linear inch. The presently preferred embodiment has the following dimensions: total flight length, 24½ inches; linear distance between adjacent thread crests, 3 inches; depths of flights relative to the root diameter of the rotor; 7¾ inches; width of crest on the standard threads, 0.75 inches; and, pitch (width of slow surface of the linear threads of 3 inches.
[0034] In a preferred embodiment, the Lowenherz threads has a diameter of 225.425 millimeters and a pitch of 76.2 millimeters while resulting threads per inch number 3.
[0035] In the enlarged, broken out view of FIG. 7 , such depicts the alignment configuration of the driving shaft 53 of FIG. 3 to each of the modified rotor pair 52 L/R ( FIG. 5 ) of the present invention. Note drive shaft 53 ( FIG. 7 ) seats along recess 60 , of the rotor end which is provided in the longitudinal end flange, 58 R. This is reflected in the left side view of the present rotor assembly of FIG. 4 .
[0036] At each end of the rotor ends there are provided, specially configured recesses, or slots. In the upstream end of rotor 50 R ( FIG. 4 ) is seen a right angle, cross-type key 62 R ( FIG. 8 ), surrounded by a plurity of tapped bore holes 64 A-J, for receiving the mounting bolts (not seen) on the upstream end of rotors of rotors FIG. 4 .
[0037] At the downstream end of the paired rotors thereof, is provided a like right angle to cross-type key slot 66 R for receiving and driving the D/S bearing shaft of 70 of FIG. 4 . A similar plurality 68 A-J of bore holes are provided. These keying components have been developed to provide higher torque carrying capability in the operation of the modified flight threads, rotors of the present invention. In a preferred embodiment, the total square inches of the drive key is greater than 4.5 inches.
[0038] As to a suitable packing of gland seal assembly, which is not part of the present invention, see U.S. Pat. No. 6,399,666 (May 21, 2002), which discloses such an assembly, in FIGS. 4-8 thereof, and in the associated description, being a suitable means. As to rotor dimensions, those set out below are typical of the present rotor assembly. It is well within the skill of the rotor parts machining art to modify such physical dimensions appropriately, so to adapt the approved rotor assembly to other particulate materials with various viscosities being blended in the inventive assembly here disclosed.
[0039] With regard to the described rotor of the present invention ( FIGS. 3, 4 , and 5 ), a representative set of physical dimensions are now set forth: total body length of 56.12 inches; rotor diameter proximal the downstream end, 6.12 inches; span of the dual flight, set of threads from end flange to inception of connected helix 24.5 inches; span between apexes of adjacent lower horizontal threads, 3 inches (six inches overall)l; span between apexes of standard threads, 3 inches (nine inches overall); diameter of trough between threads, 7.37 inches; height of threads outward of rotor body, 0.75 inches; and, width of crown of standard threads, 0.75 inches. Such dimensions may be varied to accommodate the variety of plastic materials being blended and/or the volumes per unit times be effected.
TABLE 1 Lowenherz Thread Dimensions and Ratios Approximate Approximate No. of No. of Diameter Pitch, Threads Diameter Pitch, Threads Millimeter Inches Millimeter Per Inch Millimeter Inches Millimeters Per Inch 1.0 0:0394 0.25 101.6 9.0 0.3543 1.30 19.5 1.2 0.0472 0.25 101.6 10.0 0.3937 1.40 18.1 1.4 0.0551 0.30 84.7 12.0 0.4724 1.60 15.9 1.7 0.0669 0.35 72.6 14.0 0.5512 1.80 14.1 2.0 0.0787 0.40 63.5 16.0 0.6299 2.00 12.7 2.3 0.0995 0.40 63.5 18.0 0.7087 2.20 11.5 2.6 0.1024 0.45 56.4 20.0 0.7874 2.40 10.6 3.0 0.1181 0.50 50.8 22.0 0.8661 2.80 9.1 3.5 0.1378 0.60 42.3 24.0 0.9450 2.80 9.1 4.0 0.1575 0.70 36.3 26.0 1.0236 3.20 7.9 4.5 0.1772 0.75 33.9 28.0 1.1024 3.20 7.9 5.0 0.1968 0.80 31.7 30.0 1.1811 3.60 7.1 5.5 0.2165 0.90 28.2 32.0 1.2599 3.60 7.1 6.0 0.2362 1.00 25.4 36.0 1.4173 4.00 6.4 7.0 0.2756 1.10 23.1 40.0 1.5748 4.40 5.7 8.0 0.3150 1.20 21.1 . . . . . . . . . . . . | In the field of continuous mixer apparatus for commingling particulate thermoplastic materials, employing at least one main rotor with a helical profile body configuration, an improved profile for the peripheral threads is provided. It presents a first upstream feed flight having a plurality of Lowenherz profile outer threads and second downstream feed flight having a plurality of screw-type outer threads, both being adjacent and integral with the periphery of the main rotor. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a knitting density adjusting method and, more particularly, to a method of adjusting the knitting densities of respective courses when a flat knitted fabric is to be produced.
If the knitting cams of a lock are positioned at an equal height at righthand and lefthand sides during the rightward and leftward strokes of a carriage when a knitted fabric is to be produced by a flat knitting machine, the knitting density of the stitches made during the leftward stroke of the carriage is not identical to that of the stitches made during the rightward stroke of the carriage. This is considered to come from the following reasoning. Specifically, when the carriage is transferred, in case a feed source of yarns such as a bobbin is disposed at one side of the frame of the knitting machine, to the opposite side from the yarn feed source, it is transferred, while pulling out the yarn from the bobbin or the like, to apply a tension to the yarn. When the carriage is turned at the end portion of the knitting machine so that it approaches the yarn feed source, the yarn is already pulled out so that the knitting operation is conducted by the use of said pulled-out yarn, whereby no tension is applied to the yarn. On the other hand, even in case the yarn feed sources such as the bobbins are disposed at both the sides of the machine frame so that the yarns are pulled out from the bobbins at the two sides and are fed to one feeder, the tensions to the yarns are delicately different for the rightward and leftward strokes of the carriage so that there arises a difference in the knitting density between the rightward and leftward knitting strokes of the knitted fabric. This results in a difference in the consumption rate of the yarns between the rightward and leftward strokes of the carriage. This difference is not clear just at a glance of the knitted fabric if it is several percentages. The good appearance of the knitted fabric, however, is deteriorated if the difference increases.
On the other hand, there is a tendency that the knitting density increases for the increase in the knitting speed of the knitting machine. As a result, if the knitting speed is changed during the knitting operation, the knitting density is accordingly changed so that knitting irregularities are caused in the courses of the knitted fabric produced.
Moreover, in case there is difference in the lengthes of the knitting yarns for knitting the respective courses, as has been described in the above, it is impossible to know in advance the length of the knitting yarn of one garment, and still the worse it becomes difficult to knit a fabric with patterns unless excess amount of dyed yarns is prepared for the knitting.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method for adjusting the knitting densities of respective courses of a flat knitted fabric.
Further object of the present invention is to eliminate any irregularity of the knitting densities of the courses by making constant the length of the knitted yarn forming each course.
According to the present invention, there is provided a knitting density adjusting method characterized: in that the yarn length of the reference course, which is fed to the needles of the reference section on the needle floor, is used as the reference yarn length; in that the knitted yarn length having been used in the reference section is compared in the subsequent course knitting operation with the reference yarn length to actuate the knitting density drive unit on the basis of the compared values so that the knitting cam is so rose, when the knitted yarn length is shorter than the reference yarn length, as to increase the knitting density and is so lowered, when the knitted yarn length is longer than the reference yarn length, as to decrease the knitting density; and in that the comparisons of the reference yarn length and the knitted yarn length are compared until the two lengthes become coincident. As a result, during the knitting operation, the knitted yarn length for knitting the respective courses can be so compensated at all times as to approach the reference value so that the knitted cloth having its respective courses uniformly knitted can be attained.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view showing the lock;
FIG. 2 is a sectional view showing the central portion of the lock; and
FIG. 3 is a block diagram showing the flat knitting machine and the control system therefor.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described in the following with reference to the accompanying drawings in connection with one example of a system for practising the method of the present invention.
FIG. 1 schematically shows a lock 1. This lock 1 is disposed in one set or in a necessary number of sets in the carriage. The following description will be made upon one set of the lock because the construction and operation of the present invention are identical for the one set.
Indicated at reference numeral 2 is a raising cam, in which a guard cam 4 and knitting cams 5 and 6 are arranged through a passage 3 of a butt (not shown), at the top and at the lefthand and righthand sides, respectively. The knitting cams 5 and 6 are fixed in parallel with the slopes 7 and 7 of the raising cam 2 on sliding members 10 and 11 which in turn are fitted obliquely slidably in grooves 9 formed in the base plate 8 of the carriage. The knitting cams 5 and 6 are so biased as to be pulled down by springs 12 which are spread between the sliding members 10 and 11 and the base plate 8, respectively. Indicated at reference numeral 13 is a sliding member stopper which is supported in a manner to slide to the right and left on the base plate 8 by the coactions of a not-shown guide member disposed on the base plate 8 and a guide groove 15 formed in a lifting lever 14. If the knitting cam 5 is to be lowered when the sliding member 13 has been moved leftward, the sliding member stopper 13 abuts against the lower end of the sliding member 10 of the knitting cam 5 thereby to stop the downward movement of the knitting cam 5. If the knitting cam 5 is to be lowered when the sliding member 13 has been moved rightward, the sliding member stopper 13 abuts against the lower end of the sliding member 11 of the knitting cam 6 thereby to stop the downward movement of the knitting cam 6. The lifting lever 14 is slidably supported on the base plate 8 by means of a not-shown member and is equipped with roll pins 20 and 21. Rocking arms 24 and 25 are supported at the lefthand and righthand sides of the lifting lever 14 in a rocking manner by means of pivot pins 22 and 23 which are anchored at the base plate 8. The rocking arms 24 and 25 have their upper end portions abutting against roll pins 26 and 27, which are disposed in the sliding members 10 and 11, respectively, and have their lower end portions made movable to and from the roll pin 21. Since, in the construction described in the above, the sliding members 10 and 11 are biased downward by the springs 12, the rocking arm 24 is urged to turn counter-clockwise through the roll pin 26 whereas the rocking arm 25 is urged to turn clockwise through the roll pin 27. At this time, if the end portion of the sliding member stopper 13 comes into abutment contact with the lower end of the sliding member 10, for example, the sliding member 10 is blocked from its lowering movement, but only the sliding member 11 is allowed to be lowered so that only the rocking arm 25 is turned clockwise to cause only the lower end of the rocking arm 25 and the roll pin 21 to contact with each other but the roll pin 21 and the lower end of the rocking arm 24 to release each other.
Indicated at reference numeral 30 is a pulse motor which is supported on the base plate 8 by means of a support member 31 and which has its shaft 32 equipped with a cam 33. This cam 33 has its recessed wall providing a cam face 34, against which the pin 20 abuts. The contact pressure of the pin 20 with the cam face 34 is based upon the elastic force of the spring 12.
As a result, when the cam 33 is turned by the pulse motor 30, the roll pin 20 inscribed in the cam 33 is moved up or down to have its position regulated so that the lifting lever 14 is accordingly moved up or down. As a result, the roll pin 21 rocks the rocking arm 24 or 25 in accordance with the position of the roll pin 20 so that the sliding members 10 and 11 are moved down by the elastic forces of the springs 12 or up against the same elastic forces through the roll pins 26 and 27.
The mechanism for controlling the rotations of the pulse motor 30 will be described in the following.
Indicated at reference numeral 40 in FIG. 3 is a flat knitting machine, in which a carriage 42 is reciprocated to the right and left along the upper face of a needle bed 41 having a flat or angular shape. The carriage 42 is equipped, in the shown example, with two sets of the aforementioned locks 1 on its needle bed and with a needle pitch sensor 43. In parallel with the needle bed 41, there is disposed a needle pitch indicating member 44, which is located by the needle pitch sensor 43 made to reciprocate with the movement of the carriage. The needle pitch indicating member 4 is formed with marks 45 and 46 for determining the range of measurement of the yarn length for the later-described yarn length measurement. Indicated at numerals 47 and 48 are feeders which are identical to such well-known mechanism as can move together with the carriage 42 in accordance with the movement of the carriage 42 while being retained on the carriage 42. Numerals 49 and 50 indicate pulse encoders for yarns 51 and 52, and numerals 53 and 54 indicate packages for yarn feed sources. In the embodiment thus far described, the yarn feed sources 53 and 54 and the pulse encoders 49 and 50 are arranged at both the lefthand and righthand sides of the machine frame, but it is quite natural that they may be disposed only at one side of the machine frame. The pulse encoders 51 and 52 are used to measure the lengthes of the yarns and to generate one or a predetermined number of pulses for each rotation, and their signals are fed to an encoder control unit 61. The output of the needle pitch sensor 43 of the carriage 42 is inputted to a needle pitch sensor control unit 62.
A main control unit 60 receives the signals from the encoder control unit 61 and the needle pitch sensor control unit 62 and outputs a signal to a knitting density drive unit 63. The encoder control unit 61 receives the signals, which have measured the yarn lengthes on the basis of the pulse numbers outputed by the pulse encoders 49 and 50, and compares them with the pulse number for a predetermined reference yarn length. On the basis of those data, the signal for driving the knitting density drive unit 63 is outputed from the main control unit 60. The needle pitch sensor 62 detects a reference section for measuring the yarn lengthes on the basis of the marks 45 and 46 of the needle pitch indicating member 44.
Next, the operations of the method of the present invention will be described in the following.
First of all, the mechanical operations for moving up and down the knitting cam 6 so as to adjust the knitting density will be described. The pulse motor 30 for actuating the knitting cam 6 is suitably changed, as will be described hereinafter, by the measured values of the lengthes of the knitted yarns which have been used for the knitting operations in the reference course. This change is conducted by turning the cam 33 through a rotation of such a predetermined angle of the pulse motor 30 as is based upon the aforementioned measured values.
FIG. 1 shows the state of the lock 1 in case the carriage 42 is moved from the left to the right.
At the end of the rightward stroke of the carriage 42, the cam member 17 exerts its action upon the roll pin 16, which is anchored at the lifting lever 14, to push down the roll pin 16 downwardly in FIG. 1 thereby to slide the lifting lever 14 downwardly in FIG. 1. As a result, the rocking arms 24 and 25 rocked through the roll pin 21 of the lifting lever 14 so that the sliding members 10 and 11 are rose against the elastic forces of the springs 12 through the roll pins 26 and 27 which are in engagement with the leading ends of the rocking arms 24 and 25.
Next, the sliding member stopper 13 is pushed to the left, as shown in FIG. 1, by a not-shown mechanism to bring the lefthand end of the sliding member stopper 13 to below the sliding member 10. Moreover, when the aforementioned cam member 17 is moved to the center, as shown in FIG. 1, the lifting lever 14 is rose, because it receives the elastic forces of the springs 12 through the roll pins 26 and 27, the rocking arms 24 and 25 and the roll pin 21, and is stopped as a result that the roll pin 20 integrated with the lifting lever 14 abuts against the cam face 34 of the cam 33. Simultaneously with this, the sliding members 10 and 11 are lowered, but, since at this time the sliding member stopper 13 is pushed leftwardly in FIG. 1 by the not-shown mechanism, the leftend portion 18 of the sliding member stopper 13 is positioned below the sliding member 10 so that is comes into abutment against the lowered sliding member 10 thereby to block the further downward movement of the same. As a result, the knitting cam 5 made integral with the sliding member 10 is stopped while being blocked from its downward movement. On the other hand, the sliding member 11 is moved down by the elastic forces of the springs 12, but, since the lifting lever 14 is stopped with the roll pin 20 being abutting atainst the cam face 34 of the cam 33, as has been described in the above, the sliding member 11 cannot be lowered any more thereby to position the knitting cam 6 made integral with the sliding member 11.
As has been described hereinbefore, the lower positions of the knitting cams 5 and 6 are determined by the position of the lifting lever 14, and the stop position of the lifting lever 14 is determined by the abutting positions of the roll pin 20 and the cam face 34. As a result, the position of the knitting cam 6, i.e., the height of the same to be positioned in accordance with the level of the knitting density is determined by the abutting positions of the cam face 34 of the cam 33 and the roll pin 20 of the lifting lever 14.
The cam 33 is turned by the pulse motor 30, and its angle of rotation is determined by the number of the pulses inputed to the pulse motor 30.
In the present invention, the length of the knitted yarn of the knitted fabric, which has been made between the predetermined needles of the reference course, is referred so that, when a subsequent course is knitted, the knitting cam is moved to decrease the knitting density when the same knitting cam is to knit the subsequent course, if the length of the knitted yarn used between the predetermined needles of said course is longer than the aforementioned reference, and to increase the knitting density if the length of the knitted yarn used is shorter than the reference.
In FIG. 3, the yarn 51, which is pulled out of the package 53 and fed through the feeder 47 to the needle (although not shown) of the needle bed 41, is retained midway of its way by the pulse encoder 49 to turn this encoder 49 so that the yarn length is measured. The measured signal of the yarn length is inputed to the encoder control unit 61. In this encoder control unit 61, it is compared whether the measured yarn length is longer or shorter than the reference yarn length.
More specifically, when the carriage is reciprocally moved in the flat knitting machine, the yarns are alternately fed by the feeder in the two directions, i.e., to the right and left with respect to the knitted fabric. However, since the yarn knitted in the rightward stroke of the carriage and the yarn knitted in the leftward stroke of the carriage are different in the lengthes between predetermined wales in the knitted cloth, the height of the knitting cam in the rightward stroke of the carriage and the height of the knitting cam in the leftward stroke have to be made different. For this requirement, the length of the knitted yarn, which has been used to knit the course in the same direction as that of the course to be knitted, has to be referred to. As a result, the reference becomes different when the carriage is moved to the right and to the left.
In accordance with the movement of the carriage 42, on the other hand, the needle pitch sensor 43 made integral with the carriage 42 locates the needle pitch indicating member 44 juxtaposed to the needle bed 41 and to detect the marks 45 and 46, which are attached to the needle pitch indicating member 44, thereby to input to the needle pitch sensor control unit 62 the signal indicating whether the carriage has stealed into the measured yarn length section (or the reference section) or not.
In the above: the yarn length knitted into the reference section is designated at X; the knitted yarn length is designated at Xp in terms of the number of pulses; the number of pulses measured by the pulse encoders is designated at P; the number of pulses generated for one rotation of the encoders is designated at Z; the diameter of the encoders is designated at D; the number of the needles between a predetermined section is designated at N; and the number of gauges is designated at G. Let the case be considered in which the pulse encoder is placed for the yarn feeding operation at the lefthand side of the frame of the flat knitting machine.
The yarn length X is expressed when the carriage is moved from the left to the right (i.e., in the direction of A): ##EQU1##
The yarn length X is expressed when the carriage is moved from right to the left (i.e., in the direction of B): ##EQU2##
In case the yarn length is expressed in terms of pulses,
for the movement of the carriage from the left to the right (i.e., in the direction of A): ##EQU3##
for the movement of the carriage from right to the left (i.e., in the direction of B): ##EQU4##
By way of example, in case P (taken in the direction A)=1,000, P (taken in the direction B)=420, Z=100, N=100, D=40 and G=7;
in the direction A: ##EQU5##
in the direction B: ##EQU6## Thus, the knitted yarn has the different lengthes for the knitting operations in the directions A and B. In case of the knitted yarn length is 894 mm, the length of one loop to be made by one needle is 9.94 mm because the number of the needles is 100. By one step of the pulse motor 30 for the knitting density control, moreover, the knitting cams 5 and 6 are moved by about 0.1 mm in terms of their vertical strokes, and the length of one loop is shortened by 0.2 mm for one step-up and elongated by 0.2 mm for one step-down. As a result, in case the reference length is set at 894 mm, the pulse motor for the knitting density control may be stepped up by one if the length X of the actually knitted yarn is 884 mm and down by one if the yarn length X is 904 mm.
In the operations thus far described, the signals of the encoder control unit 61 and the needle pitch sensor control unit 62 are analyzed by the main control unit 60, and the signal of this main control unit 60 is received by the knitting density drive unit 63 to suitably rotate the pulse motor 30.
The aforementioned operations will be summarized in the following: (1) the measurement starting istruction is inputed to the needle pitch sensor control unit 62, and the number of the encoder pulses is simultaneously inputed to the encoder control unit 61 as a result that the portion of the mark 45 of the needle pitch indicating member 44 is passed by the carriage in accordance with the progress of the carriage; (2) reference is made to the reference value which is stored in advance in the encoder control unit 61; (3) when the knitted yarn length fails to coincide, the knitting density drive unit 63 is instructed by a compensated value through the main control unit 60 after the reference; and (4) the compensated value is inputed from the knitting density drive unit to the knitting density control pulse motor thereby to adjust the heights of the knitting cams 5 and 6. Next, the aforementioned steps (1) and (2) are repeated again, and the steps (3) and (4) are also repeated unless the yarn length fails to coincide with the reference. Moreover, if the yarn length becomes coincide with the reference after the thrice repetition of the steps (1) and (2), the knitting operation is thereafter continued in that state. | A method of adjusting the knitting densities of respective courses when a flat knitted fabric is to be produced. The knitted yarn length having been used in the reference section is compared in the subsequent knitting operation with the reference yarn length to actuate the knitting density drive unit on the basis of the compared values so that the knitting cam is so rose or lowered as to increase or decrease the knitting density and the comparisons of the reference yarn length and the knitted yarn length are compared until the two lengths become coincident. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119 to provisional application U.S. Ser. No. 61/021,189 filed Jan. 15, 2008, herein incorporated by reference in its entirety.
INCORPORATED BY REFERENCE
Please incorporate by reference the following in their entirety: U.S. Pat. No. 7,171,738 to Dick et al. issued Feb. 6, 2007; U.S. Pat. No. 4,736,511 to Jenkner issued April 1988; U.S. Pat. No. 4,830,075 to Jenkner issued May 1989; U.S. Pat. No. 6,640,855 to Giles issued November 2003; U.S. Application Publication No. 2003/0041919 to Giles published March 2003; and U.S. Pat. No. 7,031,789 to Dick et al. issued Apr. 1, 2006.
FIELD OF THE INVENTION
The present invention relates in general to methods and apparatus for sawing lineal material to length.
BACKGROUND OF THE INVENTION
Electrically powered crosscut saws have been in existence for decades and have been manufactured in many different configurations. In order to improve the productivity and consistency of cut on these saws many manufacturers have added apparatus both pneumatic and electromechanical to automatically cycle the rotating saw blade through the stock. This cut cycle has traditionally been initiated by a foot or knee pedal so that the operator's hands are free to manipulate the stock. While this configuration is effective for the efficient throughput of material through the saw, it does not prevent the operator from accidentally cycling the saw while his hands or arms are in harm's way.
To address this unsafe condition, manufacturers have offered these saws with a two-hand anti-tie down control that prevents the initiation of the cutting cycle unless two buttons spaced far enough apart to prevent one-handed operation are depressed simultaneously.
The logic circuit that monitors these buttons will not initiate the cycle unless both buttons are depressed within a few milliseconds of one another. This logic prevents the operator from defeating the system by tying one button down and then using only one hand to cycle the saw. Hence the name two-hand anti-tie down. This type of control is widely accepted throughout industry as a safe method for initiating a machine cycle.
Since the nature of the two-hand anti-tie down circuit is to ensure that the operator's hands are safely away from the process to prevent injury, their use on automatic saws prevents the operator from being able to hold the stock against the saw's fence while the cut is being performed. So in order to effectively implement this safety feature, manufacturers must add pneumatic clamping to the saw thereby adding significant cost and complexity to the product as well as reducing the throughput due to added motion on behalf of the operator.
From the foregoing, it can be seen that a need exists for further enhancements to the implementation of two-hand anti-tie down systems onto automatic saws in order to meet today's more rigorous safety requirements while maintaining or improving usability and productivity of the products.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention, the disclosed sawing system enhancement, and the method of operation thereof, substantially reduce or eliminates the disadvantages and shortcomings associated with the prior art techniques. According to one aspect of the invention, the two buttons that are monitored by the anti-tie down circuit are mounted on handrests positioned above the work area and on either side of the cutting line. These hand rests are mounted on linear bearings that allow them to slide horizontally in a plane parallel to the saw blade and to the saw table top and perpendicular to the saw back fence. The hand rests may be joined together or they may move independently depending on the embodiment of the invention. Either integrated into the design of the hand rests or mechanically connected to the hand rests are mechanical features that extend down toward the table top to within a short distance of its surface. These features will come in contact with the stock to be cut as the operator applies forward force to the hand rests causing them to slide toward the back fence of the saw. In this way the operator can crowd stock against the saw's back fence yet still operate the two-hand anti-tie down switches positioned to keep his hands a safe distance from the cutting area.
In accordance with another aspect of the invention, additional buttons can be positioned on the hand rests to perform functions such as controlling a digitally controlled positioning device attached to the saw to position the stock to obtain a desired cut length. As an example the hand rests might include a JOG button and a NEXT PART button. The operator could place his stock on a positioning table next to the saw; depress the JOG button on the hand rest assembly, thereby feeding the stock toward the saw. When the stock is in a position where the saw will make a proper trim cut, the operator would release the JOG button stopping the forward motion of the stock. The operator would then initiate the saw cycle via the two-hand anti-tie down buttons on the hand rest to trim the end of the part. He would then depress the NEXT button on the hand rest signaling the digital positioner to advance the stock adequately to a position where a further saw cycle will produce a part of desired length. When the stock is in position, the operator would again initiate the saw cycle by simultaneously depressing the two-hand anti-tie down buttons. The operator has now produced a part with both ends cleaned up and of a proper length without having to remove his hands from the hand rests. This not only keeps the operator's hands a safe distance from the cutting area but also eliminates the time and effort required for him to manipulate the lineal stock manually
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of the apparatus.
FIG. 2 shows a front view of the apparatus.
FIG. 3 shows an end view of the apparatus.
FIG. 4 shows a cutaway view of the apparatus taken along line 4 - 4 of FIG. 3 .
FIG. 5 shows a top view of the apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Details of the preferred embodiment of the present invention will now be discussed with reference to FIGS. 1-5 .
An improved safety device for an electrically powered crosscut saw is described and best shown in FIG. 1 . An electrically powered crosscut saw 10 features a base 11 supporting a tabletop 12 through which a saw blade 14 (see FIG. 4 ) may pass in order to cut stock. The stock is secured by an operator against a back fence 26 so as to ensure a clean cut. A blade guard 18 is typically located on the tabletop 12 and aligned with the saw blade 14 such that when the saw blade 14 is cutting the stock, the operator is separated from the saw blade 14 by the blade guard 18 . The blade guard 18 thereby protects the operator from debris during the cutting process, while also reducing the potential for contact between the operator and the saw blade 14 . The blade guard 18 also acts as a top clamp and may move vertically to secure stock.
According to the preferred embodiment, a pair of rails 20 are located adjacent the blade guard 18 and do not move when the blade guard clamps the stock. Handles 22 are slideably attached to the rails 20 . Mechanical arms 30 attached to the handles 22 allow the operator to secure the stock against the back fence 26 without removing his hands from the handles 22 . A pair of anti-tie down buttons 24 are located on the handles 22 so that the anti-tie down buttons 24 must be depressed while the operator grips both handles 22 . The anti-tie down buttons 24 are integrated into a pneumatic or electrical logic circuit ensuring that a cutting cycle cannot be engaged unless both anti-tie down buttons 24 are depressed substantially simultaneously (e.g. within 0.5 seconds). This safety measure ensures that an operator can not operate the saw blade 14 without having both hands on the handles 22 . This setup drastically reduces the potential for injury while still allowing the operator to properly hold the stock against the back fence 26 during operation, without the use of additional clamping devices.
Additional buttons may also be incorporated onto the handles 22 or mechanical arms 30 for performing other tasks commonly associated with crosscut saws. For example, a digitally controlled positioning device may be implemented with the invention, the controls included on the handles 22 . This digitally controlled positioning device might include a JOG button or toggle 32 and NEXT PART button 34 ; the buttons allowing the operator to advance the stock to be cut so as to eliminate knots in a piece while cutting pieces of a desired length.
During operation of the apparatus with the above described additional buttons, an operator, once finished with a part, would depress the JOG toggle 32 so as to advance the stock past a knot. The operator would then depress both of the anti-tie down buttons 24 together, engaging the motor 16 and cutting the stock to remove the defect. The operator would then depress the NEXT PART button 34 , advancing the stock a predetermined length. The operator would again depress both of the anti-tie down buttons 24 simultaneously, engaging the motor 16 and cutting a finished part from the stock. The operator has thus formed a part of a proper length having both ends cleaned up without requiring the operator to remove his hands from the handles to position or secure the stock.
Included with the table saw is an optimization system which is capable of analyzing a piece of stock lumber in order to determine the optimal cut pattern so as to eliminate waste and avoid flaws in cut pieces. A computer terminal may be positioned adjacent to the operator stand. The optimization system includes an interface, such as a camera and image recognition software, for identifying defects in the stock. Once the defects have been identified, the computer program creates a cut pattern so as to optimize the usefulness of the board by eliminating waste.
One preferred method of operating an optimization system intended for use with the above described invention includes the steps of:
1) An electronic cutlist file is generated either manually or by some third party design software. 2) The cutlist is converted from a comma separated ascii file into a database file, such as Microsoft Excel. This step may be performed by either a desktop computer or integrated into the optimization system. 3) The database is sorted into groups according to criteria established by the user. 4) The operator chooses which group he wishes to process. 5) The operator puts the optimization system into DEFECT MODE and presses MOVE TO SCAN START. 6) The optimization system positions a pusher at the SCAN START position. 7) Mounted to the pusher is a line laser that casts a line across the table perpendicular to the fence. 8) The operator positions the stock alongside the pusher path with the end of the stock aligned with the line laser. 9) He then holds the NEXT button down and uses the joystick to jog the pusher (laser) to the point at which he intends the first trim cut to be made. 10) He then releases the NEXT button. 11) He then jogs the laser to the beginning of the first defect, depresses the NEXT button and holds it down until the laser has passed over the defect then releases it. 12) The operator repeats this process for all defects on the board including the tail trim. 13) Finally the operator uses the joystick to position the laser on the end of the board and presses the END OF BOARD/OPTIMIZE button which signals the software to calculate an optimized cutting solution based on the information gathered from the defecting process. 14) The optimized cutting solution then appears on the screen and the operator now uses the next button to advance the stock for trimming and cutting the parts from the board.
In order to make a cut according to the preferred embodiment, the operator first advances the stock to a cut position, either by the JOG 32 or NEXT PART 34 buttons or by manually advancing the stock. The operator then pushes the handles 22 forward, causing the mechanical arms 30 to contact the stock. The mechanical arms 30 allows the operator to crowd the stock against the back fence 26 , preventing the stock from moving during the cut, thereby reducing the chance of splintering or injury. The blade guard 18 may also provide clamping of the stock. Finally, the operator depresses both of the anti-tie-down buttons 24 simultaneously. These anti-tie-down buttons 24 communicate to the machine that the operator has both hands on the hand rests, and that it is safe to engage the cutting cycle. If the operator should remove his hands from either of the anti-tie-down buttons the saw blade will be retracted, stopped, or otherwise safely removed from a zone of danger about the operator.
Other precautions eliminate the potential for the operator to override the anti-tie-down buttons. The buttons must be depressed substantially simultaneously (e.g. within 0.5 seconds), so that the operator cannot press one button and then the next with one hand. Also, if one or both buttons are depressed for a long time (e.g. more than a minute) relative to the cycle time of the saw, the system will shut down. This prevents the operator from tying, taping, gluing, or otherwise fixing one or both buttons into an “on” position to circumvent this safety precaution.
The above described invention is exemplary and other variations of the invention may be appreciated by those skilled in the art. Any limitations of the present invention appear in the claims as allowed. | An enhancement for use with automatically cycled saw systems that provides an operator access to two-hand anti-tie down buttons and other machine control functions while manually crowding the material to be cut against the saw's fence. The enhancement includes anti-tie down buttons to prevent a cutting cycle unless both buttons are depressed within preset time limit of each other. | 8 |
This invention relates to ferrous metal alloys which are superior to stainless steels and nickel-chromium alloys under conditions where both abrasion and corrosion of the metal may occur, especially in wet-process phosphoric acid plant reactors.
BACKGROUND OF THE INVENTION
Phosphoric acid, an important ingredient of chemical fertilizers, is produced from natural deposits of phosphate rock by the so-called wet-process, in which ground phosphate rock is reacted with sulfuric acid to produce phosphoric acid as a solution and gypsum as a precipitate.
The composition of the reactor slurry in phosphoric acid production processes varies somewhat but such slurries typically contain ground rock, about 33% phosphorous pentoxide (equivalent to about 45.55% phosphoric acid), 2 to 5% sulfuric acid, 1 to 3% fluosilicic acid, fluosilicates and small amounts of chlorides and hydrofluoric acid. The operating temperature is typically about 80° C.
Metallic equipment for handling phosphoric acid reactor slurry is subjected to scouring or abrasive action of the suspended solid particles as well as to chemical attack by the acid solution. Pump parts, elbows and other cast shapes are particularly susceptible to damage.
Stainless steels and nickel-chromium corrosion resistant alloys have been used for phosphoric acid reactor equipment. Such alloys have been hardened by cold working, phase transformation of the metallic matrix, precipitation of hard carbides, or precipitation of other hard phases including borides, silicides and sigma phase. Cold working and deformation, however, do not substantially enhance abrasion resistance. Moreover, cold working and deformation are not applicable to cast shapes. Alloys which are hardened with significant amounts of borides, silicides and sigma phase have generally been quite brittle due to the brittle nature of these phases.
Alloys previously formulated for service in abrasive, erosive or corrosive environments include Illium B, Illium P, Lewmet, HC250 and SPA, but these alloys have not provided satisfactory performance in phosphoric reactors and typically only provide a service life of about two to four months. There remains, therefore, a need for an improved alloy to handle both the corrosive and the abrasive actions of phosphoric acid slurries. Since phosphoric acid processes employ large quantities of sulfuric acid, it is desirable for the selected alloy to also be resistive to that acid.
SUMMARY OF THE INVENTION
Among the several objects of the present invention, therefore, may be noted the provision of alloys resistant to the corrosive and abrasive attack of hot wet-process phosphoric acid reactor slurries; the provision of such alloys that are also resistant to hot concentrated sulfuric acid solutions; the provision of such alloys that have an austenitic matrix and only moderate hardness and that may therefore be readily machined; the provision of such alloys that may be easily formulated from the readily available elements, iron, nickel, chromium, molybdenum, copper, carbon and the usual steelmaking deoxidizers; the provision of such alloys that may be easily melted and cast in air.
Briefly, therefore the present invention is directed to air-meltable, castable, machinable, hardenable alloys that are resistant to highly corrosive and abrasive slurries, especially those employed in the handling of wet-process phosphoric acid reactor fluids or hot concentrated sulfuric acid. The instant alloys consist of, by weight, about 11% to about 40% nickel (plus cobalt), about 27% to about 42% chromium, about 1% to about 4% copper, about 3% to about 4.5% silicon, about 0.7% to about 2% carbon, about 0.3% to about 3% manganese, up to about 4.5% molybdenum, and the balance essentially iron plus the usual minor impurities.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the invention, alloys are formulated which have hard carbides imbedded in a soft wholly austenitic matrix, that is, a matrix of face center cubic crystal structure, and provide excellent resistance to slurry abrasion and corrosion.
The primary components of the alloys of the invention are:
______________________________________CHROMIUM 27 TO 42% BY WEIGHTNICKEL (PLUS COBALT) 11 TO 40%SILICON 3 TO 4.5%COPPER 1 TO 4%CARBON 0.7 TO 2%MANGANESE 0.3 TO 3%MOLYBDENUM UP TO 4.5%IRON ESSENTIALLY THE BALANCE.______________________________________
For most applications it has been found preferable to restrict the ranges of elements to the following ranges:
______________________________________CHROMIUM 27 TO 34% BY WEIGHTNICKEL (PLUS COBALT) 13 TO 31%SILICON 3.2 TO 4.5%COPPER 2.5% TO 4%CARBON 0.7 TO 1.6%MANGANESE 0.5 TO 1.5%MOLYBDENUM 1 TO 4%IRON ESSENTIALLY THE BALANCE.______________________________________
The nickel content of the alloys of the invention is selected with respect to the other elements present and to anticipated heat treatment so that the alloys are always composed of carbides imbedded in a matrix of austenite. When the alloys are to be cast into thin sections, or cast into heavier sections and cooled from 2000° F., a minimum of about 11% nickel is sufficient to provide the austenitic matrix. For normal casting procedures a minimum of about 12% Ni will ordinarily be required to ensure an austenitic matrix. The nickel content is maintained below about 40% because it is a relatively expensive element and there is no need for higher nickel content to ensure the proper matrix in these alloys.
The alloys of the present invention are formulated so as to contain between about 0.7% and 2% C. This carbon level is selected in order to supply sufficient carbon for the formation of the quantity of carbides necessary to provide the desired resistance to attack in phosphoric acid slurries. For these alloys a lower carbon content within the range of 0.7% to 2% generally results in a shorter expected service life whereas a higher carbon content provides a longer expected service life. Alloys of higher carbon content within this range, e.g., 1.5% C or greater, however, are generally more brittle and less machinable than their lower carbon counterparts. It is therefore often necessary to accept a sacrifice in service life in order to attain the desired machinability. More particularly, an alloy of the invention having 0.7% C has an expected service life of about one fourth that of an alloy having 1.5% C. The expected service life of an alloy having 1% C is about one half that of an alloy having 1.5% C. However, in certain applications where ductility is desired, for example, where the alloy is to be machined into a complex shape, an alloy having about 0.7% to 1.0% C may be preferred over an alloy having 1.5% C despite the sacrifice in expected service life. Specifically, alloys of the invention having about 0.7% C to about 1% C typically would have about 2% to 5% tensile elongation, with about 4% to 8% elongation possible by heat treatment. It is reasonable to use the lower carbon alloys of the invention, and to accept less-than-optimum expected service life, because in typical acid slurries for which the present alloys are intended, they have an expected service life of up to several years and of the order of ten to twenty times that of prior art alloys.
The selected chromium content must be sufficient to provide chromium for two purposes, to combine with carbon to form carbides and to remain in the matrix for corrosion resistance. The combination of chromium with carbon accounts for an amount of chromium roughly on the order of 6 to 10 times the carbon content by weight. For these alloys containing between about 0.7% and about 2.0% C, I have found that a total chromium content of about 27% to 42% is required for sufficient chromium to remain in solid solution after casting and whatever aging or other heat treatments are to be performed to provide the corrosion and abrasion resistance required for the applications for which these alloys are intended.
Because chromium carbides account for a proportion of the total chromium content of the alloys of the invention, an alloy of a given total chromium level and relatively low carbon level will have a higher chromium content in its metallic matrix than will an alloy of the same total chromium level having a higher carbon level. Also, for any desired chromium level in the matrix, a lower carbon alloy requires less total chromium than a higher carbon alloy because a smaller portion of the total chromium exists as carbides. For example, an alloy of the invention having about 1% C and about 30% total Cr would consist of about 6 to 10% Cr in the carbides and about 20 to 24% Cr in solution in the metallic matrix. Furthermore, if the carbides constitute about 14% of the alloy, the matrix would constitute about 86% of the alloy.
It has been found that up to about 1% Co, up to about 1% Nb (Cb) and up to about 2% W may be present in the alloys of the invention without detriment to corrosion resistance. These elements may be present as a result of using scraps, turnings and similar materials in the formation of the alloys. However, greater than about 0.5% each of niobium or tungsten must be compensated for by some nickel increases in some instances. These two elements are therefore not intentionally added to alloys of the invention.
The molybdenum content of these alloys is up to about 4.5% and may be varied depending on the expected service conditions. For example, for applications involving solutions of 70% or less sulfuric acid or solutions of phosphoric acid, the alloys should contain at least about 2% Mo, preferably between about 2% and 4.5% Mo. For applications involving 95-98% sulfuric acid, the alloys may contain little or no molybdenum.
Silicon and manganese are commonly employed in steelmaking as deoxidizers. Additionally, up to about 4.5% Si may be employed for handling hot, concentrated sulfuric acid or hot, concentrated nitric acid. Up to about 3% Mn may be used without detriment to the instant alloys. Copper is employed in amounts between about 1% and 4% to enhance resistance to attack by sulfuric acid and certain other substances.
While the hardness of high carbon, high chromium austenitic alloys can be significantly increased by aging heat treatments, it now appears that in many slurries the as cast alloys of the invention are at least as resistant to corrosion and abrasion as are those in the age hardened condition. It has been discovered that, even though in certain instances it was previously thought best to increase the hardness of prior art alloys as much as practicably possible, increasing the hardness of the high carbon, high chromium alloys formulated according to this invention, contrary to what might be expected, does not necessarily provide improved abrasion resistance. Moreover, it is often desirable to have alloys available that have some ductility and tensile elongation so that they are conducive to machining into complex shapes. The hardness of the alloys of the invention, therefore, is preferably below about 380 BHN when they are to undergo significant amounts of machining.
The following examples further illustrate the invention:
EXAMPLE 1
Heats of several different alloys were prepared in accordance with the invention. Corrosion test blocks of each alloy measuring 2.5 inches long by 1.25 inches wide by 0.4 inch thick were cast in dry sand molds. The composition of these alloys is set forth in Table I with the balance in each case being essentially iron.
TABLE I______________________________________ALLOYS OF THE INVENTIONCOMPOSITION BY WEIGHT PERCENTAGESALLOY Ni Cr Mo Cu Si Mn Cb C______________________________________A 25.1 32.1 2.20 1.13 3.51 1.02 -- 1.19B 16.3 29.1 .42 2.06 3.10 .99 .41 1.62C 36.9 34.3 .43 3.42 3.89 .75 -- 1.20D 38.2 39.8 1.52 2.11 3.29 .59 .29 1.39E 27.1 29.9 -- 2.59 4.32 2.82 -- 1.08F 25.2 32.2 3.03 1.98 3.49 1.13 -- 1.02G 26.6 33.2 .33 3.53 3.02 2.95 -- 1.22H 22.8 32.6 2.50 2.88 3.52 .43 -- .93I 23.9 31.9 3.73 3.36 3.56 .28 -- .84______________________________________
Test blocks in the as cast condition were immersed in 600 ml beakers containing various solutions in such a manner that they were supported on one end by a bed of half-inch diameter glass marbles and on the other end by the side of the beaker so that all faces were in contact with the solutions. Each test block was weighed to the nearest 1,000th of a gram before and after the immersions and the weight loss was converted to a figure of average depth of corrosion penetration in mils per year (MPY) in accordance with the relationship: ##EQU1## where
______________________________________Wo = ORIGINAL WEIGHT OF SAMPLEWf = FINAL WEIGHT OF SAMPLEA = AREA OF SAMPLE IN SQUARE CENTIMETERST = DURATION OF THE TEST IN YEARSD = DENSITY OF THE ALLOY IN GRAMS PER CUBIC CENTIMETER.______________________________________
Samples from experimental heats A, D, F, H and I were tested in a solution of 46% phosphoric acid (33% phosphorus pentoxide), 3.5% sulfuric acid and 100 parts per million of chloride ion at 80° C. for a period of 24 hours. The weight loss in each case was 1.8 MPY or less.
These same five alloys were then tested for 24 hours at 90° C. in a solution of the same composition. The weight loss in each case was 2.6 MPY or less.
EXAMPLE 2
Samples of the experimental heats of Example 1 except the molybdenum-free alloy E were tested for 24 hours at 80° C., 90° C. and 100° C. each in 80%, 85%, 90%, 93% and 96% sulfuric acid water solutions. The results of these tests are set forth in Table II. Values over 10 MPY are rounded to the nearest MPY.
TABLE II__________________________________________________________________________WEIGHT LOSS IN VARIOUS SULFURIC ACID-WATERSOLUTIONS AT 80° C., 90°, & 100° C., MPYACIDSTRENGTH TEMP. A B C D F G H I__________________________________________________________________________80% 80° C. 15 18 3.4 13 11 10 3.6 2.8 90° C. 26 27 5.6 NT NT NT 5.4 6.2 100° C. 42 42 10.2 NT NT NT 9.7 10.185% 80° C. 3.2 8.5 2.1 7.9 4.6 3.9 1.9 2.2 90° C. 3.8 12 3.5 11 7.2 6.2 3.4 2.9 100° C. 7.9 18 5.0 17 10 8.1 4.6 5.390% 80° C. 11 9 1.6 9.2 8.1 10 1.7 2.0 90° C. 15 13 3.1 12 12 14 2.8 3.3 100° C. 22 18 4.2 16 17 21 3.8 3.993% 80° C. 8.2 9.2 1.1 7.2 8.3 6.4 1.3 1.4 90° C. 9.3 13 2.1 10 12 10 1.9 2.4 100° C. 10 18 3.1 11 17 15 2.8 3.396% 80° C. 1.0 2.2 0.8 0.6 2.2 1.1 1.0 0.9 90° C. 1.1 3.3 1.7 0.8 4.1 3.8 1.8 1.9 100° C. 1.7 11 2.8 1.5 6.2 5.8 2.6 3.1__________________________________________________________________________ NT = NOT TESTED
If a maximum permissible loss of 20 MPY is assumed, which those working in the art accept as reasonable, it appears from Table II that for alloys of the invention to be used above 80° C. in sulfuric acid strengths below about 93%, the chromium index "CI", defined as the chromium content minus 6.08 times carbon content, should not be less than 25. For example, for sample A, which exhibited 26 MPY weight loss when tested at 90° C. in 80% sulfuric acid, the chromium index is less than 25: ##EQU2## In contrast, for sample H, which exhibited only 5.4 MPY weight loss when tested at 90° C. in 80% sulfuric acid, the chromium index is not less than 25: ##EQU3##
The alloys of the invention of at least about 0.33% Mo and at least about 3.5% Si may be employed at least to 100° C. at all acid strengths of 80% or higher when this calculation is at least about 27. For example, for the test of sample C at 100° C. in 96% sulfuric acid, which exhibited only 2.8 MPY weight loss, the chromium index is at least about 27: ##EQU4##
EXAMPLE 3
In a manner similar to Examples 1 and 2 above, samples from heats C, D, E, F, G, H and I were tested for 24 hours in 95 to 98% strength sulfuric acid at temperatures from 80° C. to 200° C. The results from these tests are set forth in Table III.
TABLE III______________________________________WEIGHT LOSS IN 95-98% SULFURICACID AT VARIOUS TEMPERATURES, MPYTEMPER-ATURE C D E F G H I______________________________________ 80° 0.6 0.4 0.6 1.4 3.6 2.2 2.4 90° 1.5 0.8 0.7 3.2 5.8 2.8 3.1100° 2.5 3.1 3.3 4.6 7.9 3.7 4.6120° 17 19 5.9 7.2 11 6.7 7.9140° 20 32 11 12 13 10 11160° 17 19 8.5 8.3 9.2 7.4 8.6180° 11 14 8.8 9.1 11 8.3 10200° 12 16 9.6 13 14 10 12______________________________________
These tests demonstrate that alloys of the invention are suitable for handling of hot concentrated sulfuric acid to at least 200° C.
EXAMPLE 4
Samples from the experimental heats of Example 1 were measured for hardness in the as cast condition and also after two cycles of aging for four hours at 1400° F. followed by rapid air cooling. The results of these hardness tests are set forth in Table IV.
TABLE IV______________________________________BRINELL HARDNESS NUMBERS IN ASCAST AND HEAT TREATED CONDITIONALLOY AS CAST HEAT TREATED______________________________________A 243 302B 275 354C 240 300D 260 325E 233 290F 245 275G 254 315H 218 266I 208 262______________________________________
Test data for prior art alloys in abrasive and corrosive wet process phosphoric acid slurries indicate that the alloys of the invention would have substantially improved service life, on the order of ten or more times the service life of prior art alloys, under such conditions. Such improvements in service life are expected even in instances in which the higher carbon alloys of the invention are not suitable due either to casting mass, design or a need for greater casting toughness in service. In view of the above, it will be seen that the several objects of the invention are achieved.
Although specific examples of the present invention are provided herein, it is not intended that they are exhaustive or limiting of the invention. These illustrations and explanations are intended to acquaint others skilled in the art with the invention, its principles, and is practical application, so that they may adapt and apply the invention in its numerous forms, as may be best suited to the requirements of a particular use. | Air-meltable, castable, machinable, hardenable alloys that are resistant to highly corrosive and abrasive slurries, especially those employed in the handling of wet-process phosphoric acid reactor fluids or hot concentrated sulfuric acid. The alloys consist of, by weight, about 11% to about 40% nickel (plus cobalt), about 27% to about 42% chromium, about 1% to about 4% copper, about 3% to about 4.5% silicon, about 0.7% to about 2% carbon, about 0.3% to about 3% manganese, up to about 4.5% molybdenum, and the balance essentially iron plus the usual minor impurities. | 2 |
This is a continuation-in-part of application Ser. No. 07/581,260 filed Sep. 11, 1990, now abandoned, which is a continuation of application Ser. No. 07/325,596, filed Mar. 20, 1989, now abandoned.
FIELD OF THE INVENTION
The invention relates to process gas atmospheres for reflow soldering with non-rosin-based flux containing solder which yield substantially no organic or inorganic residues, good wetting of the substrate and of the components, relatively broad temperature operation windows and relatively short component exposure to higher temperatures. These advantages result in good solder joint integrity and reduced component failure.
BACKGROUND OF THE INVENTION
Reflow soldering is employed extensively in the surface mount industries and particularly in the automated manufacture of printed circuit boards. Generally, miniature electronic components are surface mounted on a printed circuit board to which a solder in a creamy or paste-like consistency has been applied by a method such as screen printing, stenciling or dispensing.
The printed circuit board is then subjected to a sufficiently high temperature, generally 50° C. greater than the melting point of the alloy, to cause the flux and the alloy in the solder to liquify and to contact the components so that upon subsequent cooling of the printed circuit board, the components are soldered in place on the board. The heat can be supplied by, for example, infrared, vapor phase, heated conveyor belt (hot belt) or convective means.
The solder is conventionally comprised of a soft powdered metal alloy dispersed in a liquid medium containing a flux, an organic solvent, and a thickening agent specially selected to impart the desired consistency to the mixture. Ideally, the flux component should be non-corrosive, thereby yielding flux residues after completion of soldering which are themselves non-corrosive and non-conducting. In practice, however, such is not the case. Rosin-based flux materials, such as abietic acid-based flux, are used in most commercially available solders specifically formulated for use in the surface mount industries. These fluxes commonly contain activators, such as halides, particularly bromides, which leave corrosive and conductive residues requiring expensive and time-consuming removal techniques. Conventionally, these removal techniques utilize organic solvents, e.g. fluorochlorocarbons which give rise to environmental problems. As an alternative, aqueous systems have been tried for residue removal. However, due to poor wetting, it is difficult to obtain the penetration necessary with such systems to achieve the required cleaning. Additionally, removal of flux residues is difficult, particularly from areas of printed circuit boards beneath the components soldered thereto.
Rosin-based fluxes have additional disadvantages whether or not they contain conventional activators. For example, corrosive, rosin-based flux residues tend to be sticky, thereby inhibiting the automatic testing of the circuits and proving aesthetically objectionable.
The use of rosin-based or mildly activated rosin-based flux-containing solders can also result in poor wetting by the solder of the substrate and of components to be soldered.
Flux residues tend to be hygroscopic, thereby causing spattering, and some fluxes also undermine solder joint integrity by mechanisms such as permitting alloy particles in the solder to migrate from the solder site, giving rise to the formation of numerous small discrete balls of soft solder around the soldered joint, in effect creating electrical short circuits.
Hedges, et al, U.K. Patent No. GB 2,198,676 have attempted to solve the flux residue problems with a solder formulated without the rosin-based flux whereby the liquid medium in which the powdered alloy is dispersed comprises a substantially water-immiscible organic solvent, such as terpineol, containing at least one organic acid other than a rosin or a modified rosin, an amine or an amine hydrohalide as a flux; and at least one thickening agent. This non-rosin-based flux containing formula is commercially available as Multicore® X-32 from Multicore Solders, Hertfordshire, England.
However, the Hedges, et al solder still yields a discernable residue when reflowed in air even when the recommended temperature profile for heating is followed. It also wets poorly. This suggests that the operation window for reflow operations in air with the above solder is narrow and consequently difficult to practice commercially.
Oxidation on the surface of molten solder in lead tinning processes has been controlled by utilizing a nitrogen-purge system eliminating any contact of oxygen with the solder. See The Welding Journal, Vol. 65, No. 10, p 65 (1986). Lead tinning is performed on components prior to any soldering operations. Nitrogen has also been demonstrated to reduce white haze and to increase the chances of soldering marginally-solderable components. It is also suspected of reducing nonwetting, opens, solder balls, bridges and misalignments. See M. J. Mead and M. Nowotarski, The Effects of Nitrogen for IR Reflow Soldering, Technical Paper, SMT-IV-34, presented at the SMART IV Conference, Jan. 11-14, 1988.
The present invention surprisingly overcomes the above-mentioned problems and ensures good wetting of the substrate and of the components. In addition, the present invention leaves only a very mimimal post-solder residue and thereby eliminates post-solder cleaning operations. It is therefore an object of the invention to provide a method of reflow soldering which minimizes post-solder residue. It is a further object of the invention to provide a method of reflow soldering that can operate over a broad range of temperatures. It is yet a further object of the invention to provide a method of reflow soldering which ensures good wetting of the substrate and of the components. Another object of the invention is to provide a method of reflow soldering which exposes the components to maximum temperatures for a relatively short period of time.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a method of joining at least one solderable component to a substate by heating a non-rosin-based flux containing solder in the presence of said component in a low oxidizing atmosphere.
A preferred feature of the invention is an atmosphere comprising no more than about 1500 parts per million of oxygen gas; no more than about 1.5 percent by volume of water vapor; and a primary gas selected from the group consisting of nitrogen, carbon dioxide, hydrogen, an inert gas or mixtures thereof; wherein if water vapor or oxygen is present, hydrogen is present in an amount effective to reduce the oxidation potential of the water vapor or oxygen, and wherein if neither oxygen or water vapor are present, then said primary gas is selected from the group consisting of nitrogen, carbon dioxide, hydrogen, or mixtures thereof.
Further contemplated by the present invention is a method of joining at least one component to a substrate comprising (i) applying a non-rosin-based flux containing solder to a substrate or to a component on said substrate, the non-rosin-based flux containing solder comprising finely divided soft solder alloy dispersed in a liquid medium, the liquid medium comprising a substantially water-immiscible organic solvent containing one or more organic acids other than rosin or modified rosin, an amine or amine hydrohalide salt as a flux; and one or more thickening agents; (ii) placing the substrate in a low oxidizing atmosphere comprising no more than about 1500 parts per million of oxygen; no more than about 1.5 percent by volume of water vapor; and a primary gas selected from the group consisting of nitrogen, carbon dioxide, hydrogen, an inert gas or mixtures thereof; wherein if water vapor or oxygen is present, hydrogen is present in an amount effective to reduce the oxidation potential of the water vapor or oxygen; and wherein if neither oxygen nor water vapor is present then said primary gas is selected from the group consisting of nitrogen, carbon dioxide, hydrogen or mixtures thereof; and (iii) heating the solder alloy in the non-rosin-based flux containing solder and fusing the solder joints of the components to form solder joints substantilly free of residue.
A method is also disclosed wherein step (ii) is performed before step (i).
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a graphic illustration of two heating profiles for reflow soldering with a preferred non-rosin-based flux containing solder in an atmosphere comprising air and in a low oxidizing atmosphere.
DETAILED DESCRIPTION OF THE INVENTION
The atmosphere of the present invention is a low oxidizing atmosphere. It preferably comprises no more than about 1500 parts per million of oxygen; no more than about 1.5 percent by volume of water vapor; and a primary selected from the group consisting of nitrogen, carbon dioxide, hydrogen, an inert gas or mixtures thereof; wherein if water vapor or oxygen is present, hydrogen will be present in an amount effective to reduce the oxidation potential of the water vapor or oxygen; and wherein if neither oxygen nor water vapor is present, then said primary gas is selected from the group consisting of nitrogen, carbon dioxide, hydrogen or mixtures thereof. Further preferred are atmospheres wherein water vapor comprises from about 0.5 percent by volume to about 1.5 percent by volume of the atmosphere.
Additionally, preferred are atmospheres wherein hydrogen comprises from about 2 to about 20 percent by volume of the total volume of the atmosphere, remembering that hydrogen is always present in an effective amount to reduce the oxidation potential of any water vapor or oxygen present in the atmosphere. The oxidation potential of each of water vapor and oxygen or the net oxidation potential of the two combined must be so low that little or no residue is formed during reflow soldering. This results in hydrogen generally being present in amounts by volume greater than the amount of water vapor, as hydrogen will reduce the oxidation potential of water. Oxygen is limited to merely trace amounts so that oxidation will not occur and will not thereby interfere with the soldering process. Hydrogen also reduces the oxidation potential of oxygen. Any of the inert gases are satisfactory in the present invention. However, if neither oxygen nor water vapor is present then the primary gas is nitrogen, carbon dioxide, hydrogen or mixtures thereof.
The most preferred atmosphere of the present invention comprises, by volume, about 1 percent of water vapor, about 15 percent of hydrogen and about 84 percent of nitrogen.
Non-rosin-based flux containing solders are distinguished from rosin-based or mildly activated rosin-based (RMA) flux containing solders typically used in the surface mount industries in that they do not contain significant amounts of rosinous acids in the flux, such as to fail the OOS-571E Copper mirror Corrosion Test commonly used to characterize solder paste vehicle systems, and do not contain significant amounts of halide-containing activators, such as to reduce the surface insulation resistance below the control value as described in the Bellcore Technical Reference TR-TSY-000078, Section 13.1 or IPC Standard IPC-SF-818.
The non-rosin-based flux containing solder of the present invention is typically a cream or a paste.
The organic acids useful in formulating the preferred non-rosin-based flux containing solder of the present invention include aliphatic carboxylic acids such as propionic acid, oxalic acid, adipic acid, malic acid, maleic acid and citric acid, as well as aromatic carboxylic acids such as salicylic acid. In a preferred embodiment, two or more aliphatic carboxylic acids, for example, malic acid and adipic acid, comprise the non-rosin-based flux. Other organic acids which may be used are sulfonic acids.
Amines and amine hydrohalides useful as the non-rosin-based flux include alkyl or cycloalkyl amines and aromatic amines, and the hydrohalide salts of such amines, for example, diethylamine, triethylamine, cyclohexylamine, N-methylanilide and the corresponding hydrohalide of the foregoing such as triethylamine hydrobromide.
Substantially water-immiscible organic solvents useful in the present invention include monohydric compounds such as terpineol, and esters such as 2-ethoxyethyl acetate. Such solvents will have a relatively low melting point, a boiling point below the soldering temperature and low moisture absorption. These solvents may optionally be blended with polyhydric compounds such as glycols, for example, diethylene glycol, dipropylene glycol, or hexylene glycol; or hydric ethers, for example, triethylene glycol monethyl ether or tetraethylene glycol dimethyl ether, provided that the blend has a relatively low melting point, a boiling point below the soldering temperature, and low moisture absorption.
The thickening agent may be any of those conventionally employed in the art of the preparation of solder creams such as, for example, ethylcellulose or hydrogenated castor oil. In a preferred embodiment, two or more thickening agents are present in the non-rosin-based flux containing solder cream, for example, ethylcellulose and hydrogenated castor oil.
The volatile amine which is preferably present in the liquid medium may be, for example, morpholine or tributylamine. A chelating agent may also optionally be present, for example, benzotriazole or imidazole which is capable of reducing any discoloration created by solder reaction products.
Preferably, the liquid medium of the solder cream contains, on a percent by weight basis, from 0.2 to 10 percent, preferably from 0.5 to 5 percent of organic flux; from 0.1 to 10 percent, preferably from 0.5 to 5 percent of thickening agent(s); from 0 to about 10 percent, preferably from 0 to about 3 percent of organic amine; and from 0 to about 1 percent, preferably 0 to 1 percent, preferably from 0 to about 0.5 percent by weight of chelating agent.
The powdered soft solder alloy used in the non-rosin-based flux containing solder may comprise on a weight basis, particles of, for example, tin:lead alloy, tin:lead:antimony alloy, tin:lead:silver alloy, or tin:lead:silver:antimony alloy. Such alloys comprise on a weight basis, for example, 60 percent tin:40 percent lead, 63 percent tin:37 percent lead, 63 percent tin:36.7 percent lead:0.3 percent antimony, 63 percent tin:35 percent lead:2 percent silver, 62 percent tin:36 percent lead:2 percent silver or 62 percent tin:35.7 percent lead:2 percent silver:0.3 percent antimony. The solder alloy powder preferably has a particle size in the range of from 10 to 150 microns and most preferably from 20 to 100 microns.
The non-rosin-based flux containing solder may be prepared by admixing the powdered soft alloy with the liquid medium in a conventional manner. Preferably, the solder comprises from 70 to 95 percent by weight of alloy and correspondingly from 5 to 30 percent by weight of liquid medium and most preferably from 75 to 90 percent by weight of alloy and correspondingly from 10 to 25 percent by weight of liquid medium based upon 100 percent by weight of alloy and liquid medium combined.
The powdered soft solder alloy can be prepared in an atmosphere of only nitrogen or an inert gas in order to substantially eliminate oxidation of the alloy particles to produce a solder substantially free of oxides, i.e. less than 0.1 percent by weight based upon the total weight of the alloy.
The heating step of the present invention can be conducted by infrared, convective, vapor or heated conveyor belt (hot belt) means. The chamber or vessel in which the operation may take place may comprise a furnace or the like.
FIG. 1 heat profile A is the typical heat profile used in conventional reflow soldering. The substrate, the solder and the components are subjected to the maximum temperature for a relatively prolonged time as illustrated by the plateau in the middle of the heat cycle. Although such a heat profile may be used with the present invention, preferred heat profiles are of the type illustrated in FIG. 1, heat profile B wherein the maximum heat is reached during a relatively short period illustrated as a spike. Consequently, the substrate, the solder and the components are subjected to maximum heat for a shorter period of time than in the conventional heat profile, and component failures are reduced.
Suitable substrates include without limitation printed circuit boards, hybrid circuits, clean metals such as copper and the like, and mildly oxidized metals such as mildly oxidized copper and the like.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples illustrate the invention without limitation.
EXAMPLES 1-3
A non-rosin-based flux containing solder paste, alloy composition 62 wt. percent Sn:36 wt. percent Pb:2 wt. percent Ag (Multicore® X-32,), is applied to the surface of a mildly oxidized copper coupon substrate, to a printed circuit board substrate, and to a hybrid circuit substrate. The substrates are placed in a chamber containing an atmosphere of 1 percent by volume of water vapor, 15 percent by volume of hydrogen gas and 84 percent by volume of nitrogen gas and then are heated by infrared means according to a heat profile of a preheat setting of 175° C. for 200 seconds and a peak temperature of 260° C. for 5 seconds. The solder reflows, the texture is unremarkable, and there is no visible residue.
EXAMPLES 4-6
A non-rosin-based flux containing solder paste, alloy composition 62 wt. percent Sn:36 wt. percent Pb:2 wt. percent Ag (Multicore® X-32), is applied to the surface of a clean copper coupon substrate, a printed circuit board substrate, and a hbrid circuit substrate. The substrates are placed in a chamber containing an atmosphere of 0.55 percent by volume of water vapor, 5 percent by volume of hydrogen gas, and 94.45 percent by volume of nitrogen gas and then are heated by infrared means according to a heat profile of a preheat setting of 175° C. for 200 seconds and a peak temperature of 260° C. for 5 seconds. The solder reflows, the texture is rough, and there is no visible residue.
EXAMPLE 7
The procedure of Example 4 is followed substituting a mildly oxidized copper coupon substrate for the substrate and an atmosphere of 0.60 percent by volume of water vapor, 5 percent by volume of hydrogen gas and 94.4 percent by volume of nitrogen gas for the atmosphere. The solder reflows, the texture is rough, and there is no visible residue.
EXAMPLES 8-9
The procedure of Example 7 is followed substituting a printed circuit board substrate and a hybrid circuit substrate for the substrate. The solder reflows well, the texture is rough, and there is no visible residue.
COMPARATIVE EXAMPLES 10-12
The procedures of Examples 1-3 are followed substituting an atmosphere of 1 percent by volume of water vapor, 2 percent by volume of hydrogen gas and 97 percent by volume of nitrogen gas for the atmosphere. The solder reflows, and there is a residue.
EXAMPLES 13-15
The procedures of Examples 7-9 are followed substituting an atmosphere of 15 percent by volume of hydrogen gas and 85 percent by volume of nitrogen gas for the atmosphere. The solder reflows well, and there is a minimal amount of residue.
EXAMPLE 16
The procedure of Examples 4 is followed substituting an atmosphere of nitrogen gas for the atmosphere. The solder reflows well, and there is some visible organic residue. There is adequate wetting of the substrate.
EXAMPLES 17-18
The procedures of Examples 5 and 6 are followed substituting an atmosphere of nitrogen gas for the atmosphere. The solder reflows well, and there is some visible residue.
EXAMPLE 19
The procedure of Example 16 is followed substituting a mildly oxidized copper coupon substrate for the substrate. The solder reflows well, and there is little organic residue.
EXAMPLE 20
A non-rosin-based flux containing solder, alloy composition 62 wt. percent Sn:36 wt. percent Pb:2 wt. percent Ag (Multicore® X-32), is applied to the surface of a mildly oxidized copper coupon substrate. The substrate is placed in an atmosphere of carbon dioxide gas and then is heated by infrared means according to a heat profile of a preheat setting of 200° C. for 180 seconds and a peak temperature of 260° C. for 5 seconds. There is adequate wetting of the substrate.
COMPARATIVE EXAMPLES 21-23
An non-rosin-based flux containing solder paste, alloy composition 62 wt. percent Sn:36 wt. percent Pb:2 wt. percent Ag (Multicore® X-32), is applied to the surface of a clean copper coupon substrate, to a printed circuit board substrate and to a hybrid circuit substrate. The substrates are placed in an atmosphere of 100 percent helium at a total flow of 2 cu.ft./hr. and then are heated by infrared means according to a heat profile of a preheat setting of 175° C. for 200 seconds, and a peak temperature of 260° C. for 6 seconds. The solder does not melt.
COMPARATIVE EXAMPLES 24-26
The procedures of Comparative Examples 21-23 are followed substituting a heat profile of a preheat setting of 175° C. for 200 seconds and a peak temperature of 260° C. for 7 seconds. The solder does not melt.
COMPARATIVE EXAMPLES 27-29
The procedures of Examples 4-6 are followed substituting an atmosphere of air for the atmosphere. atmosphere. The solder melts but reflows only partially, and there is solder ball formation.
COMPARATIVE EXAMPLE 30
The procedure of Comparative Example 27 is followed substituting a mildly oxidized copper coupon substrate for the substrate. The solder melts but reflows only partially. The solder does not wet the copper coupon substrate, and there is solder ball formation.
All patents, applications and publications mentioned above are hereby incorporated by reference.
Many variations of the present invention will suggest themselves to those skilled in this art in light of the above, detailed description. For example, other alloys may be used to formulate the solder and other means may be used to supply heat. All such obvious variations are within the full scope of the appended claims. | A method of joining components to a substrate by reflow soldering with non-rosin-based flux containing solder is disclosed comprising heating the solder in the presence of the components in a low oxidizing atmosphere. | 1 |
This is a division of Application Ser. No. 734,969 filed Oct. 22, 1976 now U.S. Pat. No. 4,107,821.
FIELD OF THE INVENTION
This invention relates to a drawing device for sliver.
In such a device, sliver passes between two endless moving elements which control and retain the fibres whilst they are drawn by drawing cylinders downstream of the device.
DESCRIPTION OF THE PRIOR ART
A known such device comprises two sets of high population needles which penetrate the sliver and constitute retention members.
This device has the disadvantage of high cost and limited speed. The latter is due to the mode of propulsion which is by means of a screw and to the limited strength of the welds connecting the needles to their support. The limited speed means limited sliver processing.
An object of the invention is to obviate these disadvantages by providing a simple drawing device which allows good control of the sliver, which is of a relatively low cost and which makes high speed working possible.
BRIEF DESCRIPTION OF THE INVENTION
The invention provides a device for drawing sliver, comprising, for the control and the retention of the sliver, two endless moving elements between which the sliver passes, one of which, at least, is constituted by an assembly of transverse bars mounted between two endless chains for movement on a closed circuit, the hinged transverse bars carrying member for penetration into the sliver, having a convex cylindrical active surface for contact with the sliver, and forming a materially continuous apron in the working zone.
In a preferred embodiment the two endless elements have the same structure, the members for penetration into the ribbon being staggered from one element to the other in the working zone.
In another embodiment, only one of the endless elements is arranged as described above and the other has any practical suitable structure. This can, for example, be a smooth apron having depressions for the passage of the members carried by the first element and smooth raised surfaces cooperating with the convex surface of the needle-carrying elements in order to control the ribbon.
In accordance with another embodiment, the bodies of the element which carries penetration members are provided only with a single row of members. This row can be disposed in the middle of the body, or be off-set with regard to the centre, that is to say be located in a plane parallel to the median longitudinal plane of the body. With regard to the direction of advance of the material, this single row can be located before or after the median longitudinal plane.
In accordance with one feature of the invention, the bodies of the element which carries penetration members have a circular cylindrical convex surface which, upon passage of the bars over a pair of return wheels guiding the endless element at the exit from the drawing zone, is coaxial to the said wheels so that the penetration members leave the sliver with the minimum of relative speed and create a disturbance of the sliver which is as small as possible.
In accordance with another feature, one of the two pairs of return wheels, at the exit from the drawing zone, is set back relative to the other pair so that that of the two drawing cylinders which has the largest diameter can be brought nearer to the said other pair, so that the distance which the sliver covers between the end of the control zone and the drawing cyclinders is as small as possible.
In accordance with another feature, usable in the first preferred embodiment of the invention, the feed cylinders, arranged upstream of the control zone, are placed so that the sliver co-operates first with one of the endless elements and then with the other, to create a progressive entry of the two sets of penetration members into the sliver.
In accordance with another feature of the invention, all the penetration members, or only a part thereof, can be inclined relative to the median longitudinal plane of the bodies, towards the front or towards the rear relative to the direction of circulation of the bars.
In accordance with another feature of the invention, the bodies of the element which carries penetration members are contiguous, that is to say that, in the working zone, and preferably only in this zone, they are very close to one another in order to form a practically continuous apron not allowing fibres, fluff or other waste to penetrate into the mechanical part of the machine or even onto the elements which are underneath, on their return path.
In another embodiment of the invention, the drawing device is characterised by the combination, on the one hand, of a control field equipped with an endless element having a succession of hinged transverse bars carrying small population penetration members and having a convex cylindrical active surface, with, on the other hand, a control field equipped with an endless element having a succession of transverse strips having a flexible lip for contact with the sliver which they apply to the convex surface of the bars carrying the penetration members.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described further, by way of example, with reference to the accompanying drawings, wherein;
FIG. 1 is a schematic side view, with section and with parts broken away, of a drawing device in accordance with a preferred embodiment of the invention;
FIG. 2 is a perspective view of a convex needle bar of the device of FIG. 1;
FIG. 3 is a cross section of the bar of FIG. 2;
FIGS. 4 and 5 show, in broken-away perspective, two modifications of bar of the device of the invention;
FIG. 6 shows, in cross section, a modification in which the bars of the two endless elements are each equipped with only a single row of needles;
FIG. 7 shows, in cross section, a modification in which the bars of the two endless elements are of a different structure;
FIG. 8 shows, in side view, the part next to the drawing station, in another modification; and
FIG. 9 is a cross section of the control device of FIG. 8 to show how the fibres are maintained and controlled by the penetration members constituted by needles co-operating with contact members constituted by flexible lips.
DESCRIPTION OF PREFERRED EMBODIMENTS
The drawing device shown in FIG. 1 comprises a feed station 1 for feeding in sliver 2, a control station 3 for retention of the sliver, and a drawing station 4.
The feed station 1 comprises, in known manner, two cylinders 5, 6 between which the sliver 2 passes and which is delivered thereby at a desired speed.
The control and retention station 3 comprises, also in a known manner, two endless elements 7, 8 situated one above the other and circulating around pairs of driving inlet wheels 9, 10, pairs of return outlet wheels 11, 12 and pairs of detour wheels 13, 14 for the return runs. Between the pairs of inlet wheels 9, 10 and outlet wheels 11, 12, the active runs of the endless elements 7, 8 are parallel and circulate jointly in the same direction and at the same linear speed.
The drawing station 4 comprises, also in a known manner, an upper cylinder 15 and a lower cylinder 16 of smaller diameter, which attract the sliver 2 controlled and partially retained by the elements 7, 8.
In accordance with the invention, more especially to ensure a good control of the sliver, at least one of the elements 7, 8 is constituted by a succession of transverse bars 17, hinged one to the other, carrying members of low population for penetration into the sliver and having a convex cylindrical active surface for contact with the sliver. The convex surface has a crown portion which is closest to the other element as the elements pass in facing relation through the control station 3. In FIG. 3 the crown portion is symmetrically located between the edges of the transverse bar.
In accordance with the embodiment shown in FIGS. 1 to 3, the bars 17 are each in the form of the block comprising ends 18, 19 for the hinged coupling to lateral chains 20, 21 (FIG. 1) and an elongate body 22 having a convex cylindrical active surface 23. Needles 24 are secured to the body 22, in a suitable manner, for example by driving in with force.
The needles 24 are implanted with a low population, in two parallel rows symmetrical relative to the median longitudinal plane of the bodies 22, that is, the plane through the crown portion of the convex surface. In other words, the needles are spaced from the crown portion of the transverse bars which represents the surfaces of the bars closest together with the work zone. They are, by way of example, arranged perpendicular to the direction of advance of the elements 7, 8 in the rectilinear zone of co-operation of these, but they could also be inclined forwards or backwards. The bars 17 of one of the two elements are off-set relative to those of the other elements, in the direction of advance, so that the rows of needles are spaced apart one from the other by the same distance, in the work zone.
The lateral chains 20, 21 co-operate with the toothed wheels 9 to 14 for driving the bars 17. In the said rectilinear zone, the flat inner surface 25 of the bars 17, remote from the convex outer surface 23, co-operates with upper fixed guides 26 and lower fixed guides 27 which determine the distance between the elements 7, 8 in the said zone.
In operation, the sliver is delivered by the feed cylinders 5, 6 and pulled by the drawing cylinders 15, 16. Between these two pairs of cylinders, the sliver 2 is controlled and retained by the bars 17, in two ways simultaneously; on the one hand, by the needles 24 which penetrate into the structure of the sliver and control it internally and, on the other hand, by the convex surfaces 23 which control it externally.
In the embodiment of FIG. 1, the two elements 7, 8 are of the type having bars with needles 24 and having a convex surface 23; the needles of the bars 17 are off-set from one element to the other, in the zone of co-operation of the said elements.
In accordance with one feature of the invention, the convex surface 23 of each bars 17 is of a circular cross-section and of a radius such that, at the passage of the chains 20, 21 over the outlet wheels 11, 12, the circular contour of the corresponding bars is coaxial to the said wheels; in this way, the outlet movement of the needles from the structure of the sliver at the end of control is effected materially without any relative movement between the needles and the sliver, since the sliver unrolls from the convex surfaces 23, with reduces to its minimum the displacement of the fibres created by the exit of the needles.
In accordance with another feature of the invention, the pair of upper return wheels 11 is set back relative to the pair of lower wheels 12, so that the upper drawing cylinder 15, of a larger diameter than the lower drawing cylinder 16, can occupy a position very close to the lower endless element 8; in this way, as is shown in FIG. 1, the distance which the drawn sliver 2a covers between the end of the control zone and the drawing cylinders is very short.
In accordance with another feature of the invention, the feed cylinders 5, 6 are so positioned that the sliver 2 cooperates first with the needles 24 of one of the elements 7, 8 for example with those of the lower element 8, then with those of the other element; in this way there is established a progressive entry of the two fields of needles 24 into the sliver 2. Generally, the inlet wheels 9, 10 are situated at the same level; this is why, as is shown in FIG. 1, the feed cylinders 5, 6 are vertically off-set relative to the median horizontal plane of the wheels 9, 10.
In FIGS. 4 and 5 there have been shown two modifications for the bars 17 which differ from those of FIGS. 1 to 3 only by the structure of their median part. In FIG. 4, the bar 17 comprises, in its median part, a channel 28 having two reentrant upper flanges 29. The interior of the channel is filled with a filling material 30, flexible or rigid, and, under the flanges 29 there are slid convex small plates 31 placed side-by-side and having protruding teeth 32, or the like, of low population.
In FIG. 5, the median part of the bar 17 is in one piece and has integral projections 33, in the form of teeth, needles, blades, etc., of low population.
In the modification of FIG. 6, the bars 17 of the endless elements 7, 8 differ from those of FIGS. 1 to 3 only by the presence of a single row of needles 24 on the body 22 of the bars and by the off-setting by half a pitch of the bars of the upper 7 and lower 8 elements, the needles 24 being offset relative to the median longitudinal plane of the body 22.
As indicated previously, only one of the two endless elements 7, 8, for the control of the sliver, can comprise bars having needles, or the like, and having a convex surface. There is shown in FIG. 7 a part of a device in accordance with the invention having such an arrangement. In this figure, the lower endless element 8 comprises bars 17 having needles, or the like, and having a convex surface, while the upper endless element 7 is of any suitable structure whatsoever. It comprises, for example, bars 34, mounted and hinged like the bars 17, and having, on their active surface, grooves 35 for the passage of the needles of the element 8, and smooth raised portions 36 for co-operating with the convex surface 23 of the bars 17 having needles 24, in the control of the sliver.
In all the embodiments, the bars 17 or 34 of one and the same endless element 7, 8 are very close together, at least in the working zone, to form a materially continuous apron not allowing the fibres, fluff or other waste, to pass into the mechanical part of the machine or onto the return run of the elements 7, 8.
Finally, in another modification shown partially in FIGS. 8 and 9 (in which there have been retained the same reference numbers as in FIG. 1 for denoting the corresponding members) the feed station has not been shown.
The station 3 for control and retention of the sliver comprises two endless elements 7 and 8 situated one above the other and their active runs circulate jointly in the same direction and at the same linear speed.
The lower field 8 comprises the transverse bars 17 hinged one to the other and fixed, at each of their ends, to a chain 21 driven by a toothed wheel 12. The bodies 22 of the bars 17 have a convex cylindrical active surface 23 and comprise only a low population of members for penetration into the sliver, namely a single row of needles 24 arranged, in the example shown, perpendicular to the direction of advance of the element 7 in the rectilinear portion of the active run of the chain, and, offset laterally, in the direction of advance, relative to the vertical plane of symmetry or crown portion of the convex surface of the bar 17. The needles 24 could moreover be inclined forwards or backwards.
The upper field 7 comprises transverse strips 40 having a flexible lip, of a kind known from French Pat. No. 1,593,755 of the assignee firm, which are made of a resilient material such as rubber, elastomer or leather, fixed at each end on a chain 41 driven by a toothed wheel 11.
Each of the transverse strips 40 is engaged, in its mounting portion, in the curved edges of a metallic part 42 in the form of a channel 42 while, in its working portion, it is, preferably, hollowed out at 43 to facilitate the suppleness of the movements of the lip; this latter is inclined backwards, relative to the direction of circulation, to provide, on its contact with the convex bar 17, a jamming or interference effect. The strips 40 and the bars 17 are arranged so that the needles 24 of a bar place themselves into the gaps between the flexible lips of two consecutive strips 40. Thus, the sliver 2, coming from the food cylinders (not shown), is supported and controlled by the lower endless element 8 and the upper endless element 7 in order to be drawn by the drawing cylinders 15, 16 and to emerge as a drawn sliver 2a.
It can easily be seen that, thanks to such a combination of means, the fibres are well held and controlled by the interacting action of the convex bars 17 having needles 24 and of the flexible lips 40, and wall parallelised and in more regular bunches through the effect of the needles. Up to the point A, the last line of strong pinching between the fields 7 and 8 before the drawing cylinders 15 and 16, the fibres are well held, and it is only between the points A and B (B being the line of nip of the said drawing cylinders) that the drawing process takes place.
In FIG. 9 there has been shown the configuration which is assumed by a strip 40 having a flexible lip which exerts on the sheet of fibres 2 being treated a pressure which is greater, the greater the thickness of the sliver. In the middle of the sliver, that is to say at the point of its maximum thickness, the pressure is also maximum, while, on the edges where the thickness of the sheet is slight, the pressure is much less.
It emerges from the foregoing that the device of the invention, by virtue of the combination of the members having low population for the penetration into the structure of the sliver and of the convex surfaces, ensures a good control of the sliver and can be constructed in an economical manner. Moreover, the device is sturdy and makes possible operation at high speed.
In addition, the connecting parts of slivers pieced before the entry into the device, are well equalised and smoothed thanks to the presence of the needles; on the other hand, thanks to the low population of the needles, one eliminates the risk of catching and of winding of the fibres, and the decrease of control of the fibres by the needles is compensated for by the control by the convex surfaces. Thus, with a device in accordance with the invention, thanks to the double control by needles and convex surfaces, the advantages of the control by needles are preserved and the disadvantages eliminated.
It is understood that the invention is not restricted to the embodiment described and shown and that one can, on the contrary, conceive various modifications without departing from its scope.
Thus the needles 24 can be replaced by knives, blades, teeth or by any other penetration member. | In a drawing device for sliver comprising two endless moving elements having cooperating working runs between which the sliver passes, at least one of the elements is constituted by a plurality of bars extending between a pair of parallel carriers (e.g. chains) and each bar has a convexly curved outer working surface from which penetration members, (e.g. needles) extend. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of, and claims priority to U.S. patent application Ser. No. 9/783,236, filed Feb. 13, 2001, for Implantable Retinal Electrode Array Configuration for Minimal Retinal Damage and Method of Reducing Retinal Stress.
GOVERNMENT RIGHTS
[0002] This invention was made with government support under grant No. R24EY12893-01, awarded by the National Institutes of Health. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] This invention relates to a prosthetic medical ocular device and methods, and more particularly to an intraocular electrical retinal stimulation device that minimizes retinal damage during and after surgery, is easily manipulated by the surgeon performing the implant procedure, and to a method of reducing retinal stress.
[0005] 2. Description of the related art including information disclosed under 37 CFR Secs. 1.97-1.99
[0006] In 1755 LeRoy passed the discharge of a Leyden jar through the orbit of a man who was blind from cataract and the patient saw “flames passing rapidly downwards.” Ever since, there has been a fascination with electrically elicited visual perception. The general concepts of electrical stimulation of retinal cells to produce these flashes of light or phosphenes has been known for quite some time. Based on these general principles, some early attempts at devising a prosthesis for aiding the visually impaired have included attaching electrodes to the head or eyelids of patients. While some of these early attempts met with some limited success, these early prosthesis devices were large, bulky and could not produce adequate simulated vision to truly aid the visually impaired.
[0007] In the early 1930's, Foerster investigated the effect of electrically stimulating the exposed occipital pole of one cerebral hemisphere. He found that, when a point at the extreme occipital pole was stimulated, the patient perceived a small spot of light directly in front and motionless (a phosphene). Subsequently, Brindley and Lewin (1968) thoroughly studied electrical stimulation of the human occipital cortex. By varying the stimulation parameters, these investigators described in detail the location of the phosphenes produced relative to the specific region of the occipital cortex stimulated. These experiments demonstrated: (1) the consistent shape and position of phosphenes; (2) that increased stimulation pulse duration made phosphenes brighter; and (3) that there was no detectable interaction between neighboring electrodes which were as close as 2.4 mm apart.
[0008] As intraocular surgical techniques have advanced, it has become possible to apply stimulation on small groups and even on individual retinal cells to generate focused phosphenes through devices implanted within the eye itself. This has sparked renewed interest in developing methods and apparati to aid the visually impaired. Specifically, great effort has been expended in the area of intraocular retinal prosthesis devices in an effort to restore vision in cases where blindness is caused by photoreceptor degenerative retinal diseases such as retinitis pigmentosa and age related macular degeneration which affect millions of people worldwide.
[0009] Neural tissue can be artificially stimulated and activated by prosthetic devices that pass pulses of electrical current through electrodes on such a device. The passage of current causes changes in electrical potentials across neuronal membranes, which can initiate neuron action potentials, which are the means of information transfer in the nervous system.
[0010] Based on this mechanism, it is possible to input information into the nervous system by coding the information as a sequence of electrical pulses which are relayed to the nervous system via the prosthetic device. In this way, it is possible to provide artificial sensations including vision.
[0011] One typical application of neural tissue stimulation is in the rehabilitation of the blind. Some forms of blindness involve selective loss of the light sensitive transducers of the retina. Other retinal neurons remain viable, however, and may be activated in the manner described above by placement of a prosthetic electrode device on the inner (toward the vitreous) retinal surface. This placement must be mechanically stable, minimize the distance between the device electrodes and the neurons, and avoid undue compression of the neurons.
[0012] In 1986, Bullara (U.S. Pat. No. 4,573,481) patented an electrode assembly for surgical implantation on a nerve. The matrix was silicone with embedded iridium electrodes. The assembly fit around a nerve to stimulate it.
[0013] Dawson and Radtke stimulated cat's retina by direct electrical stimulation of the retinal ganglion cell layer. These experimenters placed nine and then fourteen electrodes upon the inner retinal layer (i.e., primarily the ganglion cell layer) of two cats. Their experiments suggested that electrical stimulation of the retina with 30 to 100 uA current resulted in visual cortical responses. These experiments were carried out with needle-shaped electrodes that penetrated the surface of the retina (see also U.S. Pat. No. 4,628,933 to Michelson).
[0014] The Michelson '933 apparatus includes an array of photosensitive devices on its surface that are connected to a plurality of electrodes positioned on the opposite surface of the device to stimulate the retina. These electrodes are disposed to form an array similar to a “bed of nails” having conductors which impinge directly on the retina to stimulate the retinal cells. Such a device increases the possibility of retinal trauma by the use of its “bed of nails” type electrodes that impinge directly on the retinal tissue.
[0015] The art of implanting an intraocular prosthetic device to electrically stimulate the retina was advanced with the introduction of retinal tacks in retinal surgery. De Juan, et al. at Duke University Eye Center inserted retinal tacks into retinas in an effort to reattach retinas that had detached from the underlying choroid, which is the source of blood supply for the outer retina and thus the photoreceptors. See, e.g., E. de Juan, et al., 99 Am. J. Opthalmol. 272 (1985). These retinal tacks have proved to be biocompatible and remain embedded in the retina, and choroid/sclera, effectively pinning the retina against the choroid and the posterior aspects of the globe. Retinal tacks are one way to attach a retinal array to the retina.
[0016] The retina is extraordinarily fragile. In particular, retinal neurons are extremely sensitive to pressure; they will die if even a modest intraocular pressure is maintained for a prolonged period of time. Glaucoma, which is one of the leading causes of blindness in the world, can result from a chronic increase of intraocular pressure of only 10 mm Hg. Furthermore, the retina, if it is perforated or pulled, will tend to separate from the underlying epithelium, which will eventually render it functionless. Thus attachment of a conventional prosthetic retinal electrode device carries with it the risk of damage to the retina, because of the pressure that such a device could exert on the retina.
[0017] Byers, et al. received U.S. Pat. No. 4,969,468 in 1990 which disclosed a “bed of nails” electrode array which in combination with processing circuitry amplifies and analyzes the signal received from the tissue and/or which generates signals which are sent to the target tissue. The penetrating electrodes are damaging to the delicate retinal tissue of a human eye and therefore are not applicable to enabling sight in the blind.
[0018] In 1992 U.S. Pat. No. 5,109,844 issued to de Juan et al. on a method of stimulating the retina to enable sight in the blind wherein a voltage stimulates electrodes that are in close proximity to the retinal ganglion cells. A planar ganglion cell-stimulating electrode is positioned on or above the retinal basement membrane to enable transmission of sight-creating stimuli to the retina. The electrode is a flat array containing 64-electrodes.
[0019] Norman, et al. received U.S. Pat. No. 5,215,088 in 1993 on a three-dimensional electrode device as a cortical implant for vision prosthesis. The device contains perhaps a hundred small pillars each of which penetrates the visual cortex in order to interface with neurons more effectively. The array is strong and rigid and may be made of glass and a semiconductor material.
[0020] U.S. Pat. No. 5,476,494, issued to Edell, et al. in 1995, describes a retinal array held gently against the retina by a cantilever, where the cantilever is anchored some distance from the array. Thus the anchor point is removed from the area served by the array. This cantilever configuration introduces complexity and it is very difficult to control the restoring force of the cantilever due to varying eye sizes, which the instant invention avoids.
[0021] Sugihara, et al. received U.S. Pat. No. 5,810,725 in 1998 on a planar electrode to enable stimulation and recording of nerve cells. The electrode is made of a rigid glass substrate. The lead wires which contact the electrodes are indium tin oxide covered with a conducting metal and coated with platinum containing metal. The electrodes are indium tin oxide or a highly electrically conductive metal. Several lead-wire insulating materials are disclosed including resins.
[0022] U.S. Pat. No. 5,935,155, issued to Humayun, et al. in 1999, describes a visual prosthesis and method of using it. The Humayun patent includes a camera, signal processing electronics and a retinal electrode array. The retinal array is mounted inside the eye using tacks, magnets, or adhesives. Portions of the remaining parts may be mounted outside the eye. The Humayun patent describes attaching the array to the retina using retinal tacks and/or magnets. This patent does not address reduction of damage to the retina and surrounding tissue or problems caused by excessive pressure between the retinal electrode array and the retina.
[0023] Mortimer's U.S. Pat No. 5,987,361 of 1999 disclosed a flexible metal foil structure containing a series of precisely positioned holes that in turn define electrodes for neural stimulation of nerves with cuff electrodes. Silicone rubber may be used as the polymeric base layer. This electrode is for going around nerve bundles and not for planar stimulation.
SUMMARY OF THE INVENTION
[0024] The apparatus of the instant invention is a retinal electrode array assembly in various embodiments with features that reduce irritation of the retina and the surrounding tissues during surgery and post-operatively and that facilitate installation by making the mounting aperture for placement of a surgical tack easy to locate and by providing a handle for use by the installing surgeon.
[0025] The retinal electrode array is made up of the electrode array body, which contains an array of electrodes and which is attached directly to the retina, feeder cable for transmitting electrical signals to the retina, and electronics which process the electrical signal before it is sent to the electrodes.
[0026] The electrode array body is made of soft silicone, having a hardness of about 50 on the Shore A scale as measured with a durometer, to assure intimate contact with the retina and to minimize stress concentrations in the retina. It has an over all oval shape avoiding stress concentrations in the retina by eliminating array corners. It is spherically curved so that it conforms readily to the curvature of the eye thereby minimizing contact stresses with the retina. It also has rounded edges to avoid contact stresses with the retina or tearing of the retina at the edge of the electrode array body. The edges may alternatively be progressively thinned (like a diver's flipper) to make a taper. The radius of curvature is reduced near the edge of the electrode array body, thus lifting the edge of the electrode array body away from the retina, thereby avoiding edge stress concentrations.
[0027] The electrode array body has at least one mounting aperture for attaching the electrode array to the retina by means of a mounting tack. The array also has a colored reinforcing ring that surrounds the mounting aperture in the array. The reinforcing ring is used for visually locating the mounting aperture during surgery and for structural support of a surgical tack.
[0028] In an alternate embodiment, the aperture and mounting tack are replaced with a ferromagnetic keeper that is placed in the electrode array body for mounting the electrode array body to the retina using magnetic attractive forces between the ferromagnetic keeper and a magnet.
[0029] The electrode array body contains an array of conductive electrodes to transmit electrical signals to the retina. One electrode may serve as a reference or ground potential return.
[0030] In order to eliminate stress in the retina from the mounting tack a strain relief internal tab is formed by placing a strain relief slot partially around the mounting aperture. The strain relief internal tab may be made of thinner silicone to minimize stress transfer from the mounting tack to the retina.
[0031] A grasping handle that is attached to the electrode array body is provided for use by the surgeon during placement of the electrode array body to avoid trauma to the eye during implantation. The feeder cable carries electrical signals between the electrodes and the electronics and contains a coil of electrical conductors to eliminate pulling of the array by the cable post-operatively due to mechanical or thermal stresses. The feeder cable is filled with soft silicone to stabilize the wire and to allow the coil to move somewhat within the cable.
OBJECTS OF THE INVENTION
[0032] It is the object of the invention to attach an electrode array body to the retina of an eye and enable blind people to see images.
[0033] It is the object of the invention to attach an electrode array body to the retina while avoiding or minimizing harmful stresses on the retina from the electrode array body.
[0034] It is the object of the invention to enable a surgeon to easily locate the mounting aperture for attachment of an electrode array body to the retina of an eye by a surgical tack.
[0035] It is the object of the invention to provide tabs for attachment of the electronics and feeder cable to the recipient of the retinal electrode array.
[0036] Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] FIG. 1 illustrates a perspective view of the retinal electrode array assembly showing the electrodes and signal conductors as well as mounting aperture for tacking the assembly inside the eye, wherein both the array and its associated electronics are located inside the eye.
[0038] FIG. 2 illustrates a perspective view of the retinal electrode array assembly showing the electrodes and signal conductors as well as mounting aperture for tacking the assembly inside the eye, wherein the associated electronics are located outside the eye.
[0039] FIG. 3 illustrates a perspective view of the retinal electrode array assembly wherein the array is installed inside the eye and the associated electronics are installed outside the eye at some distance from the sclera wherein the feeder cable contains both a coiled cable leading between the electronics and the sclera and a series of fixation tabs along the feeder cable for securing the feeder cable by suture.
[0040] FIG. 4 depicts a cross-sectional view of the retinal electrode array, the sclera, the retina and the retinal electrode array showing the electrodes in contact with the retina.
[0041] FIG. 5 depicts a cross-sectional view of the retinal electrode array showing a strain relief slot, strain relief internal tab and a mounting aperture through a reinforcing ring for a mounting tack to hold the array in position.
[0042] FIG. 6 illustrates a cross-sectional view of the retinal electrode array showing a strain relief slot and a ferromagnetic keeper to hold the array in position.
[0043] FIG. 7 illustrates a cross-sectional view of the retinal electrode array showing a strain relief slot and a mounting aperture through a reinforcing ring for a mounting tack to hold the array in position, wherein the strain relief internal tab containing the mounting aperture is thinner than the rest of the array.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0044] FIG. 1 provides a perspective view of a preferred embodiment of the retinal electrode array, generally designated 2 , comprising oval-shaped electrode array body 4 , a plurality of electrodes 6 made of a conductive material, such as platinum or one of its alloys, but that can be made of any conductive biocompatible material such as iridium, iridium oxide or titanium nitride, and single reference electrode 6 A made of the same material as electrode 6 , wherein the electrodes are individually attached to separate conductors 8 made of a conductive material, such as platinum or one of its alloys, but which could be made of any biocompatible conductive material, that is enveloped within an insulating sheath 10 , that is preferably silicone, that carries an electrical signal to each of the electrodes 6 . “Oval-shaped” electrode array body means that the body may approximate either a square or a rectangle shape, but where the corners are rounded. The reference electrode 6 A is not necessarily stimulated, but is attached to a conductor, as are electrodes 6 . The electrodes could be used in another application as sensors to transmit electrical signals from a nerve. The electrodes 6 transmit an electrical signal to the eye while reference electrode 6 A may be used as a ground, reference, or control voltage.
[0045] Electrode array body 4 is made of a soft material that is compatible with the body. In a preferred embodiment array body 4 is made of silicone having a hardness of about 50 or less on the Shore A scale as measured with a durometer. In an alternate embodiment the hardness is about 25 or less on the Shore A scale as measured with a durometer. It is a substantial goal to have electrode array body 4 in intimate contact with the retina of the eye.
[0046] Strain relief internal tab 12 , defined by a strain relief slot 13 that passes through the array body 4 , contains a mounting aperture 16 for fixation of the electrode array body 4 to the retina of the eye by use of a surgical tack, although alternate means of attachment such as glue or magnets may be used. Reinforcing ring 14 is colored and opaque to facilitate locating mounting aperture 16 during surgery and may be made of tougher material, such as high toughness silicone, than the body of the electrode array body to guard against tearing.
[0047] Signal conductors 8 are located in an insulated flexible feeder cable 18 carrying electrical impulses from the electronics 20 to the electrodes 6 , although the electrodes can be sensors that carry a signal back to the electronics. Signal conductors 8 can be wires, as shown, or in an alternative embodiment, a thin electrically conductive film, such as platinum, deposited by sputtering or an alternative thin film deposition method. In a preferred embodiment, the entire retinal electrode array 2 including the feeder cable 18 and electronics 6 are all implanted inside the eye. Electronics 20 may be fixated inside the eye to the sclera by sutures or staples that pass through fixation tabs 24 . The conductors are covered with silicone insulation.
[0048] Grasping handle 46 is located on the surface of electrode array body 4 to enable its placement by a surgeon using forceps or by placing a surgical tool into the hole formed by grasping handle 46 . Grasping handle 46 avoids damage to the electrode body that might be caused by the surgeon grasping the electrode body directly. Grasping handle 46 also minimizes trauma and stress-related damage to the eye during surgical implantation by providing the surgeon a convenient method of manipulating electrode array body 4 . Grasping handle 46 is made of silicone having a hardness of about 50 on the Shore A scale as measured with a durometer. A preferred embodiment of the electrode array body 4 is made of a very soft silicone having hardness of 50 or less on the Shore A scale as measured with a durometer. The reinforcing ring 14 is made of opaque silicone having a hardness of 50 on the Shore A scale as measured with a durometer.
[0049] FIG. 2 provides a perspective view of the retinal electrode array assembly 2 wherein the electrode array body 4 is implanted inside the eye and the electronics 20 are placed outside the eye with the feeder cable 18 passing through sclera 30 . In this embodiment, electronics 38 are attached by fixation tabs 24 outside the eye to sclera 30 .
[0050] FIG. 3 provides a perspective view of retinal electrode array 2 wherein electrode array body 4 is implanted on the retina inside the eye and electronics 38 are placed outside the eye some distance from sclera 30 wherein feeder cable 18 contains sheathed conductors 10 as silicone-filled coiled cable 22 for stress relief and flexibility between electronics 38 and electrode array body 4 . Feeder cable 18 passes through sclera 30 and contains a series of fixation tabs 24 outside the eye and along feeder cable 18 for fixating cable 18 to sclera 30 or elsewhere on the recipient subject.
[0051] FIG. 4 provides a cross-sectional view of electrode array body 4 in intimate contact with retina 32 . The surface of electrode array body 4 in contact with retina 32 is a curved surface 28 substantially conforming to the spherical curvature of retina 32 to minimize stress concentrations therein. Further, the decreasing radius of spherical curvature of electrode array body 4 near its edge forms edge relief 36 that causes the edges of array body 4 to lift off the surface of retina 32 eliminating stress concentrations. The edge of electrode array body 4 has a rounded edge 34 eliminating stress and cutting of retina 32 . The axis of feeder cable 18 is at right angles to the plane of this cross-sectional view. Feeder cable 18 is covered with silicone.
[0052] FIG. 5 provides a cross-sectional view of electrode array body 4 showing spherically curved surface 28 , strain relief slot 13 and mounting aperture 16 through which a tack passes to hold array body 4 in intimate contact with the eye. Mounting aperture 16 is located in the center of reinforcing ring 14 that is opaque and colored differently from the remainder of array body 4 , making mounting aperture 16 visible to the surgeon. Reinforcing ring 14 is made of a strong material such as tough silicone, which also resists tearing during and after surgery. Strain relief slot 13 forms strain relief internal tab 12 in which reinforcing ring 14 is located. Stresses that would otherwise arise in the eye from tacking array body 4 to the eye through mounting aperture 16 are relieved by virtue of the tack being located on strain relief internal tab 12 .
[0053] FIG. 6 provides a cross-sectional view of a preferred embodiment of electrode array body 4 showing ferromagnetic keeper 40 that holds electrode array body 4 in position against the retina by virtue of an attractive force between keeper 40 and a magnet located on and attached to the eye.
[0054] FIG. 7 is a cross-sectional view of the electrode array body 4 wherein internal tab 12 is thinner than the rest of electrode array body 4 , making this section more flexible and less likely to transmit attachment induced stresses to the retina. This embodiment allows greater pressure between array body 4 and the retina at the point of attachment, and a lesser pressure at other locations on array body 4 , thus reducing stress concentrations and irritation and damage to the retina.
[0055] Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | This invention is a retinal electrode array assembly and methods of using the same that facilitate surgical implant procedures by providing the operating surgeon with visual references and grasping means and with innovations that reduce actual and potential damage to the retina and the surrounding tissue. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a national stage application of International Patent Application PCT/US2015/012294 filed, Jan. 21, 2015. International Patent Application PCT/US2015/012294 claims the benefit under 35 U.S.C. §119(e), to U.S. Provisional Application 61/964,973, filed Jan. 22, 2014, entitled “CANDLEHOLDER II AND METHOD” which is incorporated by reference in its entirety and made part of this specification.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of candleholders, and more particularly to user manipulated candleholders permitting a user to adjust a candle's position within a candleholder.
BACKGROUND
[0003] Candleholders have been known in the art for some time, and traditional wax candles utilize wax candles in a glass candle holder which are sold full. Over time the candle's wax and wick are consumed, resulting in the candle surface becoming progressively lower relative to the candleholder's surface opening. As a result, certain challenges are presented. Candles burning low in a candleholder are more difficult to light, may allow less air and oxygen to the flame. Further, as a candle burns, the wick may be frayed and discolored, and a user desires to trim the candle's wick. Where the wick position is low in a candleholder, this task is more difficult. Further, many candles are scented, and burning a scented candle releases scent into the surroundings. To optimize scent dissipation, it is useful to have a candle burn near a candleholder's surface—not deep within a candleholder. Further, wax candles tend to be relatively hard and immobile within a candleholder. Lastly, candles burning deep within candleholders typically leave unsightly black soot or carbon deposits on the candleholder's interior making the candleholder, and often candle, black, unsightly, and sooty appearing.
SUMMARY
[0004] Aspects of the present invention disclose a candleholder that may be manipulated by a user to advance a candle within a candleholder to facilitate optimal burning. Embodiments describe a candleholder having a platform to move candle within the holder. Embodiments disclose a prepackaged semi-soft candle, bundled with a candleholder, wherein the semi-soft candle is readily movable against a candleholder's inner surface. Embodiments of the present invention disclose a handle permitting a user to manipulate platform height, allowing a candle to be raised or lowered within a candleholder. Embodiments disclose a disc, sized larger than the platform, preferably formed of soft rubber sponge which stabilizes the candle and prevents candle wax from moving below the platform's surface. Embodiments disclose omission of the disc, and utilization of a platform shaped to define at least one seal at the perimeter.
DRAWINGS
[0005] FIG. 1 is a perspective view of an embodiment candleholder.
[0006] FIG. 2 is a cross-section of an embodiment candleholder taken through line 2 - 2 of FIG. 1 .
[0007] FIG. 3 is an exploded view of an embodiment candleholder.
[0008] FIG. 4 is a perspective view of an embodiment integrally formed candleholder.
[0009] FIG. 5 is a perspective view of an embodiment candleholder where the base is disposed substantially within the barrier.
[0010] FIG. 6 is an exploded view of an embodiment candleholder where the base is disposed substantially within the barrier.
[0011] FIG. 7 is a schematic view showing an embodiment candleholder.
[0012] FIG. 8 is a schematic view showing an embodiment wick fitting.
[0013] FIG. 9 is a schematic view showing an embodiment ring stop.
[0014] FIG. 10 is a schematic view showing an embodiment threaded first end.
[0015] FIG. 11 is a schematic view showing an embodiment candleholder with a peelable tamper-resistant seal.
[0016] FIG. 12 is a schematic view showing an optional candleholder having a threading and rotatable platform.
[0017] FIG. 13 is a schematic view showing an embodiment platform surface, necked-in second opening, and bottom cover.
[0018] FIG. 14A is a schematic showing a handleless platform and 14 B an alternative embodiment platform handle.
[0019] FIG. 15 is a schematic showing a flap-handle which may be extended for use and secured to platform's bottom and an embodiment platform locking means.
[0020] FIG. 16 is a perspective view of an embodiment platform, platform handle, and disc.
[0021] FIG. 17 is a schematic showing embodiment handle texture surfaces.
[0022] FIG. 18 is side view of an embodiment flexible platform and disc.
[0023] FIG. 19 is a side view of an embodiment candleholder showing a tamper-resistant seal.
[0024] FIG. 20 is a side view of an embodiment platform showing platform, platform sidewalls, platform handle, and disc.
[0025] FIG. 21 is a side view of an embodiment platform showing a receptacle for a wick assembly.
[0026] FIG. 22 is a side view of an embodiment platform.
[0027] FIG. 23 is a side view of an embodiment platform showing two flap handles and a perimetrically placed seal.
[0028] FIG. 24 is a side view of a platform having a perimeter seal.
[0029] FIG. 25 is a side view of an adhesively attachable handle.
[0030] FIG. 26 is a bottom view of an embodiment candleholder showing an embodiment tamper-resistant seal and pull tab.
[0031] FIG. 27 is a schematic showing an embodiment candleholder with necked-in shape, a shade, and opaque, semi-opaque, and clear label zones.
[0032] FIG. 28 is a schematic showing an embodiment internal threading and rotatable platform.
[0033] FIG. 29 is a schematic view showing an embodiment cover with vents and base.
[0034] FIG. 30 is a bottom view of an embodiment square platform.
[0035] FIG. 31 is a bottom view of an embodiment cuboidally shaped candleholder having a tamper-resistant seal.
[0036] FIG. 32 is a schematic view of an embodiment simulated wax pillar candleholder.
[0037] FIG. 33 is an embodiment of a novena-style candleholder.
[0038] FIG. 34 is an embodiment disclosing an alternatively shaped candleholder body.
[0039] FIG. 35 is side view an embodiment candleholder showing a wire for elevating platform.
[0040] FIG. 36 is a side view of an embodiment candleholder showing an embodiment overlay.
[0041] FIG. 37 is an embodiment wire actuated platform.
[0042] FIG. 38 is a side view of an embodiment candleholder showing a necked-in shape.
[0043] FIG. 39 is a side view of an embodiment glass candleholder showing a tapered shape.
[0044] FIG. 40 is a schematic view of an embodiment candleholder having a vented top, scent holes, and scent chip.
DESCRIPTION
[0045] Turning now to FIGS. 1-3 , a candleholder has cylindrical candle barrier 5 has a first end 7 and second end 9 and a diameter and diametrical void. Barrier 5 has a short axis and long axis. Base 10 is affixed to the second end 9 of barrier 5 . In one embodiment, base 10 is adhesively affixed. In an alternative, base 10 is coupled by snap or press fit. The base 10 is shaped to define a base bottom surface 25 and base bottom surface opening 30 across the diameter from one base bottom surface 25 to the opposing edge. A piston or platform 40 spans substantially across barrier 5 's short axis to substantially fill barrier 5 's diametrical void. Platform 40 is shaped to define a platform top 42 , platform bottom 44 , a platform sidewall 43 , and a platform handle 55 (best seen by FIG. 2 ). Platform 40 has a circumferential surface 3 . Platform 40 sidewall 43 aids in stabilizing platform 40 within cylindrical barrier 5 . Platform 40 is sized to have a greater diameter than base bottom surface opening 30 .
[0046] FIG. 2 is a cross-section taken through line 2 - 2 of FIG. 1 . Disc 60 is disposed on the top surface 42 of platform 40 , in one embodiment being adhesively affixed. Disc 60 has a diameter larger than the diameter of platform 40 , and thus overhangs platform 40 . In a preferred embodiment, disc 60 is comprised of foam rubber sponge. In use, when platform 40 is moved upwardly within barrier 5 , the perimeter of disc 60 seals barrier 5 and retains wax above disc 60 's surface. Base bottom opening 30 serves as a platform access opening where a user may access platform 40 and platform 40 's handle 55 . FIG. 3 illustrates an exploded view, demonstrating base 10 , platform 40 , disc 60 and cylindrical barrier 5 . The difference in size between platform 40 and base bottom opening 30 maintains platform 40 between base 10 and inside barrier 5 and prevents platform 40 from being dislodged from the candleholder.
[0047] During use, a user applies force to platform 40 , when the desired candle position is reached, the user withdraws the application of force. Frictional contact between platform 40 and/or disc 60 and the inner surface of barrier 5 provides sufficient force to maintain platform 40 and a candle in a static position.
[0048] In one embodiment, an inventive method is disclosed including, providing a candle; providing a cylindrically shaped candle barrier 5 having a first end 7 and second end 9 , and inner surface, wherein said cylindrical candle barrier has a diameter and diametrical void, wherein said cylindrical candle barrier has a short axis and long axis. A base 10 affixed to the second end 9 of cylindrical candle barrier 5 , the base having a base bottom surface 25 , wherein said base is shaped to define a base bottom opening 30 having a diameter. A platform 40 has a diameter, wherein said platform's 40 diameter is less than the diameter of said cylindrical candle barrier 5 , wherein the platform 40 is sized to substantially fill the diametrical void of the barrier 5 across the short axis of said cylindrical candle barrier 5 , wherein said platform 40 is shaped to define a handle 55 , wherein said platform 50 is shaped to define a top surface 42 and a sidewall 43 , wherein the diameter of the platform 40 is greater than the diameter of the base bottom surface opening 30 ; a disc 60 disposed on the top surface 42 of platform 40 , wherein said disc 60 has a diameter, wherein the diameter of the disc is larger than the diameter of the platform 40 . Placing said candle within said barrier 5 on the disc 60 . Determining a desired candle height and applying force along the barrier's 5 long axis, wherein the user directs force in the direction of the first end 7 sufficient to move platform 40 , disc 60 , and candle toward first end 7 . The user recognizes that the desired candle height has been reached and withdraws the application of force, wherein the forward movement of the platform 40 , disc 60 , and candle ceases. The frictional contact between the platform 40 and disc 60 , within the barrier's 5 inner surface maintains the platform 40 , disc 60 , and candle in a static position.
[0049] FIG. 4 demonstrates an alternative preferred embodiment, cylindrical candle barrier 5 and base 10 are omitted as independent elements. An integrally molded candleholder 400 is described. FIG. 4 illustrates a perspective view of an integrally molded candleholder body 415 shaped to define a cylindrically shaped molded candleholder body 415 having a first end 411 and a second end 422 , where the second end 422 is a molded bottom 425 further shaped to define a molded bottom opening 430 . Platform 440 is disposed within candleholder body 415 . Platform 440 has a diameter larger than the diameter of opening 430 , thus platform 440 is prevented from passing through opening 430 and out of candleholder body 415 .
[0050] FIGS. 5 and 6 demonstrate an internal platform stopper embodiment. In this embodiment, a cylindrically shaped candle barrier 505 having a first end 511 and second end 522 , wherein said cylindrical candle barrier 505 has a diameter and diametrical void, wherein said cylindrical candle barrier 505 has a short axis and long axis. A base 569 shaped to define a top end 571 and bottom end 573 , said base 569 affixed substantially within the second end of cylindrical candle barrier 505 , the base 569 having a bottom end, wherein said base 569 is shaped to define a base bottom opening 530 having a diameter, wherein said bottom end 573 of said base 569 defines a candleholder footing. A platform 540 is sized to substantially fill the diametrical void of cylindrical candle barrier 505 across the short axis of said cylindrical candle barrier 505 , wherein said platform 540 is shaped to define a handle 555 , wherein said platform 540 shaped to define a top surface and a sidewall, wherein the diameter of the platform 540 is greater than the diameter of the base bottom surface opening 530 , wherein the top 571 of base 569 defines a platform stop. A disc 560 disposed on the top surface of platform 540 , wherein said disc 560 has a diameter, wherein the diameter of the disc is larger than the diameter of the platform 540 .
[0051] In use, a user may move a candle disposed on said disc 560 in the direction of the long axis of said cylindrical candle barrier, in the direction of the first end, wherein a candle, as it is consumed, may be advanced such that a candle surface may be maintained near the relative first end.
[0052] Turning now to FIG. 7 , a candleholder features candleholder body 715 which may be formed of metal (including tin), alloy, acrylic, urethane, wood, and in a preferred embodiment—glass, or any material capable of withstanding heat generated from wick burning, relatively centrally, within. Candleholder body may be cuboidially shaped and in a preferred embodiment is cylindrically shaped. Candleholder body 715 has a top end 720 and bottom end 725 . Bottom end 725 is shaped to define at least one platform access opening 730 . Platform 740 is disposed within candleholder body 715 . Platform 740 is shaped to define a top surface 742 and bottom surface 744 and perimetrical surface, which in one preferred embodiment is a circumferential surface 743 , best appreciated by FIG. 16 . In embodiments disclosed herein generally, platform shape approximates the shape of candleholder body across the short axis, with the platform occupying at least 70% of the candleholder body's cross-sectional area.
[0053] The circumferential surface 743 is in close contact with the inner surface of candleholder body 715 . In one embodiment, illustrated by FIGS. 23 and 24 , the perimetrical surface may be sealed by seal 2367 and seal 2476 respectively, making contact with a candleholder's inner surface.
[0054] In one embodiment, a portion of platform 40 's bottom surface 44 is shaped to define a platform handle 755 . The platform access opening 730 and platform handle 755 are positioned such that a user can access platform handle through platform access opening 730 . In one embodiment, the platform handle may be a foldable handle 2255 ( FIG. 22 ). In various embodiments, platform handle 755 is integrally molded.
[0055] Candleholder body 715 has a body bottom 725 . Body bottom 725 is shaped to define at least one platform access opening 730 through which platform 740 is accessible.
[0056] In one embodiment, platform access opening 730 is shaped wide enough to allow an average human index finger. In another embodiment, platform access opening 730 is shaped wide enough to allow access to at least a portion of platform push handle 755 . In one embodiment platform access opening 730 is sized in the range of 1 cm to 12 cm.
[0057] Disc 760 is disposed on top surface 742 of platform 740 within candleholder body 715 . In a preferred embodiment, disc 760 operates as a candle securing member and is comprised of a rubber sponge. Disc 760 may be affixed adhesively.
[0058] Candleholder body 715 has top end 720 . In one embodiment, top end 720 has a top end engagement 722 to permit a cover to be secured on candleholder body 15 . In one embodiment, top end engagement is a threaded engagement 1005 ( FIG. 10 ) to accommodate a threaded cover which may be twisted on and secured. Engagement 722 may be flush to accommodate a friction fit cover. Engagement 722 may have a ridge to allow a ridged cover to be snapped on.
[0059] In one embodiment of the present invention, a candle 766 may be prepackaged with the holder. Candle 766 is set within candleholder body 15 and on top of a candle securing member, such as disc 60 . In a preferred embodiment, candle 766 is a soft candle such as soy or soy blend, palm wax, soft paraffin.
[0060] In an alternative embodiment, candleholder body 715 is packaged without the candle. In this embodiment, wax, in a flowable state, may be poured into candleholder body 715 and allowed to cool. This may occur in a factory/manufacturer setting or may be poured by a user. In one embodiment, a candleholder body is sold as a kit to an end user, with wax varieties independently obtainable, allowing a user to heat and melt wax suitable for pouring into the candleholder. Platform 740 is sealed sufficiently against the inner wall of candleholder body 715 by disc 760 to keep wax, liquid, semisolid, or solid, substantially above platform 740 .
[0061] It is generally useful to have the surface of a candle 766 burning as close as possible to the opening on top end 720 . As candle 766 burns wax and wick are consumed and decrease; the candle's top surface 768 becomes lower relative to candleholder top end 720 . A candle burning near the top end 720 will allow more oxygen to the flame, will burn better, provide more light, enhance the dissipation of candle scent, and create less smoke. In addition, a candle closer to a candleholder top surface will be easier to light, and the wick easier to trim.
[0062] A user may advance candle 766 's top surface 68 in the direction of top end 720 by accessing platform 740 through platform access opening 730 . In one embodiment, a user introduces a finger or digit through platform access opening 730 and makes contact with platform 40 and exerts pressure sufficient to move platform 740 and candle 766 upward toward top end 720 . In another embodiment, user extends the foldable handle 1555 ( FIG. 15 ), which forms a portion of platform 740 , grasps handle 1555 and exerts a pushing force in the direction of top end 720 sufficient to move platform 740 and candle 766 upward toward top end 720 . The user, desiring to move candle 766 , downwardly grasps handle 1555 and exerts a pulling force in the direction of bottom end 725 sufficient to move platform 740 and candle 766 downwardly toward bottom end 725 .
[0063] FIG. 8 discloses a candle with a push in wick 205 on metal base 210 . In one embodiment, wick 805 may be factory assembled and adhesively affixed. In an alternative embodiment, a candleholder may be sold as a kit, replacement wicks being available. In this embodiment, more than one wick may be utilized and reversibly snapped into place.
[0064] FIG. 9 illustrates a schematic sectional view of an embodiment candleholder body 915 featuring a stop ring 918 . In one embodiment, stop ring 918 is affixed to the outer circumference of candleholder top end 920 . Stop ring 918 can be made of metal, or other materials, and press-fitted or glued to the circumferential surface of candleholder top end 920 . In one embodiment, candleholder body is shaped to define stop ring such that stop ring is integrally formed. FIG. 9 also illustrates disc 960 . It should be noted that a stop ring can be integrally formed by manufacturing a glass prominence, heat resistant plastic or urethane prominence, or by rolled tin.
[0065] FIG. 10 discloses an embodiment candleholder body 1015 shaped to define a necked-in candle stop 1017 . FIG. 10 additionally illustrates top end 1020 having threading 1005 .
[0066] FIG. 11 demonstrates a push-up candleholder. In this embodiment, barrier 1105 fits within base 1110 . Base 1110 has base opening 1130 . Peelable seal 1150 is disposed across and covers base opening 1130 to prevent movement of platform and/or tampering with the candle before intended use. During use, peelable seal 1150 is removed exposing base opening 1130 , and a portion of platform 1140 . A user desiring to move a candle upward, makes contact with platform 1140 , either by finger or other object, and applies force in the direction of candle top 1120 sufficient to drive platform 1140 upward and move candle toward candle top 1120 . Barrier 1105 may be glass or metal, and may be secured to base 1110 by push fit, snap fit, or adhesively affixed. In a preferred embodiment, barrier 1105 is cylindrically shaped glass. Base 510 may be plastic, metal, wood or glass.
[0067] FIG. 12 candleholder body 1215 is shaped to define a threading 1219 on candleholder body's 1215 inner surface. Platform 1240 has threading 1243 which mates with threading 1219 on candleholder body 1215 . Platform 1240 has platform handle 1255 that may be accessed through platform access opening 1230 on bottom 1225 of candleholder body 1216 and rotated within candleholder body 1215 . By virtue of threadable engagement, rotation of platform handle 1255 rotates platform 1240 and advances platform 1240 toward candle top 1220 . Threading 1219 may be molded or stamped metal.
[0068] FIG. 13 . candleholder body 1315 shaped to define and open bottom 1307 and necked in bottom area 1309 which retains platform 1340 within candleholder body 1315 . In an embodiment, platform 1340 is shaped to define platform sidewall 1343 , which makes contact with necked in bottom area 1309 and platform handle 1355 . A removable bottom cover 1376 may secure open bottom 1307 and platform 1340 until intended use, and may be used with or without a seal, such as seal 1150 ( FIG. 11 ). Top surface 1342 of platform 1340 has a studded surface 1344 which facilitates contact with a candle. In use, a user removes bottom cover 1376 and may grip handle 1355 and move platform 1340 up or down within candleholder body 1315 .
[0069] FIG. 14A demonstrates an embodiment platform 1440 omitting a handle, and featuring long sidewalls 1443 . FIG. 14B shows an option where platform handle is embodied as a handle ring 1455 .
[0070] FIG. 15 illustrates an embodiment featuring projections 1503 on inner surface 1507 of barrier 1505 . Platform 1540 is shaped to define platform recesses 1549 which are capable of engaging projections 1503 to function as a detent mechanism, maintaining platform 1540 temporarily in a fixed position relative to barrier 1505 . To change positions, the user applies a force sufficient to move platform 1540 upwardly or downwardly. Projections 1503 could be on platform 1540 , and recesses 1549 on inner surface 1507 . Further, in one embodiment, a portion of platform 1540 's bottom surface 1546 is shaped to define a foldable platform handle 1555 that may be extended perpendicular to bottom surface, and folded in either direction and secured to the bottom surface 1546 by a detent mechanism 1563 . Foldable handle 1555 allows platform 1540 to be pushed or pulled along barrier 1540 's long axis.
[0071] FIG. 16 shows an embodiment platform 1640 having a platform handle 1655 , a disc 1660 , which in one embodiment is a foam sponge rubber top, and sidewall 1643 . Sidewall 1643 stabilizes the platform's 1640 position within a barrier, such as barrier 1605 , or a candleholder, such as candleholder 10 , preventing platform 1640 from inverting. Platform 1640 has a perimetrical surface 1603 .
[0072] In all embodiments disclosed herein, the platform has a perimetrical surface—in the case of a round platform, a circumferential surface. In one preferred embodiment, a disc, such as disc 1660 , is omitted, and the perimetrical surface itself is flush again the inner wall of a candleholder and the platform is self-sealing. In another embodiment, perimetrical surface has a soft seal which provides a sealing engagement with the inner wall of a candleholder.
[0073] FIG. 17 demonstrates textured grip lines 1701 in handle 1755 improve a user's grip on the handle 1755 surface, improving a user's ability to push or pull handle 1755 .
[0074] FIG. 18 shows a flexible platform 1840 having a platform top surface 1842 , which is covered by a disc, such as foam rubber sponge 1860 . Flexible platform 1842 may be deformed sufficiently to place within a barrier or candle housing in which either the top opening 20 or platform access opening 30 is a smaller diameter than platform 1840 .
[0075] It should be apparent to one skilled in the art that the platform and disc share a size and shape relationship. It should be noted that a disc displaced on the top surface of a platform has been disclosed. In an alternative embodiment, a square, or other shape platform is utilized—the shape corresponding to the candleholder body's shape. According, a disc is replaced with a square candle stabilizing and sealing member, such as a square foam rubber sponge, which may be disposed on the top of a platform and used to seal the candleholder to keep wax above the level of the platform. In one embodiment, this square stabilizing and sealing member is sized slightly larger than the platform. In another embodiment, the square stabilizing member is the same size as the platform. In another embodiment, the sealing member is omitted, and a platform is sealed in the manner described in paragraph [0071].
[0076] FIG. 19 illustrates a molded candleholder glass container 1915 having a bottom 1925 shaped to define a platform access opening 1930 . A seal 1950 covers platform access opening 1930 . In one embodiment, seal 1950 is transparent. In one embodiment, seal 1950 covers platform access opening and at least a portion of the external surface of bottom 1925 .
[0077] One problem frequently encountered is difficult with mobility of a candle within a candleholder. In a preferred embodiment, the candle is a soy or soy blend, palm wax, soft paraffin. These candles were unexpectedly found to provide less resistance against a candleholder's inner wall. Thus, the present invention preferentially uses semi-soft candles to facilitate the user's ability to move a candle within a candleholding vessel.
[0078] FIG. 20 demonstrates a platform 2040 with handle 2055 and platform sidewall 2043 and a candle stabilizing and sealing member 2060 , such as a foam sponge rubber which could be in the shape of a disc. Member 2060 overhangs platform 2040 in an resulting in an overhanging portion 2061 , wherein the overhanging portion makes contact with the inner wall of a candleholder such as the inner wall of candleholder body 15 ( FIG. 1 ). When platform 2040 is advanced upwardly, the overhanging portion 2061 of member 2060 makes contact with the inner wall of a candleholder or barrier, such as the inner wall of barrier 5 , or the inner wall of candleholder body, such as candleholder body 415 . The ends of the overhanging portion 1461 are directed downwardly—sealing the platform within the candleholder.
[0079] FIG. 21 demonstrates an embodiment platform 2140 having a top surface 2142 bearing a wick receptacle 2143 can accommodate a push-in, or snap-in wick assembly 2146 . Wick assembly 2146 is comprised of wick base 2148 attached to wick 2160 . Wick base 2148 may be adhesively affixed to platform 2140 —particularly where assembled in a factory setting. Alternatively, where a candleholder is sold as part of a kit, wicks may be replaceable, thus wick assembly 2146 may be reversibly affixed by push-in or snap-in attachment to wick receptacle 2143 .
[0080] FIG. 22 illustrates an embodiment platform 2240 shaped to define wax gripping projections 2244 . Foldable handle 2255 can be molded, glued in, or affixed adhesively.
[0081] FIG. 23 illustrates a platform 2340 having two foldable handles 2355 . In an independent embodiment, piston 2340 's is itself is molded to define flexible thin seals 2376 located on the perimeter of platform 2340 to keep wax above platform 2340 . This is particularly required when filling an embodiment candleholder with hot soy, paraffin, wax, or other candle forming materials. Seals 2376 also prevent solid or semi-solid wax from moving under platform 2340 during use, when moving the candle up and down within a candleholder. Seals 2376 prevent wax from leaking when below the level of platform 2340 when flowable candle-forming material—such as hot wax—is poured into vessel.
[0082] FIG. 24 illustrates an embodiment wing seal 2476 on platform 2440 . Wing seals 2476 are formed by affixing rubber, silicone, plastic, or urethane to the perimeter border 2403 of platform 2440 . Wing seals 2476 keep wax above platform 2440 , particularly when filling a candleholder with hot soy, paraffin, wax, or other candle forming materials. Wing seals 2476 also prevent wax from moving under platform 2440 during use, when moving the candle up and down within a candleholder. Seals 2476 permit a sealed sliding engagement between platform 2440 and inner surface of a barrier or candleholder body.
[0083] FIG. 25 describes an embodiment stick-on handle assembly 2500 which has an adhesive surface 2523 and a peel-out handle tab 2555 . Handle tab 2555 may be peeled back, and used to push or pull a platform. A peelable handle 2555 can be affixed to the bottom surface or a platform, such as bottom surface of platform 2040 or platform 2440 allowing a platform to be manipulated—specifically allowing platform to be pulled back. In one embodiment a prepackaged LIFT ‘N’ PEEL® brand peelable handle could be utilized.
[0084] FIG. 26 illustrates a bottom view of the bottom 2625 of candleholder body 2015 having seal 2650 , which could be clear or opaque, having a pull tab 2653 . Seal 2650 prevents tampering. In another embodiment, a removable cover, such as removable bottom cover 1376 is fittable over bottom 2625 to seal a candleholder body opening such as base bottom surface opening 30 .
[0085] FIG. 27 illustrates an embodiment candle product 2700 with candleholder body 2715 and candle 2766 set within. Candle 2766 is formed of soft wax materials, such as soy wax, and disposed on a disc which is in one embodiment, foam sponge rubber top 2760 . The foam sponge rubber top 2760 is disposed on the top surface 2742 of platform 2740 . Platform 2740 is within candleholder body 2715 . Bottom surface 2744 of platform 2740 is shaped to define a handle 2755 . Candleholder body 2715 has a bottom 2725 with candleholder bottom opening 2730 . A tamper evident seal (such as shown by 1950 in FIG. 19 ) may cover bottom opening 2730 . In one embodiment, at least one label is located on the outer aspect of candleholder body 2715 . The first label is located in the bottom zone 2713 of the outside of candleholder body 2715 and is opaque and designed to hide platform 2740 . A semi-clear label is located on the middle zone 2717 of candleholder 2715 . A clear label is in the top zone 2719 of candleholder. A lamp shade 2777 fits into top opening 2720 of candleholder body 2715 .
[0086] FIG. 28 illustrates a method of lifting candle 2866 within candleholder through use of heat resistant internal threading 2819 along the circumferential inner wall of candle housing 2815 . Threading 2819 can be integrally formed, or can be a freestanding insert inserted into candleholder body 2815 . Platform 2840 has handle 2855 , which may be twisted to elevate platform 2840 and candle 2866 upwardly toward open top 2820 , or rotated in the opposite direction to move candle 2866 downwardly toward candle bottom 2825 .
[0087] FIG. 29 illustrates a candle 2966 within a candleholder body 2915 . Platform 2940 is disposed within candleholder body 2915 . Base bottom opening 2930 is covered by a seal which may be seal 1950 ( FIG. 19 ); the seal may be clear, foil, or a pop metal seal. A shade 2936 is fitted to candleholder top 2920 , with at least one vent hole 2938 in the candleholder shade 2936 . Shade 2936 may be formed of glass, tin, or other metal and used when the candle is burning. Shade 2936 provides light inside the shade. A candle flame 2977 burning at the relative top of a candleholder body 2915 , an optimal burning zone, and provides more light, more scent, and burns better and brighter.
[0088] FIG. 30 shows a bottom view of a square embodiment platform 3040 demonstrating platform handle 3055 . Square embodiment platform may be used in a cuboidally shaped candleholder body.
[0089] FIG. 31 is a bottom view of an embodiment cuboidally shaped candleholder barrier 3115 showing a cuboidally shaped glass, tin, or other metal candleholder body 3115 shaped to define platform access opening 3130 covered with seal 3150 . It should be noted that platform access opening 3130 is smaller than platform 3040 to be sure platform 3040 is retained within candleholder body 3115 . As with the circumferential embodiments, a cuboidally shaped embodiment may be integrally formed.
[0090] FIG. 32 demonstrates a simulated pillar candle 3200 having a push or twist platform 3240 to drive candle 3266 upwardly. The exterior of candleholder body 3215 features simulated wax—emulating the look of an authentic pillar candle.
[0091] FIG. 33 illustrates a novena-style candle 3300 , which is relatively tall and thin. Candle 3366 is within candleholder body 3315 and atop platform 3340 within. Candle 3300 is packaged with push-up rod 3302 . Candleholder body 3315 is shaped to define platform access opening 3330 . When the user desires to advance platform 3340 , the user inserts rod 3302 through access opening 3330 and applies sufficient force to raise platform 3340 and candle 3366 upwardly toward candle top 3320 . In one embodiment, instead of a handle, platform 3340 is shaped to define a void 3355 , and rod 3302 may be inserted into that void to more effectively move platform 3340 upwardly. In one embodiment void 3355 , and one end of rod 3302 , have mateable threading, such that one end of rod 3302 may be screwed into void 3355 , allowing platform 3340 to be pushed or pulled. When a user is finished adjusting candle height, the user unscrews rod 3302 from void 3355 , and platform 3340 with candle 3366 atop, maintains its position. Base cover 3399 may fit within platform access opening 3330 and may also serve, in one embodiment, as a push base to provide support one end of rod 3302 during the application of force to raise platform 3340 .
[0092] FIG. 34 shows a triangularly-shaped candleholder 3400 , wherein the candleholder body 3405 has rounded corners 3401 , featuring a cover 3496 shaped to define a brush holder 3498 to hold a brush. Platform 3440 is similarly shaped to substantially occupy the void across the short axis of body 3405 .
[0093] FIG. 35 illustrates a pull-up wire 3513 where wire 3513 is located under platform 3540 . In use, a user pulls wire 3513 causing tension in wire 3513 and elevation of platform 3540 toward candle opening top 3520 .
[0094] FIG. 36 demonstrates a tin container candleholder body 3605 with an overlay 3688 which may be clear or printed, located on the outside of candleholder body 3605 . In an alternative, clear glass or plastic container body 3605 , overlay is located on the outside of candleholder body 3605 , but could be inside as well, as it will be visible through the clear glass or plastic.
[0095] FIG. 37 demonstrates an embodiment platform 3740 having a central wick hole 3743 and at least one wire hole 3746 , in a preferred embodiment there being a plurality of wire holes 3746 . Wire holes permit wire 3513 ( FIG. 35 ) to be passed through platform 3740 and secured along the bottom surface of platform 3740 . In use, a user can pull wire 3513 that is secured under platform 3740 , which draws platform 3740 upwardly.
[0096] FIG. 38 illustrates a candleholder 3800 shaped to define a tapered top opening 3820 . A sufficient force applied to platform 3840 will move platform 3840 and candle 3866 upwardly, toward top opening 3820 . Candle 3866 is prevented from moving past necked-in tapered point 3817 . Barrier 3805 sits within base 3810 .
[0097] FIG. 39 illustrates an embodiment candleholder 3900 where barrier 3905 is glass and within base 3910 . Ridges 3988 and tapered point 3917 prevent candle 3966 from moving past opening 3920 as platform 3940 moves candle 3966 against the inner wall of barrier 3905 .
[0098] FIG. 40 illustrates an embodiment candleholder 4000 having a cover 4011 with scent holes 4012 with a scent chip 4016 which may be reversibly affixed to cover 4011 . In one embodiment, chip 4016 is snappably affixed to cover 4011 . Vents 4018 may be opened or closed to facilitate candle flame burning and the dissipation of scent. When not in use, cover 4011 may be removed from candleholder and inverted to provide scent.
[0099] A preferred embodiment of the present invention discloses an integrally molded candleholder body having an inner surface, a first end, and second end, wherein the second end is shaped to define a molded bottom and a bottom surface opening; a platform sized to fit within a candleholder body, such that the platform is perpendicularly disposed relative to the inner surface, wherein said platform is sized to substantially fill the void of the candleholder body, wherein said platform shaped to define a top platform surface, wherein the platform is sized greater the base bottom surface opening, wherein said platform has a perimeter; a seal affixed to at least a portion of platform's perimeter; wherein a user may move a candle disposed on said platform, within said candleholder body in the direction of the first end, wherein a candle, as it is consumed, may be advanced such that a candle surface may be maintained near the first end.
[0100] Embodiments of this invention have disclosed a platform that substantially fills the void across barrier or candleholder body. An optimal embodiment has found to be a platform length of at least 70% of the void in the diameter. Further, embodiments of this invention have disclosed an optimal burning zone for a candle flame. An optimal embodiment has found an optimal burning zone to be within 15 centimeters from a candleholder top.
[0101] Although the present invention has been described with reference to the preferred embodiments, it should be understood that various modifications and variations can be easily made by those skilled in the art without departing from the scope and spirit of the invention. Accordingly, the foregoing disclosure should be interpreted as illustrative only and is not to be interpreted in a limiting sense. It is further intended that any other embodiments of the present invention that result from any changes in application or method of use or operation, which are not specified within the detailed written description or illustrations contained herein yet, are considered apparent or obvious to one skilled in the art are within the scope of the present invention. Further, it should be noted that several inventive embodiments are disclosed together for convenience; unless specified otherwise, all embodiment inventive options disclosed herein may be used independently or together with any other embodiment. | Aspects of the present invention disclose a candleholder that may be manipulated by a user to advance a candle within a candleholder to facilitate optimal burning. Embodiments describe a candleholder having a platform to move a candle within a holder. Embodiments disclose a prepackaged semi-soft candle, which is readily movable against a candleholder's inner surface. Embodiments of the present invention disclose a handle permitting a user to manipulate platform height, allowing a candle to be raised or lowered within a candleholder. Embodiments disclose a disc, sized larger than the platform, preferably formed of a soft rubber sponge which stabilizes the candle and prevents candle wax from moving below the platform's surface. An alternative embodiment omits the disc, the platform being sealed by a seal around the platform's perimeter. | 5 |
REFERENCE TO RELATED APPLICATION
[0001] The present application relates and claims priority to Applicant's U.S. Provisional Patent Application Ser. No. 61/876,379, filed Sep. 11, 2013, the entirety of which is hereby incorporated by reference.
BACKGROUND
[0002] 1. Field of Invention
[0003] The present invention relates generally to lawn and garden sprayers.
[0004] 2. Background of Art
[0005] Lawn or garden sprayers use pressure to apply liquid fertilizers, pesticides, or other chemicals. A recent development is to utilize a battery-powered electric motor in the sprayer wand to provide the spraying pressure, rather than hand pumping.
[0006] For present-day sprayers packaged at point of sale, the wand and its hose are stored separately from the sealed container and held in a separate “holster” carry device that is attached to the container, with the wand pointing up. Once the wand and hose are unpackaged and assembled for use, the holster may then be used for continued carry and storage of the wand. The holster uses tabs and knobs to reattach the wand, which is cumbersome for the user, and as a result does not hold the wand and hose as securely as originally packaged.
[0007] The hose is typically connected to the container by sliding the hose end plug onto the horizontally positioned spout on the container cap. In this position the spout mechanism is designed such that the container is sealed. To use the sprayer, the spout must be rotated from the horizontal to the vertical position. With the spout in the up position, the fluid circuit to the wand is opened. Simultaneously, a small open port in the cap under the spout is exposed which permits air to enter the container; without this air port the fluid would not flow. For storage, the spout can be repositioned horizontally, in order for the spout mechanism to seal the container.
[0008] For contemporary battery-powered wand sprayers, the batteries, electric motor, pump mechanism, and related electrical and fluid circuits are housed in the wand handle. A user-operated trigger functions to actuate the motor and to simultaneously allow fluid to flow to the pump. Fluid flow to the pump is controlled by a valve body that is separate from the motor housing. Having the valve body separate from the motor housing adds complexity to the design.
[0009] 3. Objects and Advantages
[0010] It is a principal object and advantage of the present invention to provide a sprayer that enables improved ease of operation and increased functional efficiency.
[0011] Other objects and advantages of the present invention will in part appear hereinafter and in part be obvious.
SUMMARY OF THE INVENTION
[0012] In accordance with the foregoing objects and advantages, an embodiment of the present invention provides a lawn and garden sprayer system having a container and a spray wand fluidly connected to the container is provided. The spray wand includes a wand housing that has a slot formed in one side thereof that is configured to engage a lug formed on one side of the container for purposes of stowing the wand during shipping and when not in use. A communications card assembly is detachably connected between the container and spray wand during shipment and prior to its first use. The hose includes a coupler end that engaged a cap on the container and facilitates creation of a fluid circuit between the fluid contents in the container and the wand. In another embodiment of the invention a motor is housed in a wand handle and includes a fluid valve body integrated therein which is actuable between open and closed positions via a manually operable trigger mounted to the wand housing.
[0013] In one aspect, the present invention provides a sprayer assembly, comprising a container; a spray wand; a hose fluidly interconnecting the spray wand to said container; and a fluid circuit that comprises: a coupler attached to the hose and adapted for attachment to the container; a stem extending downwardly from the coupler along a longitudinal axis; air and fluid passageways extending from within the container through the coupler; a plunger extending along the longitudinal axis and movable between sealed and unsealed relation to the air and fluid passageways; and a spring extending along the longitudinal axis and positioned between the stem and the plunger, whereby the spring is compressed when the coupler is attached to the container and biases the plunger out of sealing relationship with the air and fluid passageways.
[0014] In another aspect, the present invention provides a sprayer assembly, comprises: a container; a spray wand; a hose fluidly interconnecting the spray wand to the container; and a fluid circuit that comprises: a coupler attached to the hose and adapted for attachment to the container; a stem extending downwardly from the coupler along a longitudinal axis; an air passageway extending from within said container through the coupler; a fluid passageway extending from within the container through the coupler a plunger extending along the longitudinal axis and movable between sealed and unsealed relation to the one of air and fluid passageways; a dip tube holder extending along the longitudinal axis; a valve mounted within the container and movable between sealed and unsealed relation to the one of the air and fluid passageways to which the plunger is not relatively movable; and a spring extending along the longitudinal axis and positioned between the dip tube holder and the plunger, whereby the spring is compressed when the coupler is attached to the container and biases the plunger out of sealing relationship with the one of the air and fluid passageways and biases the dip tube holder which in turn moves the valve out of sealing relationship with the one of the air and fluid passageways.
[0015] In another aspect, the present invention provides a sprayer assembly, comprising: a container; a spray wand comprising a handle portion and a wand portion, the handle portion comprising a slot formed therein; a hose fluidly interconnecting the spray wand to the container; a lug formed on the container and to which the slot can engage and mount the spray wand to the container; and a communication card assembly comprising a card retaining surface and an assembly portion that engages the lug, the communication card assembly being positioned between the container and the spray wand.
[0016] In another aspect, the present invention provides a sprayer assembly, comprising a container for storing fluid therein; a spray wand comprising a handle portion and a wand portion; a motor contained within the handle portion; and a fluid circuit assembly, comprising a manually actuable trigger mounted to the spray wand; a fluid inlet that is in fluid communication with fluid contained within the container; a fluid outlet positioned in fluid communication with the wand portion; and a valve that is movable upon user actuation of the trigger from a first position that prevents fluid from flowing from the fluid inlet to the fluid outlet and a second position wherein fluid can flow from the fluid inlet to the fluid outlet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying drawings, in which:
[0018] FIG. 1 is a perspective view of a sprayer assembly with the spray wand detached from the container in accordance with an aspect of the present invention;
[0019] FIG. 2 is a perspective view of a sprayer assembly with the spray wand attached to the container in accordance with an aspect of the present invention;
[0020] FIG. 3 is a front elevation view of the sprayer assembly in its shipped/unused condition;
[0021] FIG. 4 is a front elevation view of a refill container in accordance with an aspect of the present invention;
[0022] FIG. 5 is a perspective view of a communications card assembly in accordance with an aspect of the present invention;
[0023] FIGS. 6A-6C are partial, sequential perceptive views illustrating connection of a hose to a container in accordance with an aspect of the present invention;
[0024] FIGS. 7A-7C are perspective, exploded, and cross-sectional views, respectively, of the hose coupler and container cap in accordance with an aspect of the present invention;
[0025] FIGS. 8A and 8B are cross-sectional views of a first configuration of the hose coupler and container cap in detached and attached relation to one another, respectively;
[0026] FIGS. 9A and 9B are cross-sectional views of a second configuration of the hose coupler and container cap in detached and attached relation to one another, respectively;
[0027] FIGS. 10A and 10B are cross-sectional views of a third configuration of the hose coupler and container cap in detached and attached relation to one another, respectively;
[0028] FIGS. 11A and 11B are cross-sectional views of a fourth configuration of the hose coupler and container cap in detached and attached relation to one another, respectively; and
[0029] FIGS. 12A and 12B are cut-away and exploded perspective views, respectively, of a motor housing, motor and valve body in accordance with an aspect of the present invention.
DETAILED DESCRIPTION
[0030] Referring now to the drawings wherein like reference numerals refer to like parts throughout, there is seen in FIGS. 1 and 2 a sprayer system designated generally by reference numeral 10 essentially comprising container 12 and spray wand 14 fluidly connected to container 12 by flexible hose 16 . More specifically, flexible hose 16 extends between wand 14 and a cap 18 positioned on top of container 12 .
[0031] Spray wand 14 comprises a handle/wand housing 20 and wand portion 22 that is telescopically attached to handle 20 for sliding movement between stored (non-operational) and extended (operational) positions. A lug 24 is formed on the rear wall of container 12 and provides a mounting point for spray wand 20 . Handle 20 includes a slot 26 formed therein that is sized and shaped to securely slidingly engage lug 24 from the top, thereby permitting spray wand 14 to be stored on container 12 with wand portion 22 facing downward during shipment/display and when not in use and stored away. Having the wand portion 22 pointing down prevents liquid from falling back into the wand when it is being stored.
[0032] Referring to FIGS. 3-5 , another feature associated with container 12 is a communication card assembly 28 that attaches to lug 24 and is positioned between container 12 and spray wand 14 when the sprayer system is shipped and displayed for sale. Communication card assembly 28 comprises a card retaining portion 30 to which a card 31 may be adhered or otherwise attached and an assembly attachment portion 32 and functions to communicate product information to the consumer; contain the wand 14 and coiled hose 16 ; and provides security to the packaging. Card assembly 28 may be released from container 12 by tearing along perforation lines 34 and then discarded or recycled by the customer during the connection of the hose 16 to the container 12 . FIG. 4 simply represents a refill container 12 that can be supplied/sold without the wand assembly 14 which is facilitated due to the use of lug 24 and slot 26 that permits reuse of the wand assembly 14 .
[0033] To retain wand 14 and coiled hose 16 , card assembly 28 includes locking mechanism 36 that engages slot 26 and prevents detachment of the wand until the card assembly is detached from container 12 via performation lines 34 .
[0034] With reference to FIGS. 6A-6C and 7 A- 7 C, container 12 includes a cap 18 that is shipped with a safety seal 40 adhered there over. Upon removal of safety cap 40 and detachment of wand 14 and hose 16 from the container 12 , the coupler end 42 of hose 16 may be snappingly engaged with an exposed opening 44 on cap 38 . Coupler 42 includes a pair of opposed, biased latches 46 , 48 extending downwardly therefrom that snappingly and securely engage a flanged rim 50 formed on the underside of cap 18 to secure hose 16 to container 14 , and create a fluid circuit between the fluid contents within container 12 and wand 14 , as will be described hereinafter. Once connected, coupler 42 is capable of swiveling 360 degrees relative to cap 18 .
[0035] With reference to FIGS. 8-11 , there are four versions or configurations in which the hose 16 establishes a fluid circuit with the fluid contents of container 12 . In the first version shown in FIGS. 8A and 8B , coupler 42 includes a separate stem 52 that extends downwardly from the coupler 42 and through cap 18 . In this version both the necessary air and fluid sealing is controlled by a spring loaded plunger 54 that is positioned along the longitudinal axis X-X that extends centrally through the cap 40 and is separated from stem 52 by a spring 56 that is co-axially sandwiched between a dip tube holder 57 (that holds/retains dip tube 59 ) and plunger 54 . In FIG. 8A which shows the coupler 42 disconnected from the cap 18 , spring 56 biases plunger 54 upwardly which annularly seals the fluid circuit at point 58 and annularly seals the air passage at point 60 . In FIG. 8B which shows coupler 42 connected to cap 18 , stem 52 engages and compresses spring 56 , thereby opening a fluid passageway as reflected by arrow 62 as well as an air passageway as reflected by arrow 64 . The simultaneous opening of passageways 62 and 64 permits the flow of fluid out of container 38 (when the trigger on the wand is manually activated and compressed air is present within container 38 as understood in the art).
[0036] With reference to FIGS. 9A and 9B , a second version or configuration in which hose 16 establishes a fluid circuit with the fluid contents of container 18 is shown. In FIG. 9A , an umbrella valve 66 is positioned in sealed relation to an air passageway located at the bottom of cap 18 . As shown in FIG. 9B , when the stem 52 engages and compresses spring 56 it displaces the plunger 54 which in turn causes the fluid passageway 62 (same as first configuration) to open and also causes umbrella valve 66 to pop and open air passageway 68 . The simultaneous opening of passageways 62 and 68 permits the flow of fluid out of container 18 (when the trigger on the wand is manually activated and compressed air is present within container 38 as understood in the art).
[0037] With reference to FIGS. 10A and 10B , a third version or configuration in which hose 16 establishes a fluid circuit with the fluid contents of container 12 is shown. In this configuration, everything is identical to the first version except that stem 52 is integral with coupler 42 instead of separate as it is with the first version. Otherwise, this third version and the first version are identical.
[0038] With reference to FIGS. 11A and 11B , a fourth version or configuration in which hose 16 establishes a fluid circuit with the fluid contents of container 38 is shown. In this configuration everything is identical to the second version except that stem 52 is integral with coupler 42 instead of separate as is with the second version. Otherwise, this fourth version and the second version are identical.
[0039] With reference to FIGS. 12A and 12B , an aspect of the present invention is shown that includes integration of a valve body into a pump/motor housing. In this aspect of the invention, a wand handle 100 includes a hollow interior volume in which a motor 102 is stowed. Integrated with motor 102 is a valve body 104 that is operational between open and closed positions by means of a trigger 106 mounted on the underside of the handle 100 . The wand 108 is pivotally mounted to handle 100 and in fluid communication with a fluid outlet 110 that extends from valve body 104 . A fluid inlet 112 is placed in fluid communication with the fluid contents of container 38 (not shown in these figures) by means of a dip tube, such as dip tube 59 shown in other Figures. Upon manual movement of trigger 106 , the fluid passageway between inlet 112 and outlet 110 is opened and upon release of the trigger the passageway is closed, thereby fluidly sealing container 38 . The use of a motor to drive a pump and provide the pumping necessary to compress and expel fluid from a container is otherwise well understood in the art. | A lawn and garden sprayer system having a container and a spray wand fluidly connected to the container is provided. The spray wand includes a wand housing that has a slot formed in one side thereof that is configured to engage a lug formed on one side of the container for purposes of stowing the wand during shipping and when not in use. A communications card assembly is detachably connected between the container and spray wand during shipment and prior to its first use. The hose includes a coupler end that engaged a cap on the container and facilitates creation of a fluid circuit between the fluid contents in the container and the wand. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional application of U.S. patent application Ser. No. 09/937,916 filed Jan. 22, 2002, which in turn is based on International Application No. PCT/FI00/00204 filed Mar. 15, 2000
FIELD OF THE INVENTION
The invention relates to a method for manufacturing a thermoroll for a paper/board machine or a finishing machine including a shell made by casting and/or powder metallurgical methods.
BACKGROUND OF THE INVENTION
Heatable rolls, that is, thermorolls, are commonly used in paper machines and paper finishing or converting machines, especially in calenders and multi-roll calenders, the length of the said thermorolls being as much as 10 m, their diameters being typically of the order of approximately 500-1000 mm—with soft calender rolls 1200-1650 mm. The heating of the rolls is usually carried out by means of a heating medium, such as steam or hot water or oil. Thermorolls are typically formed by drilling axial bores close to the outer surface of the roll shell, the diameter of the bores being typically about 25-50 mm, and through which bores the heating medium is passed from one axial end of the roll to its opposite end. There are typically several such bores, distributed evenly in the circumferential direction of the roll. The heating medium may circulate in the bore, for example, once from one end of the roll to the other, or twice or several times so that in adjacent bores, the heating medium travels in opposite directions. FIGS. 1 and 2 show a prior art thermoroll of this type, in which a shell 2 is attached to end flanges 16 , 18 provided with axle journals 15 , 17 , in which shell are formed axial bores 3 , of which there are several, distributed evenly in the circumferential direction. In the axle journal 15 is formed an axial bore 14 , to which is fitted a pipe 11 extending to the opposite end flange 18 . Between the outer surface of the pipe 11 and the interior surface of the axial bore 14 remains an annular slot. The heating medium is supplied to the roll 1 from the first end (the end with the axle journal 15 ) through a pipe 11 and passed via the radial bores 12 at the opposite end to the bores 3 , and along them back to the first end, and via the radial bores 13 to the said annular slot in the axle journal 15 and from there out of the roll.
A problem associated with thermorolls provided with this type of prior art bores relates to making the axial bores by means of long hole drilling, which is relatively slow and expensive. Long hole drilling is made particularly demanding by the formation of material structure boundary surfaces in the wall construction of the shell due to the manufacturing technique. The cementite microstructure in chill cast thermorolls is brittle and susceptible to breakage due to the effect of mechanical and thermal loads. Variation in the thickness of the cementite layer may in addition cause curving of the rolls when heated. Intergranular corrosion may also occur due to paper auxiliaries. Furthermore, the current trend towards increasingly high temperatures increases the problems caused by the thermal fatigue of materials. To improve wear resistance, chilled rolls have to be coated, for example, by hard chromium plating.
OBJECTS AND SUMMARY OF THE INVENTION
Thus, one of the aims of the present invention is to achieve an improved thermoroll, where long hole drilling and other prior art disadvantages are avoided. The aim is, moreover, to achieve a roll, where good heating properties are obtained for the outer surface of the roll. To achieve this aim, it is characteristic of the thermoroll relating to the invention that the shell is made by means of casting or powder metallurgical methods, and that the ducts are formed in the matrix material of the shell which is of metal, ceramic or a composite, directly in connection with manufacture.
Of the method relating to the invention for manufacturing a thermoroll it is, on the other hand, characteristic that the shell is made by means of casting and/or powder metallurgical methods, and that the ducts are formed in the matrix material of the shell which is of metal, ceramic or a composite, directly in connection with manufacture, without machining. The object of the present invention is to provide a thermoroll for a paper/board machine or a finishing or converting machine, the said thermoroll comprising a shell of metallic, ceramic or composite material, the shell incorporating ducts for passing a heating medium from one axial end of the shell to its opposite end.
A further object of the invention is to provide a method for manufacturing a thermoroll for a paper/board machine or a finishing or converting machine, the said thermoroll comprising a shell of metallic, ceramic or composite material, the said shell incorporating ducts for passing a heating medium from one axial end of the shell to its opposite end.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in the greater detail in the following, with reference to the appended drawings in which:
FIGS. 1 and 2 show diagrammatically a prior art thermoroll solution, and
FIGS. 3 to 10 show diagrammatic views of examples of different embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 show a diagrammatic view of the prior art thermoroll disclosed in the introduction.
FIG. 3 shows a thermoroll implemented in accordance with the invention as a diagrammatic longitudinal section, in which an outer shell 4 made of metal in powder form and incorporating a heating medium duct 3 is formed around an inner base tube 5 of steel or cast iron. The metal powder is metal in spherical particulate form and having a particle diameter of the order of 0.1-0.5 mm, which is made of molten metal by means of gas atomisation. It maybe more alloyed than composition metals produced by conventional methods, and it may also contain carbide and oxide components, such as, for example, Al, B, Cr, Ti, Si, Sn, W, Zn, Zr oxides and carbides or their alloys. To produce a piece of metal powder, powder metallurgical methods can be used, which include spraying, extrusion and hot isostatic pressing (HIP). In the HIP method, for example, a piece of metal obtains its final form and density under a high pressure and temperature, the metal remaining, however, in a non-molten state, whereby the properties obtained for the product are better and more homogeneous than those of products obtained when using melting methods.
In the embodiment relating to FIG. 3, the heating medium ducts 3 are formed in the outer shell layer of metal powder as pipes with a sheet metal structure, the said pipes acting as a mould during the manufacturing process. The pipes may be left inside the shell layer 4 . When manufacturing the outer shell layer 4 by means of HIP treatment, a sheet metal capsule is formed around the inner manifold 5 at a distance corresponding to the desired thickness of the outer layer, inside which capsule is placed metal powder around the heating duct pipes 3 . After this air is sucked from the capsule almost to a state of vacuum and the capsule is subjected to a high pressure and temperature, thus effecting the formation of the final outer layer 4 of the shell. The sheet metal pipe structures forming the heating medium ducts can be designed, for example, as shown in FIG. 10, whereby the use of separate displacing elements causing local temperature differences in the axial direction of the roll can, be avoided. The use of such displacing elements is described, for example, in FI patent 91297. The flow duct can be designed either so that its diameter changes linearly ( 10 a ), or in optimised form producing a constant heat flow q(x) (FIG. 10 b ).
The outer shell layer 4 can also be made separately from the inner shell and be attached to the inner shell, for example, by means of shrink fitting technique or by glueing or soldering the shells together. FIG. 4 shows the structure of a shell obtained in this manner, in which there is a bonding layer 6 between the inner shell layer 5 and the outer shell layer 4 made of metal powder. This bonding layer 6 can also be thought to be formed as an insulating layer in order to improve the heating properties of the thermoroll on the outer surface of the roll shell.
The heating medium ducts 3 may also be located, for example, as shown in FIG. 5, on the boundary surface between the inner frame shell and the outer shell of metal powder. The heating medium ducts may be conventional axial ducts or pipes, or they can also be made to run spirally on the circumference of the shell.
FIG. 6 shows a cross-section of a thermoroll, which comprises an inner pipe 8 made of material having low thermal conductivity (heat insulator), on top of which pipe are attached smaller pipes 3 which act as heating medium ducts in the roll.
After this, an outer layer 4 of material 5 having a better coefficient of thermal conductivity, or possibly of material with even better thermal conductivity, is cast over the inner pipe 8 and the ducts 3 attached to it, or made by means of pulverisation-metallurgical methods. Finally, the roll is coated with a hard and wear-resistant coating 7 . Material layers 5 and 4 may also both be of the same material and they can be manufactured in one stage.
FIG. 7 shows a solution in which ducts 9 , for example a duct system bent from sheet metal, on the inside of which is formed, for example by casting, a base material layer 5 of e.g. cast iron, are formed on the inner surface of the outer shell layer 4 which is of a material having better thermal conductivity. There may also be an insulating layer on the inner surface of the inner layer 5 .
Table 1 shows some approximate material values of materials which can be used in the method relating to the invention.
Thermal
Fatigue
conductivity
strength
Density
Module
Material
[W/mK]
[MPa]
[kg/m 3 ]
[GPa]
Cast iron
50
80
7300
100-130
Al/SiC
175
250
2600
90-110
composite
Coal/Coal
200-250
100-500
1600
90-120
composite
By selecting the materials so that their thermal conductivity increases when moving from the inner shell layer to the outer shell layer, a higher roll surface temperature is achieved with less energy, which may lower the total costs incurred by the thermoroll. The roll structure can, moreover, be lightened, which results in cost savings especially in multi-roll calenders (such as OptiLoad calenders).
FIG. 8 shows a solution in which the entire shell body is formed of a metal powder alloy, which is produced by means of HIP treatment and in which alloy are formed heating medium ducts 3 a , 3 b on two different radial levels in the shell material. If necessary, also on the inner surface of this roll may be formed an insulating layer and the outer surface can be coated with a hard and wear-resistant coating, for example, with a ceramic material which is sprayed onto the outer surface of the shell.
FIG. 9 shows a thermoroll construction implemented without the end flanges. In this solution, the axle 10 made of steel or cast iron acts as an internal mould for the intermediate shell 6 , the composition of which intermediate shell can be selected from materials with a light density, such as aluminium-based powdered compositions. The heating medium feed and discharge ducts 20 , 23 are formed by means of bores made in the axle, and in the intermediate shell 6 are formed radial ducts 21 and 22 for supplying the heating medium to the outer shell layer 2 , which comprises axial heating medium ducts 3 . This outer shell 2 can be made as a separate pipe and then be attached over the intermediate shell 6 , 8 or the intermediate shell can be used as a mould around which the outer shell 2 is made, for example, by means of HIP treatment.
When the roll is made in accordance with the invention, optimisation of the heat transfer ducts in the longitudinal direction of the roll is possible. Holes may be placed more densely and their diameters may be smaller than those of drilled holes. The ducts do not necessarily have to be parallel with the roll axle, but may be, for example, spiral or oblique to reduce barring. Change of the diameter of the ducts in the axial direction is also easy to arrange without separate displacing elements. Especially when applying powder metallurgy, the surface of the roll can be made of material alloyed in a different manner in connection with the manufacture of the shell, whereby wear resistance can be improved without hard chromium plating or other separate coating stage. Products made by means of powder metallurgical methods are more homogenous and more controlled, which means that in critical conditions their operational safety improves. | A thermoroll for a paper/board machine or a finishing machine, the thermoroll having a shell of metallic, ceramic or composite material, and the shell having ducts for passing a heating medium from one axial end of the thermoroll to the other axial end of the thermoroll. The shell is made by casting or by powder metallurgical methods, and the ducts are formed in the matrix material of the shell which is metal and/or ceramic. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to a new and improved construction of spinning projectile with a projectile body and a hollow charge component rotatably mounted in the projectile body and axially displaceable by the propellant gases, and further incorporating means in order to maintain the hollow charge component in the displaced position.
A spinning projectile of this type has become known to the art wherein the gases developed by the propellant charge flow through an annular compartment bounded by two throttle locations and arranged between the projectile body and the hollow charge component. The hollow charge component is displaceable in the axial direction relative to the projectile body in order to produce an equilibrium condition between both throttle locations. In this equilibrium state the propellant gases flowing through the annular compartment form a bearing cushion for the hollow charge component and hold such in the work position. In this manner upon passage of the projectile through the firing barrel or tube there is prevented the spinning entrainment of the hollow charge component owing to friction at surfaces which normally are pressed against one another by the acceleration forces. The aforementioned surfaces however can be pressed against one another during the course of the flight path or trajectory owing to the effective air dynamic pressure or velocity head and the now absent propellant charge pressure, so that finally nonetheless the undesired spinning entrainment of the hollow charge component occurs.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to construct a spinning projectile of the previously mentioned type in such a manner that there can be avoided a spinning entrainment owing to friction upon the occurrence of axial acceleration or deceleration during the entire flight path.
Now in order to implement this object, and others which will become more readily apparent as the description proceeds, the aforementioned means are constructed as locking elements which maintain the hollow charge component in the displaced position at the projectile body even after abatement or yielding of the propellant charge pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a longitudinal sectional view of a spinning projectile designed according to the invention and taken along the line I--I of FIG. 2;
FIG. 2 is a front view looking in the direction of the arrow A of FIG. 1; and
FIG. 3 is a sectional view on an enlarged scale through the separation location between the projectile jacket and the hollow charge component illustrated in a position following firing of the projectile.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, according to the showing of FIG. 1 a floor or base piece 1 possesses two axially forwardly and rearwardly directed sleeve-shaped projections 2 and 3. A cylindrical jacket or shell 4 is centered at the base piece 1 and bears against a shoulder 5 thereof. A sleeve 6 possesses a conical forwardly opening front portion 7 with a flange ring 8. The sleeve 6 extends into the projection 2 of the base piece 1 and is appropriately threadably connected therewith. The rear surface of the flange ring 8 bears upon a shoulder 9 arranged at the inside of the jacket or shell 4. In the annular or ring-shaped compartment forming a combustion chamber or compartment 10 and bounded by the sleeve 6, the shell 4 and the base piece 1 there is arranged a hollow cylindrical propellant charge body 11. This propellant charge body 11 adheres to a layer 12 of a suitable thermally insulating material which has been conveniently applied to the inside of the jacket or shell 4.
A piston 13 is displaceably mounted in the sleeve 6. The piston 13 possesses a hollow cylindrical projection 14. The piston 13 together with projection 14 and the base piece 1 delimit a compartment forming a second combustion chamber 17. In the combustion chamber or compartment 17 there is arranged a propellant charge 18. a firing or detonator cap 20 is inserted in the base piece 1. A bore 19 communicates the detonator cap 20 with the interior of a sleeve 21 which is secured at the projection 3 of the base piece 1.
The base piece 1 possesses a tapped or cut-in portion 22 machined at the rear side. As best seen by referring to FIG. 2 the base piece 1 possesses six nozzle blocks 23 arranged at a uniform angular spacing from one another and possessing the same spacing from the lengthwise axis of the projectile. The nozzle blocks 23 are separated from one another by milled portions 24 in the annular part of the base piece 1 which surrounds the cut-in portion 22. The milled portions 24 are limited by surfaces 25 directed perpendicular to the projectile axis, the surfaces being located in a plane located behind the shoulder 5. The nozzle blocks 23 possess blindhole bores 26 and nozzles 27, the axes of which constitute the generatrixes of rearwardly opening conical surfaces. The apexes or tips of the conical surfaces are located at the projectile axis with which their axes coincide. The bores 26 communicate the combustion chamber or compartment 17 with nozzles 28, the axes of which are directed perpendicular thereto and are located in a plane. By means of the nozzles 27 the combustion compartment 10 is vented. Bores 29 which communicate with the combustion compartment 10 branch off from the blindhole bores 26.
A hollow propellant charge 30 is contained in a sleeve 32 possessing a conical hood 31. The sleeve 32 possesses a rearwardly protruding funnel-shaped extension 33. The outer diameters of the sleeve 32 and the jacket or shell 4 are of the same size. According to FIG. 3 the sleeve 32 possesses as the transition to the extension 33 a step-shaped shoulder with two parallel surfaces 35, 36 directed perpendicular to the projectile axis and perpendicular to an end surface 34 of the shell or jacket 4. A forwardly opening conical surface 37 intersects the surface 36 and a cylindrical surface 38, and the diameter of which corresponds to the internal diameter of the jacket 4. A sealing O-ring 39 is inserted in a ring-shaped groove 40 which is cut-in from the location of the surface 35 into the sleeve 32.
The conical extension 33 of the projectile sleeve 32 merges towards the rear into a sleeve-shaped projection 15. Threadably connected with the projection 15 is a sleeve 16 which is stepped in diameter. The sleeve 16 fixedly connected with the hollow charge component or part bears through the agency of a first, rear roller bearing 41 at the piston 13. For this purpose the piston 13 possesses a forwardly tapered, cylindrical projection 42 onto which there is mounted the inner race or ring 43 of a roller bearing 41. The outer ring or race 44 of the roller bearing 41 bears against the inner wall of the sleeve 16. The inner race 45 of second forwardly situated roller bearing 46 bears axially towards the rear at a shoulder 47 at the outside of the tapered front portion of the sleeve 16. Towards the front the inner race 45 of the roller bearing 46 bears via a ring web 48 at the conical extension 33 of the sleeve 32. The inner race 45 is thus connected so as to be axially non-displaceable with the hollow charge component. The outer race 49 of the roller bearing 46 is axially displaceably guided in the projectile body-fixed sleeve 6. It bears towards the rear via a spring or resilient ring member 50 and a bushing 51 at the piston 13 and towards the front via a ring 52 and a package or set of springs 53 at a spring or resilient ring 55 which engages in the annular or ring-shaped groove 54 ln the sleeve 6. In the axial direction of movement there is arranged in front of the spring or resilient ring 50 a further annular or ring-shaped groove 56 in the inner wall of the sleeve 6.
The mode of operation will be apparent from the aforedescribed construction.
For firing purposes the spinning projectile together with its sleeve 21 is placed upon a not particularly illustrated mandrel of a conventional firing mechanism. A likewise not illustrated firing pin pierces the firing or detonator cap 20. The ignition jet emanating from the detonator cap 20 ignites the propellant charge 18. By virtue of the gases resulting from the combustion of the propellant charge 18 the piston 13 is driven. This piston 13 thus displaces via the bushing 51 and the spring ring 50 the front bearing 46 and thus the hollow charge component towards the front and which consists of the sleeve 32 with the hollow charge 30 and the extension 33 as well as the sleeve 16. This movement occurs against the force of the package of springs 53 which in the rest position or state sealingly presses the hollow charge component at the projectile body. When the spring ring 50 is at the height of the annular groove 56 then it snaps into such groove and thereby limits the path of the piston 13 and the hollow charge component towards the front. At the end of this movement the sealing O-ring 39 and the surfaces 35 and 36 of the sleeve 32, as best seen by referring to FIG. 3, possess a spacing from the surface 34 of the jacket or shell 4.
The gases flow through the bores 26 and the nozzles 27 out of the combustion compartment 17. Consequently, tangential forces are exerted, which place the projectile into rotation or spin about its lengthwise axis, so that it initially only rotates upon the not particularly shown mandrel without placing into rotation the hollow charge component. At the same time gas flows through the bores 29 into the combustion compartment 10 and ignites the propellant charge body 11 shortly prior to the completion of the combustion of the propellant charge 18. Owing to the component of the thrust force which acts in axial direction, and which has been produced by the efflux of the gases out of the thrust nozzles 27, the projectile is now accelerated and moved away from the mandrel. The gases of the propellant charge 11 also flow through the bores 29 into the combustion compartment 17, so that the piston 13 during the entire time when the projectile is accelerated, together with the hollow charge component, is held in its advanced position. Since with the exception of the very small frictional forces transmitted by the roller bearings 41, 46 no other forces rotatably engage at the hollow charge component, the latter -- in contrast to conventional projectiles -- only carries out a very slow rotation about its axis.
After completion of combustion of the propellant charge 11 the spring ring 50 which has snapped into the annular or ring-shaped groove 56 prevents that the projectile, under the action of that inertia force which engages thereat owing to the deceleration brought about by the air resistance, can again approach the hollow charge component.
The invention has previously been described on the basis of a rocket spinning projectile, but however it is also to be understood that it is not limited to rocket spinning projectiles. Also in the case of cannon ammunition the principles of the invention can be employed. In such instance the propellant charge gases, which are present owing to burning of the propellant charge located in the cartridge sleeve, are permitted to act directly from the rear at the projectile body and the hollow charge component arranged displaceably therein. When the rifling grooves of the firing barrel for instance produce a progressive spin or twist, it is possible to separate the surfaces between the projectile body and the hollow charge component which previously where in contact, before there occurs a rotation of the projectile, so that also in this case there can be positively prevented with certainty an undesired spinning entrainment of the hollow charge component.
while there is shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. | A spinning projectile with a projectile body and a hollow charge component rotatably mounted in the projectile body and axially displaceable by the propellant gases, further including means in order to hold the hollow charge component in its displaced position. According to the invention the aforementioned means are constructed as locking elements which maintain the hollow charge component in the displaced position at the projectile body even after there has been an abatement of the pressure of the propellant charge. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] Currently, indoor air cleaning systems primarily use filters to directly clean indoor air and all air filtering systems suffer from a number of disadvantages. They do not maximize the proportion of air in a room that is cleaned because their low-height designs do not optimally facilitate the circulation of the air in the room. They operate at low air flow rates and do not optimize cleaning performance with respect to the number of times that the air in the room is exchanged over a given amount of time. They lack scalability because an air cleaning system using a filter to directly clean air is limited in design to the cross-sectional area of the filter and to the maximum flow rate of air that the filter can handle. Further, indoor air cleaning systems do not provide the means to heat or cool the air that is being cleaned. Finally, expensive filters must be replaced frequently because the amount of air being cleaned decreases over time as impurities are collected by the filter.
BRIEF SUMMARY OF THE INVENTION
[0005] My invention removes impurities from indoor air by washing the air with water. The used water is subsequently cleaned, heated or cooled, and reused. Several objects and advantages of my air cleaning system are to maximize the proportion of air in a room that is cleaned; to operate at a high capacity; to provide greater scalability to an air cleaning system; to provide the means to heat or cool the air that is being cleaned; and to continuously operate at the optimum capacity. Further objects and advantages are to reduce the costs of operating and maintaining an air cleaning system and to reduce indoor heating and cooling costs.
REFERENCE NUMERALS IN DRAWINGS
[0006] [0006] 2 vent 4 air washing mechanism 6 media container 8 reservoir 10 air slots in vent 12 hole in side near bottom of vent 14 notch with thread 16 notch with groove 18 stem 20 blade 22 conduit 24 perforations in hollow portion of blade 26 grates in solid portion of blade 28 perforations in mechanism 30 slot in annulus 32 annulus 34 hole in mechanism 36 water line 38 perforations in bottom of container 40 hole in reservoir 42 hole in reservoir 44 valve 46 removable access panel 48 slots in reservoir 50 fill line in reservoir 52 grooves along main axis of surface
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0007] The present embodiment of my invention is presented in FIGS. 1 through 6. FIG. 1 shows the rear view of the elements of the air washing system interconnected. The front and side views of the system are unremarkable. FIG. 2 shows the top view of the air washing system and denotes the view of the cross sections presented in FIGS. 3 through 6. FIG. 3 shows the vent 2 ; FIG. 4 shows the air washing mechanism 4 ; FIG. 5 shows the media container 6 ; and FIG. 6 shows the reservoir 8 .
DETAILED DESCRIPTION OF THE INVENTION
[0008] As shown in FIG. 1 the elements are generally cylindrical. To improve visual appeal and to promote assembly, the exterior surfaces of the elements contain grooves 52 along the main axis of the assemblage. An element is connected to another element by threading a contiguous thread on a notch in the element through a contiguous groove in a notch in the other element.
[0009] An air vent 2 (FIG. 3) distributes cleaned air upward and outward throughout 360 degrees to promote circulation of air within a room. The top of the vent 2 is solid and there are slots 10 in the vent 2 . The power cord for a fan (not shown) passes through a hole 12 . The bottom of the vent 2 is open and conforms to the uniform means of connecting elements of the system 14 and connects onto an air washing mechanism 4 .
[0010] The air washing mechanism 4 (FIG. 4) contains a solid stem 18 and a contiguous blade 20 wherein the revolutions of the blade 20 about the stem 18 form a conduit 22 . Air enters the conduit 22 through a slot 30 in a cocentric annulus 32 in the stem 18 . Cleaned air exits the mechanism 4 through the conduit 22 to the vent 2 . One revolution of the blade 20 is hollow and both the top and the bottom of the blade 20 are solid so that water is contained. Water enters the blade 20 through a hole 34 coupled to a quick-connect fitting. The quick-connect fitting is attached to a quick-connect fitting on a water line 36 . Two revolutions of the blade 20 are hollow and the top of the blade 20 is solid and the bottom of the blade 20 is perforated 24 so that water flows from the mechanism 4 by the forces of gravity and the static pressure head of the water. One revolution of the blade 20 is solid and grated 26 to allow the used water to trickle downward. And one revolution of the blade 20 terminates contiguous with the mechanism 4 and has perforations 28 so that water is discharged. The mechanism 4 proscribes to the uniform means of connecting elements of the system 14 and 16 and connects onto a container 6 .
[0011] The container 6 (FIG. 5) contains one or more media through which water from the mechanism 4 flows and wherein impurities removed from the air are removed from the water. Air passes through the container 6 through a cocentric annulus 32 to the mechanism 4 . The top of the container 6 is open and the bottom of the container 6 is perforated 38 so that the cleaned water trickles from the container 6 . The container 6 conforms to the uniform means of connecting elements of the system 14 and 16 and connects onto a reservoir 8 .
[0012] The reservoir 8 (FIG. 6) conforms to the uniform means of connecting elements of the system 16 . The top of the reservoir 8 is open and the bottom of the reservoir 8 is solid to contain water. A pump inside the reservoir (not shown) pumps water through a line in the reservoir 8 through a hole 40 in the reservoir 8 . The hole 40 and the line are coupled by a washer mechanism (not shown) to prevent leakage and the portion of the line protruding from the hole 40 in the reservoir 8 is the water line 36 to the mechanism 4 . A quick-connect fitting is attached to the end of the water line 36 . A water chiller (not shown) and a water heater (not shown) maintain the temperature of the water in the reservoir 8 within at a set temperature range so that the air cleaning system is able to continuously warm or cool the air that it cleans. The power cords exit the reservoir 8 through a hole 42 in the reservoir 8 and the cords and the hole 42 are coupled by a washer mechanism (not shown) to prevent leakage. A drain valve 44 can be used to manually withdraw water from the reservoir 8 . A removable access panel 46 provides access to the contents of the reservoir 8 without disconnecting the assembly. Slots 48 in the reservoir 8 allow air to be withdrawn from the room throughout 360 degrees. Air passes through the reservoir through a cocentric annulus 32 to the container 6 . Cocentric fill lines 50 about the annulus 32 denote the maximum and minimum water levels for the reservoir 8 . Portability is promoted by mounting wheels or coasters (not shown) along the bottom circumference of the reservoir 8 .
[0013] Other embodiments of my invention will force the air through the system whereas the presented imbodiment pulls air through the system. Other embodiments of my invention will be designed to automatically maintain the appropriate water level in the reservoir and to impart a slight electrical charge to the water.
[0014] The manner of setting up and operating the system follows. First, place the reservoir 8 at the desired location in the room. Place a predetermined amount of water into the reservoir 8 . Insert the access panel 46 into the reservoir 8 . Place predetermined amounts of pollutant removing media into the container 6 . Place notch 14 of the container 6 into notch 16 of the reservoir 8 and thread the container 6 onto the reservoir 8 . Place notch 14 of the air washing mechanism 4 into notch 16 of the container 6 and thread the mechanism 4 onto the container 6 . Place notch 14 of the vent 2 into notch 16 of the mechanism 4 and thread the vent 2 onto the mechanism 4 . Attach the water line 36 to the quick connect fitting 34 of the mechanism 4 . Connect the power cords for the pump, fan, chiller, and heater to a power source. Turn on the pump. Turn on the fan. Set the theromstat to the desired temperature.
[0015] The manner of regularly maintaining the system follows. Turn off the pump, fan, chiller, and heater. Allow the water to trickle into the reservoir 8 . Remove and clean the vent 2 . Disconnect the water line 36 from the mechanism 4 . Remove and clean the mechanism 4 . Remove the container 6 , discard the used media, and add new media to the container 6 . Place the water line 36 into a drain, turn on the pump, and pump most of the water in the reservoir 8 into the drain. Turn off the pump. Discard the remaining water in the reservoir 8 using the manual valve 44 . Add fresh liquid to the reservoir 8 . Reassemble and operate the system as previously described.
[0016] From the description above, a number of advantages of my air cleaning system over systems that directly filter air are evident. My invention can maximize the proportion of the air in a room that is cleaned; operate at a high capacity; provide greater scalability to an air cleaning system; provide a means to heat or cool the air that is being cleaned; and maintain a constant rate of clean air delivery. The system can reduce the cost of operating an air cleaning system by using less energy, increasing the time of operation between regular maintenance, and decreasing the cost of replacement media. The system can also reduce indoor air heating and cooling costs.
[0017] My invention can be scaled to meet either household or commercial needs such as delivering clean, disinfected air in a medical setting or delivering warm or cool air to rooms, homes, offices, and buildings. My invention can be used in many applications with the appropriate changes in the dimensions, materials of construction, pollutant removal media, and the liquid(s) used. Although the description above contains many specifications, these should not be construed as limiting the scope of my invention but as merely providing an illustration of the presently preferred embodiment of my invention. | An air cleaning system comprising the means to displace air, contact the displaced air with a liquid, exhaust the cleaned air, and discharge the used liquid; and the means to clean the used liquid, heat or cool the liquid, impart a charge to the liquid, and displace and direct the liquid whereby indoor air is cleaned and indoor air temperature is controlled. | 5 |
This application claims benefit of prior filed now abandoned Provisional Patent Application Ser. No. 60/512,872 filed Oct. 20, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to antennas and more specifically to a system and method for spectral control of same.
2. Description of the Prior Art
Practitioners of the antenna arts have long realized that a tapered antenna feed leads to an improved broadband match. Early examples of such antennas include those of Carter [U.S. Pat. No. 2,181,870], and Brillouin [U.S. Pat. No. 2,454,766]. These concepts have been applied to planar antennas as well, notably by Nester [U.S. Pat. No. 4,500,887] who taught a tapered microstrip horn. Antenna radiating elements have been similarly tapered. For instance, Barnes [U.S. Pat. Nos. 6,091,374; 6,400,329 and 6,621,462] disclosed a tapered slot antenna and the inventor disclosed a semi-coaxial horn with a tapered horn element [U.S. Pat. No. 6,538,615].
In some cases, a tapered feed and tapered radiating element have been combined in the same antenna structure. For example, Lindenblad [U.S. Pat. No. 2,239,724], invented a wideband antenna with a tapered feed connected to a tapered bulbous radiating element. More recently the inventor implemented a planar antenna with a tapered feed structure smoothly flowing into elliptically tapered planar dipole elements [U.S. Pat. No. 6,512,488 and 6,642,903].
This prior art is characterized by generally monotonic variations in impedance with distance along a signal path traversing an antenna feed structure, radiating elements, and surrounding medium or space. These monotonic variations in impedance are generally considered desirable because they help to optimize a broad band match between an antenna and a transmission line. These monotonic variations may be discontinuous (as in a Klopfenstein taper) or have points of inflection (as in an Exponential taper).
Wavy shaped or corrugated antenna structures have been adopted for diffraction control or to increase impedance [Kraus, Antennas 2 nd ed., New York: McGraw-Hill, pp. 657–9]. McCorkle [U.S. Pat. No. 6,590,545] discloses (FIG. 21) a planar UWB antenna with a wavy shaped slot. McCorkle suggests that a band stop transfer function might be possible by adjusting the width of the tapered clearance, however neither the drawings nor the detailed description provide any guidance to one skilled in the art as to how such adjustment gives rise to band stop behavior. In practice, the small periodic variations in tapered clearance shown by McCorkle are largely ineffective in giving rise to significant manipulation of an antenna transfer function, particularly since the disclosed variations maintain a continuous increase in width.
The inventor [U.S. Pat. No. 6,774,859] discovered that a practical means for implementing band stop or frequency notch filters in an otherwise ultra-wideband antenna is to incorporate a discrete narrow band resonant structure.
An alternate filtering technique, stepped impedance low pass filtering is also known in the art [David M. Pozar, Microwave Engineering, 2 nd ed., New York: John Wiley & Sons, 1998, pp. 470–473]. This technique has not been applied to control impedance of antennas and implement desired transfer functions in antennas, however.
The extreme bandwidths of ultra-wideband antennas leave them especially vulnerable to interferers. It is a challenge to design an RF-front end to provide sufficient rejection to adjacent interferers just above an antennas operating band without adversely impacting performance in a desired band. For instance, it is desirable to have an ultra-wideband antenna responsive to the 3.1–5.0 GHz band without being responsive to interferers operating above 5.0 GHz. An electrically small UWB antenna is naturally unresponsive to signals lying below its operational band. Making such an antenna unresponsive to higher frequency signals is a greater challenge.
In view of the foregoing, there is a need for a system and method of modifying an antenna slot or notch to create the large variations in impedance necessary to implement effective distributed filters. There is a further need for a method to implement filtering or a desired transfer function with minimal modifications to an existing antenna design. Additionally, there is a need for an antenna apparatus that implements filtering capability inexpensively without requiring the added expense and board space of a lumped element filter structure in the RF front end of a radio device.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a means for modifying an antenna slot or notch to create large variation in impedance necessary to implement effect distributed filters. It is a further object of the present invention to provide a desired transfer response to an otherwise broad band antenna. Yet another object of the present invention is to implement filtering capability inexpensively without requiring the added expense and board space of a lumped element filter structure in the RF front end of a radio device.
These objects and more are met by the present invention: a spectral control antenna apparatus including a feed region or feed gap and a surrounding space or medium. A signal path between a feed region and a surrounding space or medium is characterized by a length dependent impedance with a plurality of extrema whereby the antenna apparatus exhibits a desired spectral response. The invention is well-suited for application to planar antennas, particularly planar antennas characterized by a slot type transmission line structure. If such a transmission line structure is an offset slot line, then by overlapping sections of the offset slot line relatively low impedances are possible, thus enabling the large variations in impedance necessary for effective filtering behavior.
An antenna spectral control system includes an RF device, a feed region, a surrounding space or medium, and a signal path between the feed region and the surrounding space. The present invention teaches using a variation in characteristic impedance along the length of a signal path to give rise to a desired spectral response. Means for varying impedance may include dielectric loading, transmission line geometry variation, or other means for varying impedance. A particularly effective way of varying impedance involves using an offset slot line transmission line structure with overlapping sections. In alternate embodiments, discrete lumped capacitances or inductances may be distributed along a signal path for added spectral control.
In alternate embodiments, a spectral control antenna apparatus comprises a dielectric substrate, a first conducting layer, and a second conducting layer. A first conducting layer and a second conducting layer cooperate to form a slot line transmission line structure including a plurality of extrema. A first conducting layer and a second conducting layer may be co-planar on the same side of a dielectric substrate, or may lie on opposite sides of a dielectric substrate. In still further embodiments, a slot line transmission line structure includes a plurality of overlapping sections.
Further, a method for spectral control of an antenna comprises providing a signal path between a feed region and a surrounding space or medium having a characteristic impedance with dependence on a length of a signal path; and providing a means for varying impedance whereby an antenna exhibits a desired spectral response. A means for varying impedance may include using lumped elements, dielectric loading, or geometry variations.
With these and other objects, advantages, and features of the invention that may become hereinafter apparent, the nature of the invention may be more clearly understood by reference to the detailed description of the invention, the appended claims and to the several drawings herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section of a same-side slot line.
FIG. 2 is a cross-section of an overlapping offset slot line.
FIG. 3 is a cross-section of a wide offset slot line.
FIG. 4 is a schematic diagram depicting a preferred embodiment spectral control UWB magnetic slot antenna according to the teachings of the present invention.
FIG. 5 is a circuit diagram showing an equivalent circuit for a preferred embodiment spectral control magnetic slot antenna.
FIG. 6 is an exploded view of a preferred embodiment spectral control magnetic slot antenna.
FIG. 7 is a plot of an impedance profile of a potential implementation.
FIG. 8 is a plot of a spectral response of a potential implementation.
FIG. 9 is a schematic diagram of a first alternate embodiment spectral control antenna and a corresponding impedance profile.
FIG. 10 is a schematic diagram of a second alternate embodiment spectral control antenna and a corresponding impedance profile.
FIG. 11 is a schematic diagram of an elliptical dipole antenna modified according to the teachings of the present invention.
FIG. 12 is a schematic diagram of a spiral slot antenna modified according to the teachings of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Overview of the Invention
The present invention is directed to a system and method for spectral control of antennas, particularly ultra-wideband antennas. Instead of the monotonic impedance variation taught in the prior art, the present invention teaches that the impedance of an antenna may be controlled so as to create a desired frequency response.
The present invention will now be described more fully in detail with reference to the accompanying drawings, in which the preferred embodiments of the invention are shown. This invention should not, however, be construed as limited to the embodiments set forth herein; rather, they are provided so that this application 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.
Transmission Line Structures
FIG. 1 is a cross-section 100 of a same-side antenna slot 104 . Same-side slot line 104 comprises a first conducting layer 113 , a second conducting layer 115 , and a dielectric substrate 107 . A first conducting layer 113 and a second conducting layer 115 cooperate to form a transmission line structure constraining fields to a particular signal path.
FIG. 2 is a cross-section 200 of an overlapping offset slot line 206 . Overlapping offset slot line 206 comprises a first conducting layer 213 , a second conducting layer 215 , and a dielectric substrate 207 . A first conducting layer 213 and a second conducting layer 215 cooperate to form a transmission line structure constraining fields to a particular signal path. Overlapping offset slot line 206 has a low impedance and is electrically equivalent to a shunt capacitance.
FIG. 3 is a cross-section 300 of a wide offset slot line 308 . Wide offset slot line 308 comprises a first conducting layer 313 , a second conducting layer 315 , and a dielectric substrate 307 . A first conducting layer 313 and a second conducting layer 315 cooperate to form a transmission line structure constraining fields to a particular signal path. Wide offset slot line 308 has a high impedance and is electrically equivalent to a series inductance.
With shunt capacitance and series inductance, implementation of a low pass filtering response is straightforward. In alternate embodiments, however, other transfer functions like a band stop or even a high pass might be introduced, but at the cost of a larger or more complicated structure than a corresponding low pass filter.
PREFERRED EMBODIMENT
FIG. 4 is a schematic diagram 400 depicting a preferred embodiment spectral control magnetic slot antenna 461 according to the teachings of the present invention. A first conducting surface 413 on a front side of a dielectric substrate 407 and a second conducting surface 415 on a back side of a dielectric substrate 407 cooperate to form complex tapered slot 417 . Complex taper slot 417 is an example of an offset slot line, in which conducting surfaces (like first conducting surface 413 and second conducting surface 415 ) on opposing sides of a dielectric (like dielectric substrate 407 ) cooperate to form a transmission line structure defining a signal path. A plurality of first vias 419 and a plurality of second vias 421 electrically couple first conducting substrate 413 to second conducting surface 415 in the vicinity of first open termination 409 and second open termination 411 , respectively. In alternate embodiments, first conducting substrate 413 may be electrically coupled using capacitive coupling to second conducting surface 415 by overlapping first conducting substrate 413 and second conducting surface 415 . Preferred embodiment 461 is a closed slot antenna, since complex taper slot 417 is a closed slot (i.e. a closed slot transmission line structure). A closed slot is a slot formed by two conductors (like first conducting surface 413 and second conducting surface 415 ) coupled not only at a feed region but also at a termination region (like first open termination 409 and second open termination 411 ).
Complex tapered slot 417 does not vary monotonically from a narrow (low impedance) section in the vicinity of feed gap 405 to a wide (high impedance) first open termination 409 and a wide (high impedance) second open termination 411 . Instead, complex tapered slot 417 differs from conventional prior art slot 401 . Complex tapered slot 417 becomes wider at a first extremum (denoted “α”) resulting in a relatively high impedance. Complex tapered slot 417 becomes narrower and overlaps at a second extremum (denoted “β”), resulting in a relatively low impedance. Complex tapered slot 417 becomes wider at a third extremum (denoted “γ”), resulting in a relatively high impedance. Complex tapered slot 417 becomes narrower and overlaps at a fourth extremum (denoted “δ”), resulting in a relatively low impedance. A narrow or preferentially overlapping section forms a low impedance offset slot (like extrema β and extrema δ) with behavior analogous to a shunt capacitance. Thus extrema β and extrema δ have associated cross sections similar to that of overlapping offset slot line 206 . A wide, high impedance slot (like extrema α and extrema γ) is analogous to a series inductance. Thus extrema α and extrema γ have associated cross sections similar to that of wide offset slot line 308 . A large variation in impedance helps maximize filtering performance in a minimal length. An offset slot line with the ability to include low impedance overlapping sections can support a larger variation in impedance than a corresponding same side slotline. Thus, it is advantageous (although not required) to employ an offset slot line in a spectral control antenna.
FIG. 5 shows equivalent circuit 500 for complex tapered slot 417 . Equivalent circuit 500 behaves like a low pass filter coupled to an antenna 527 or means for transmitting and/or receiving electromagnetic signals. Additional inductance and capacitance may be incorporated in an antenna design using discrete components distributed along complex taper slot 417 .
The methods disclosed by the present invention are best suited for creating a low pass filter behavior, however it is also possible to implement other transfer responses in antennas using the teachings of the present invention. Also, although the teachings of the present invention are well suited for application to ultra-wideband antennas, the present invention also has application to broad band or narrow band antennas.
Complex taper slot 417 constrains signals to particular signal paths. On a second side of complex tapered slot 417 , radiated signals traverse a signal path from feed gap 405 to second open termination 411 and thence to a surrounding medium or free space intermediate first extremum α, second extremum β, third extremum γ, and fourth extremum δ. On a first side of complex tapered slot 417 , radiated signals traverse a signal path from feed gap 405 to first open termination 409 intermediate similar extrema. An antenna comprises at least one signal path defined by the geometry of the antenna. In many cases an antenna may have more than one signal path, depending on the geometry.
For ease of explanation a signal path is described in terms of radiating a signal. A received signal follows an analogous but reversed path. The principles of the present invention apply to both the reception and transmission or radiation of electromagnetic signals. For ease of explanation this application will focus primarily on radiation of signals with the proviso that it is understood that reception of signals is also inherently described.
In preferred embodiment 461 , complex tapered slot 417 has four extrema: α, β, γ, δ. In alternate embodiments, complex tapered slot 417 may have more or fewer extrema. Also, complex tapered slot 417 is shown as a symmetric slot with similar taper from feed gap 405 to a wide (high impedance) first open termination 409 and from feed gap 405 to a wide (high impedance) second open termination 411 . In alternate embodiments complex tapered slot 417 may be asymmetric.
Preferred embodiment 461 comprises complex tapered slot 417 fed across feed gap 401 . In some embodiments feed gap 401 couples to a feed line 423 . Feed line 423 couples to a connector interface 425 . In still further embodiments, feed line 423 may couple to an RF device 416 via end launcher 410 , connector 412 , and coaxial line 414 . In alternate embodiments, RF device 416 may be located on dielectric substrate 407 and directly coupled to complex taper slot 417 via feed line 423 .
Preferred embodiment 461 is a planar antenna system. Planar antennas are advantageous because they tend to be easy and inexpensive to manufacture. If implemented on a flexible or curved substrate, planar antennas may assume a variety of useful form factors.
FIG. 6 is an exploded view 600 of preferred embodiment spectral control magnetic slot antenna 461 . Exploded view 600 shows top conducting layer 613 , dielectric substrate 607 , and bottom conducting layer 615 . Terms like “front” and “back” or “top” and “bottom” are used throughout this application to aid the reader in visualizing a particular illustration of an embodiment of the invention and should not be interpreted as limiting or requiring any particular physical orientation or arrangement.
DETAILED ANALYSIS OF A POTENTIAL IMPLEMENTATION
FIG. 7 is a plot 700 of an impedance profile 741 of a potential implementation. Length along a signal path is plotted on horizontal axis 759 and impedance is plotted along vertical axis 760 . Exponential impedance trace 763 is typical of a prior art monotonically increasing impedance taper. Complex impedance trace 765 is typical of impedance responses taught by the present invention.
Note that large variations in impedance are essential to implement a significant filter response in a minimal length signal path. In the potential implementation of impedance profile 741 , the electrical length is 148 degrees measured at 5900 MHz. This is less than a quarter wavelength at 3000 MHz. Impedance variations are over more than a factor of 10 from 9 to 377 ohms. Thus, means for implementing significant variations in impedance are essential for a successful implementation. The table below provides details of this potential implementation by showing the electrical length in phase degrees of a particular impedance section in ohms.
Phase Angle
(deg)
Z(ohms)
6.9
8.62
36.8
377
11.4
14.8
78.8
377
14.1
52.4
FIG. 8 is a plot of a spectral response 800 corresponding to impedance profile 741 of a potential implementation. Spectral response plot 800 depicts frequency in MHZ on horizontal axis 827 ; scattering parameter magnitude in dB on primary vertical axis 829 ; and group delay in nanoseconds on secondary vertical axis 831 . Spectral response plot 800 shows return loss (S 11 ) response 835 , through (S 21 ) response 833 , and group delay response 837 .
Return loss (S 11 ) response 835 , is comfortably −12 dB or below between 2500 MHZ and 4500 MHz, rising to −3 dB at about 5000 MHz. Through (S 21 ) response 733 shows negligible loss between 2500 MHZ and 4500 MHz, falling off smoothly to −3 dB around 5000 MHz. Group delay response 837 shows only a modest increase around 4800 MHz. Thus, spectral response 800 is not dispersive and is thus well-suited for an antenna. Although many possible numeric and analytic techniques may be applied to develop an impedance taper corresponding to a desired transfer function (or filter response), the inventor has found that readily available analysis software such as Eagleware is an easy and quick way to accomplish this task.
ALTERNATE EMBODIMENTS
FIG. 9 is a schematic diagram 900 of a first alternate embodiment spectral control antenna, a variable dielectric horn 939 and a corresponding impedance profile 941 . Variable dielectric horn 939 comprises a first radiating element 943 , a second radiating element 945 , and dielectric loading 957 . First radiating element 943 and second radiating element 945 cooperate to form a parallel plate waveguide transmission line structure defining a signal path between feed structure 905 and a surrounding medium or space. Dielectric loading 957 comprises a first dielectric section 947 (denoted “α”), a second dielectric section 949 (denoted “β”), a third dielectric section 951 (denoted “γ”), a fourth dielectric section 953 (denoted “δ”), and a fifth dielectric section 955 (denoted “ε”). For purpose of illustration and not limitation, dielectric loading 957 comprises five discrete sections with fixed dielectric constant. In alternate embodiments, dielectric loading 957 may include more than five or fewer than five sections. In still further embodiments, dielectric loading 957 may comprise a dielectric material with continuously variable dielectric constant. Dielectric loading 957 results in impedance profile 941 . Impedance profile 941 depicts length along horizontal axis 959 and impedance along vertical axis 960 . Impedance profile 941 may be tailored to result in a desired antenna transfer function. First alternate embodiment 939 illustrates how variable dielectric loading may be employed for spectral control of an antenna. The geometry variations illustrated in first alternate embodiment 939 may be applied to any antenna structure in which variation in dielectric constant leads to variation in impedance along a signal path.
FIG. 10 is a schematic diagram 1000 of a second alternate embodiment spectral control antenna: a variable geometry horn 1039 and a corresponding impedance profile 1041 . Variable geometry horn 1039 comprises a first radiating element 1043 and a second radiating element 1045 . First radiating element 1043 and second radiating element 1045 cooperate to form a parallel plate waveguide transmission line structure defining a signal path from feed region 1005 to a surrounding space or medium.
Variable geometry horn 1039 becomes wider at a first extremum (denoted “α”) resulting in a relatively low impedance. Variable geometry horn 1039 becomes narrower at a second extremum (denoted “β”), resulting in a relatively high impedance. Variable geometry horn 1039 becomes wider at a third extremum (denoted “γ”), resulting in a relatively low impedance. Variable geometry horn 1039 becomes narrower at a fourth extremum (denoted “δ”), resulting in a relatively high impedance.
Variable geometry horn 1039 results in impedance profile 1041 . Impedance profile 1041 depicts length along a signal path on horizontal axis 1059 and impedance along vertical axis 1061 . Impedance profile 1041 may be tailored to result in a desired antenna transfer function. Second alternate embodiment 1039 illustrates how geometry variation may be employed for spectral control of an antenna. The geometry variation illustrated in second alternate embodiment 1039 may be applied to any antenna structure in which variation in geometry leads to variation in impedance along a signal path.
FIG. 11 is a schematic diagram of a planar elliptical dipole antenna modified according to the teachings of the present invention: spectral control elliptical dipole 1163 . Spectral control elliptical dipole 1163 comprises a first radiating element 1113 on a front side of a dielectric substrate 1107 , a second radiating element 1115 on a back side of dielectric substrate 1107 , and a feed region 1105 . First radiating element 1113 and second radiating element 1115 cooperate to form complex tapered slot 1117 . Complex tapered slot 1117 is yet another example of geometry variations may be employed for spectral control of an antenna. Complex taper slot 1117 is also a transmission line structure defining a signal path.
Spectral control elliptical dipole 1163 is an open slot antenna, because complex taper slot 1117 is an open slot (i.e. an open slot transmission line structure) formed by two conductors (like first conducting surface 1113 and second conducting surface 1115 ) that are not electrically coupled except at a feed region (like feed region 1105 ). The teachings of the present invention may be applied to either closed or open slot antenna structures. Other examples of open slot antennas include monopole antennas, and planar horn antennas. Open slots may include either offset or same-side slot line structures.
FIG. 12 is a schematic diagram of a spiral slot antenna modified according to the teachings of the present invention: spectral control spiral slot antenna 1261 . Spectral control spiral slot antenna 1261 comprises complex tapered spiral slot 1217 in conducting layer 1203 excited across feed gap 1205 . Appropriate selection of a geometry for complex tapered spiral slot 1217 leads to a desired impedance profile and thence to a desired antenna transfer function. Complex tapered spiral slot 1217 is an example of a same side slot line. A same side slot line may be used in conjunction with the present invention, although an offset slot line is preferred for planar antenna implementations.
Complex tapered spiral slot 1217 also employs discrete loading. Discrete loading comprises first lumped element set 1271 , second lumped element set 1272 , third lumped element set 1273 , and fourth lumped element set 1274 . A lumped element set may include a single lumped element or more than one lumped element. A plurality of lumped element sets may be employed for discrete loading to give rise to a desired impedance profile and a desired antenna spectral response.
Lumped element sets behave electrically like shunt elements. Thus if a lumped element set is an inductor, it can affect a high pass filter characteristic. In particular, if a lumped element set is an inductor in series with a resistor, low frequency components that might otherwise be reflected without radiating may be dissipated instead of contributing to poor matching behavior. If a lumped element set is a capacitor, it can affect a low pass filter characteristic. If a lumped element set is a resistor it can implement an attenuation. More complicated arrangements of lumped elements can give rise to more sophisticated impedance profiles and desired transfer functions. Discrete loading may be used alone or in any combination with geometry variation or dielectric loading.
The present application has demonstrated application of spectral control techniques to parallel plate antenna structures (such as variable geometry horn 1039 ), to closed slot type antenna structures (such as spectral control spiral slot antenna 1261 ), and to open slot or notch type antenna structures (such as spectral control elliptical dipole 1161 ). In fact, the teachings of the present invention may be applied to any antenna structure in which variation in geometry leads to variation in impedance along a signal path. The teachings of the present invention may also be applied to any antenna structure in which variation in dielectric loading leads to variation in impedance along a signal path. Further, the present application also relates to any antenna structure in which discrete loading is applied along a signal path to create a desired impedance variation.
Specific applications have been presented solely for purposes of illustration to aid the reader in understanding a few of the great many contexts in which the present invention will prove useful. It should also be understood that, while the detailed drawings and specific examples given describe preferred embodiments of the invention, they are for purposes of illustration only, that the system and method of the present invention are not limited to the precise details and conditions disclosed and that various changes may be made therein without departing from the spirit of the invention which is defined by the following claims: | A spectral control antenna apparatus includes a feed region or feed gap and a surrounding space or medium. A signal path between a feed region and a surrounding space or medium is characterized by a length dependent impedance with a plurality of extrema whereby the antenna apparatus exhibits a desired spectral response. The invention is well-suited for application to planar antennas, particularly planar antennas characterized by a slot type transmission line structure. If such a transmission line structure is an offset slot line, then by overlapping sections of the offset slot line relatively low impedances are possible, thus enabling the large variations in impedance necessary for effective filtering behavior. | 7 |
TECHNICAL FIELD
[0001] This invention relates to apparatus and method for management of digital media metrics data, and more specifically, for management and analysis of digital media metrics data received from a plurality of sources.
BACKGROUND
[0002] As a result of the increase in the number of computing devices available to users, the proportion of media viewed and/or heard by the public through an internet connection has increased. It is expected in the coming years that this proportion will increase further so that a significant proportion of the media viewed and/or heard by users will be viewed on electronic devices such as laptops, netbooks, tablets and mobile phones through interfaces such as web browsers.
[0003] The introduction of personal video recorders (PVRs), digital set-top boxes and digital radios in recent years has decreased the effectiveness of advertisements within such traditional areas as television and/or radio “ad-breaks” The placement of advertisements to capture the emerging mechanisms for viewing and listening to media has therefore been a subject of interest within the advertising industry in recent years.
[0004] In particular, digital video and/or audio advertising is increasingly used. An advertiser or advertising agency will create media, typically in the form of an advertisement, i.e. a digital video and/or digital audio. The advertisement is distributed by a publisher who delivers the digital video and/or audio content to positions within web pages to be viewed and/or heard by a user. It is common for an advertiser to pay the publisher per instance of the digital video and/or audio content delivered, in other terms per “impression” or “placement”. However, in order for the advertiser to be confident that they are receiving value for money it is important that the digital video and/or audio content is provided to the viewer and/or listener in a way that enables the viewer and/or listener to view and/or listen to the media, for example in the form of visible and/or audible digital video and/or audio content.
[0005] In order to ascertain the effectiveness, and therefore the value, of an advertising campaign directed to digital media obtained through an internet connection, a number of metrics are useful to track. Metric data may include an indication whether played media such as an advertisement is, for example: displayed on the screen; clicked on by a user during play of the advertisement; paused or stopped by a user before completion of the advertisement; fully played back by the user device; repeatedly played back by the user; etc, Tracking metric data across the internet and then analyzing the tracked metric data may be extremely memory and processing intensive as the number of user devices playing the media advertisement over a specific period of time, for example 24 hours, may be vast and produce large data sets. Accordingly, the costs in processing time and processing power in the management of metrics data may become substantial.
[0006] There is a need for a digital media metrics data management apparatus and method that addresses or at least alleviates the above issues.
SUMMARY
[0007] An aspect of the invention is a metrics data management apparatus comprising an ingestion module to receive event data of a series of events from a source, and to process the event data into a format identifying the source and a session of each event; and an event repository to populate the event data relevant to a series of connected events of a session.
[0008] In an embodiment the ingestion module receives event data from a plurality of sources.
[0009] In an embodiment the session starts at the moment a request is received at the source to access a digital media.
[0010] In an embodiment the ingestion module is arranged to process the event data into a format identifying the time order of each event data within a session.
[0011] In an embodiment the ingestion module is arranged to process the event data into a format identifying the time order of each session.
[0012] In an embodiment the ingestion module is arranged to process the event data into a format comprising a time stamp.
[0013] In an embodiment the ingestion module is arranged to process the event data into a format comprising an error correction code (ECC).
[0014] In an embodiment the ingestion module is arranged to process the event data into a format comprising a data length.
[0015] In an embodiment the source is a user device.
[0016] An aspect of the invention is a metrics data management apparatus comprising an event repository to populate event data relevant to a series of connected events of a session, wherein the event data is of a series of events from a source in a format identifying the source and a session of each event; and a session build module to determine a complete session from event data relevant to a series of connected events of a single session by a predetermined event.
[0017] In an embodiment the session ends at a predetermined event. The predetermined event may be a period of time. The predetermined event may be defined by predefined parameters.
[0018] In an embodiment the session may have a current status before the predetermined event and an expired status after the predetermined event. The session build module may be arranged to transmit the session with an expired status for further processing at a metrics data analyzer processer and the session has a confirmed status after the transmission and further processing of the expired session. The session build module may be arranged to remove the expired status session and confirmed status sessions from the session build module and corresponding event data from the event repository after transmission and further processing of the expired session.
[0019] An aspect of the invention is a metrics data management apparatus comprising an ingestion module to receive event data of a series of events from a source, and to process the event data into a format identifying the source and a session of each event; an event repository to populate the event data relevant to a series of connected events of a session; and a session build module to determine a complete session from event data relevant to a series of connected events of a session by a predetermined event.
[0020] An embodiment further comprises a metrics data analyzer comprising a metrics report generator for generating a report based on the complete session,
[0021] An aspect of the invention is a metrics data management method of comprises receiving event data of a series of events from a source; processing the event data into a format identifying the source and a session of each event; populating the event data relevant to a series of connected events of a session into an event repository; and determining a complete session from event data relevant to a series of connected events of a single session by a predetermined event.
[0022] An embodiment further comprises generating a report based on the complete session.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] For better understanding of the invention and to show how the same may be carried into effect, reference will now be made, by way of example only, to the accompanying figures, in which:
[0024] FIG. 1 illustrates schematically an overview of a system network for web media distribution and digital media metrics data management apparatus in accordance with an embodiment of the invention;
[0025] FIG. 2 illustrates schematically a diagram of data acquisition from web media in accordance with an embodiment of the invention;
[0026] FIG. 3 illustrates schematically a diagram of a user device in accordance with an embodiment of the invention;
[0027] FIG. 4 illustrates schematically a block diagram of a metrics data manager and analyzer in accordance with an embodiment of the invention;
[0028] FIG. 5 illustrates schematically a block diagram of event data flow from a plurality of metrics media servers to an ingestion module of a metrics data manager in accordance with an embodiment of the invention;
[0029] FIG. 6 illustrates schematically a data format for event data in accordance with an embodiment of the invention;
[0030] FIG. 7 illustrates schematically a block diagram of a metrics data manager in accordance with an embodiment of the invention;
[0031] FIG. 8 illustrates schematically a block diagram of a metrics data analyzer in accordance with an embodiment of the invention;
[0032] FIG. 9 is a flow chart of a method in accordance with an embodiment of the invention;
[0033] FIG. 10 is a state diagram of status of sessions in accordance with an embodiment of the invention; and
[0034] FIG. 11 is a flow chart of updating session status according to time in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0035] References will now be made in detail to the embodiments of the invention, examples of which are illustrated in the accompanying figures. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be apparent to one of ordinary skill in the art that the invention may be practiced without these specific details.
[0036] FIG. 1 illustrates schematically an overview 10 of a system network for web media distribution and paths of digital data traffic flow, as shown by the single ended arrows between components of a digital media metrics data management apparatus for delivery measurement, recordation and reporting of media metrics in accordance with an embodiment of the invention. As shown in FIG. 1 , the network may provide communications via a wired or wireless network, such as for example the Internet 12 , local area network (LAN), direct communication between components, cellular networks, or the like, as shown by dashed double ended arrows. The network comprises a user terminal or device 14 supporting a web browser and a media or ad player 16 . A metrics media server 20 or ad server runs like a plug-in for the media player 16 on the user device 14 . With metrics data manager and analyzer 22 , the metrics media server tracks and reports with metrics report 24 on the media session or ad session played on the media player 16 of the user device 14 . Parties that may be interested in the metrics report 24 include the advertiser or media promoter 18 that typically buys some advertisement volume of a publisher or publisher media server 30 and possibly one or more network publishers 32 as well. The metrics media server 20 tracks advertising metrics that may be based on advertising impressions, click-throughs for the placement, campaign, creative, etc., from the context of the advertiser 18 and the publisher 32 . The advertiser or media promoter 18 places an insertion order with the network publisher 32 , and may receive an invoice from the network publisher 32 . The network publisher 32 sends a request to create and start a session with the metrics media server 20 , The metrics media server 20 sends media or ad player configuration data to the user device 14 media player 16 and receives media or ad tracking metrics data from the user device 14 media player 16 for the advertiser. The publisher media server 30 may also receive some form of data from the user device 14 media player 16 for tracking purposes. The user terminal or user device 14 may take the form of any electronic device which is capable of running a web browser. In some examples, instead of a web browser, other types of interface through which web-based media may be obtained and made available may be used. In some examples, the user terminal 14 may be a desktop computer or personal computer (PC).
[0037] In some examples, the user terminal 14 may be a portable or mobile device with a wired or wireless data connection. In some examples, the user terminal 14 may be a tablet computing device, a netbook, a laptop or a mobile phone capable of running a web browser. In examples where a web browser is used, the web browser may, for example, comprise one of the following web browsers; Google Chrome™, Mozilla Firefox™, Internet Explorer™, Safari™, or the like. This list is not intended to be exhaustive. The user terminal 14 may comprise audio output means, or may be associated with audio output means, or both. In use, the web browser may be operated to access web pages. Some web pages may be designed to enable media to be played. In some examples, the media may be in the form of a video with associated audio or in the form of standalone video or audio content. In some examples the media may in the form of pre-roll video or pre-roll audio that is delivered before further content is delivered, in some examples, the media may take the form of digital audio or rich media. In some examples, the media may be interactive. In some examples media is presented to or played on web pages using one or more media players or netstreams.
[0038] In an embodiment the metric data may include an indication of particular events occurring on the user device 14 during the session or time the media is made available to play on the user device. A user device is the source of the metrics data or event data, wherein the source is an implementation of the media or ad tracking measurement. A session is created, for example, whenever the publisher has requested a session request from the metrics media server 20 . For example, the moment in time the media is made available on the user device for the user device to play, a metric tracking session has already been created and able to associate tracked metrics event data with the session. A metric tracking session ends after a predetermined time or event. Each session has at least a start event and an end of session event, with additional events tracked between. Signals from the digital player are programmed to return data events in order, but may refer to events out of order, for example a click followed by a pause caused by the click, and the like, For example, the types of metric events that may be useful in tracking may be whether the media that is played is: displayed on the screen; how long the media is displayed on the screen before it is played; clicked on by a user during play of the advertisement; paused or stopped by a user before completion of the advertisement; fully played back by the user device; repeatedly played back by the user; etc. Upon the occurrence of each metric event a “hitline” or event data is generated and delivered to the metrics data manager and analyzer 22 via the metrics media server 20 .
[0039] The media, for example an advertisement, may be distributed through a number of different servers before it is delivered to the web browser of the user device 14 . The distribution of media, and particularly video media such as advertisements, can be considered a marketplace of selling and re-selling of media publications. In some examples of this marketplace, the audibility of media presented to a user can be subject to a number of audio controls, this may include for example, without limitation: creative-embedded audio controls managed by an ad unit/player; player-embedded audio controls provided by a publisher or network; and site-embedded audio controls provided for example by a network. Media players or netstreams may be associated with the different parties within this marketplace.
[0040] In an exemplary arrangement, an advertiser will make an agreement with a publisher or network partner to publish media in the form of an advertisement a fixed number of times. To fulfill this agreement the publisher or network partner will arrange for distribution of the media from an advertising server 30 . The publisher or network partner will seek to publish the advertisement to a number of user terminals, in order to fulfill the agreement. If the original publisher or network partner is unable to fulfill the agreement themselves, for whatever reason, the publisher or network partner may arrange for the further distribution of the media with a second publisher or network partner in order to fulfill the original agreement,
[0041] This may then continue with the second publisher or network partner arranging for further distribution by a third publisher or network partner if the second publisher or network partner is unable to fulfill their arrangement, and so on, In the present application use of the terms “publisher” or “network partner” encompasses any or all of the publishers or network partners in this and similar scenarios.
[0042] The advertising server 30 may be a server, such as a web server, that operates to store media such as advertisements, Such media may be delivered to the user terminal 14 when a user visits a particular web page or website, In addition, advertising servers 30 may also act to target particular media to particular users depending upon a set of rules. Therefore, a specific media, such as a particular advertisement, may have been placed on a plurality of different advertising servers. However, each instance of the specific media being published to a particular user terminal 14 will have originated in a single one of the advertising servers, being supplied through one or more servers of one or more publishers or network partners such as network partner server 32 forming a chain between the source advertising server 30 and the user terminal 14 , Each advertisement receives media from a publisher when a web page is loaded. In the present application use of the term “advertiser” encompasses any or all of these scenarios.
[0043] FIG. 2 illustrates schematically a diagram 40 of data acquisition from web media in accordance with an embodiment of the invention. FIG. 2 shows a representative schematic diagram of data acquisition from web media within the network shown in FIG. 1 , FIG. 2 can be considered to show an advertisement call process, The publisher operates a web page or website which is accessed by the user terminal or device 14 within the web browser. To access the media on the publisher's web site the user terminal 14 utilises a media player 16 , here referred to as the user media player or terminal media player 16 . To play digital video and/or audio media, such as the advertisement, the terminal media player 16 of the user terminal 14 sends a call, shown as arrow 42 , to a network partner media player 44 of the network partner server 32 , and the network partner server 32 in turn sends a call, shown as arrow 46 , to an advertiser media player 48 of the publisher media server 30 in order to play the media from the advertising server 30 through the user terminal 10 . In some examples one or more of the media players may be, or comprise, netstreams. As shown in FIG. 1 , there may be further network partner servers 32 of a further network partner between the publisher media or ad server 30 and the user terminal 14 . In some embodiments there may be a greater number of network partners 32 , In other embodiments, there may be no network partners 32 . In an embodiment, the metrics media server 20 receives a request, which may be an on-line request, as a first call or ad request or unit, serves the creative and, upon playing the ad or media, triggers a second call to count the media or ad impression, which may be referred to as a media start or ad start. The media start or ad start occurs at the point in time when the first frame of media loads and is physically rendered into the destination platform. Some media may he auto play, user-initiated, click to play, cost per click, cost per engagement, and the like campaigns are identified as engagements or interactions at some creative-embedded messaging point and may be reported separately, or identified in the event data formats or signals. In other embodiments, the media or ad start is signalled by the publisher media server 30 and tracked via a metric pixel using pixel based tracking technology, as positioned by the publishers, and is therefore labelled as a publisher originating media or ad start. The source id identifies where the media start or ad start was initiated by the metrics media server 20 , publisher media server 30 , or the like.
[0044] FIG. 3 illustrates schematically a diagram 50 of a user device in accordance with an embodiment of the invention. The user terminal or user device 14 provides a source of metrics 52 for the system. The user device 14 may comprise a display 54 and a browser 56 for displaying a web page 58 and running a user device media player 16 to play media such as audio, video, advertisements 60 , and the like.
[0045] FIG. 4 illustrates schematically a block diagram 70 of a metrics data manager and analyzer in accordance with an embodiment of the invention. Metrics data manager and analyzer 72 comprise an ingestion module 74 , a metrics data manager 80 , and metrics data analyzer 90 . The metrics data manager 80 comprises an event repository 82 , a session build module 84 , and a transitory session parameter or rules module 86 . The metrics data analyzer 90 comprises a session metric storage 92 , a metrics processor 94 , and a metrics report generator 96 .
[0046] FIG. 5 illustrates schematically a block diagram 100 of event data flow from a plurality of metrics media servers to an ingestion module 74 of a metrics data manager 80 in accordance with an embodiment of the invention. FIG. 1 shows one metrics media server 20 , however, the network in accordance with an embodiment of the invention may comprise one or more, forming a plurality of metrics media servers 20 a , 20 b , 20 n. In practice, each metric media server 20 a , 20 b , 20 n is in communication with the ingestion module 74 via a node or tracker 102 a , 102 b , 102 n. The network may comprise one or more, forming a plurality of, nodes 102 a , 102 b , 102 n. The metric media servers 20 a , 20 b , 20 n typically look for the closest node 102 a , 102 b , 102 n, however, the metric media servers may send event data in the same session or different sessions to different nodes, as shown by metrics media server 20 b via node 102 b and node 102 n in FIG. 5 .
[0047] FIG. 6 illustrates schematically a signal or data format 120 for event data in accordance with an embodiment of the invention. The data format 120 is a data chunk that is a binary string that is meaningful to the processor. The data format comprises a header with source id 122 , session id 124 , The data format comprises additional information shown as format 126 . The source id 122 or ad player plug in identifies the source of the event data, such as user device 14 . The session id 124 identifies the ad session or media session. The combination of the source-identifier (source id) and the session identifier (session id) uniquely identifies the event data. The additional information in format 126 may comprise information such as data length, timestamp, error correction code (ECC) such as cyclic redundancy check (CRC) or the like, additional data that may be used in the metric analysis. Each component of the signal or data format 120 may have a variable length or a fixed length. For example, the source id 122 and the session id 124 may have a fixed length of 3 digits and session id 124 of 20 characters. The format 126 of the remaining components may comprise a datalength of 5 digits, a timestamp of 10 digits, crc32 of 8 characters, datalength of data may have a variable length.
[0048] In an embodiment, to minimise undercounting due to caching, a random number string may be generated through a JavaScript function or server-side processes and incorporated into the delivery and measurement tags. HTTP header controls (expiry, pragma and cache-control headers) may also be used in the server response to the delivery and measurement tags.
[0049] In an embodiment, the media or ad start event is media or creative embedded and comes from a media or creative integrated media player or a display format media or ad that is controlled and served by the metrics media server 20 . Accordingly, in this embodiment the media or ad start is not subject to delivery chain counting limitations/concerns typically associated with impression counting such as user abandonment, page load failures, page load latency, and the like. At first call, for example the start of the media or ad start for metrics media server 20 and publisher media server 30 originating calls, the following information or identifiers relating to a campaign which may run across multiple publisher's websites may be collected: session data and identifier and/or identification (ID); Internet protocol (IP) addresses, placement/creative/media identifiers; media or ad boot state, item numbers, time stamp; and the like. This is done continuously in real time.
[0050] FIG. 7 illustrates schematically a block diagram 140 of a metrics data manager 80 or events data holding tank in accordance with an embodiment of the invention. The metrics data manager 80 may comprise a processor 142 , an event repository, a session build module 84 , and a transitory session parameter module 86 . The event repository may comprise a storage area for storing different status of sessions of event data. For example, the different sessions may be stored as “current” build sessions 144 , “expired” sessions 146 , and “confirmed” sessions 148 . The event data or signals enter the event repository in a time-order basis, Event data is grouped by a key or identifiers such as in this embodiment by source ID and session ID. It will be appreciated that the event data may be grouped with other key, or in addition to the source ID and session ID. As the key is available on every event data or signal, the event data may be used to distribute load across multiple event repositories or holding tanks. The combination of the source-identifier (source ID) and the session-identifier (session ID) uniquely identifies a session globally. The session is considered finished after expiration as defined by a predetermined event, rules or parameters, such as for example after some amount of time has passed without seeing another hit, the session has grown above a certain size, or the like. Such status of the session is changes from a current status to an expired status. Expired sessions are dispatched to a processor, such as the processor 142 , or any other processor 94 such as shown in FIG. 4 and FIG. 8 , which may process the sessions continuously. The processor confirms the expired session causing the expired session to be flushed from memory, or if by a predetermined period of time, the expired session will be rescheduled against another processor.
[0051] FIG. 8 illustrates schematically a block diagram 160 of a metrics data analyzer 90 in accordance with an embodiment of the invention. The metrics data analyzer may comprise a processor 94 , a metrics report generator 96 , and a sessions metrics storage 92 , The sessions metrics storage may comprise expired sessions 162 and confirmed sessions 164 . In an embodiment, metrics reports may be prepared based on time ranges specifying the time zone of the associated campaign as identified in the campaign onboarding process, such as: day, 00:00:00-23:59.59 inclusive, of the day being viewed; week, 00:00:00 Monday—23:59.59 Sunday inclusive, for the week being viewed; month, 00:00:00 on day 1 of the month—23:49:49 inclusive, of the last day of the month being viewed; and the like. The detail of the report may be prepared in different degrees of granularity, for example, by the minute granularity.
[0052] FIG. 9 is a flow chart 200 of a method in accordance with an embodiment of the invention. The metrics data manager and analyzer 72 receives raw event data 202 at the ingestion module 74 from a source such as user device 14 via a string of media servers, such as metrics media server 20 , publisher media server 30 , and network publisher 32 . The raw event data is processed in source and session format 204 such that the raw event data is formatted with a header with source id and session id, followed by other information. The event data is populated per current session 206 with event data having a common source id and session id until a predetermined event is identified marking the session either expired or confirmed 208 . Once the session is expired or confirmed, the session of populated event data is transmitted 210 and flushed or removed 212 from the event repository 82 , For example, the expired and confirmed sessions are transmitted 210 to the metrics data analyzer and stored, such as in the session metrics storage 92 of the metrics data analyzer 90 for metric analysis.
[0053] FIG. 10 is a state diagram 240 that shows the change or transfer of status of sessions in accordance with an embodiment of the invention. The first state of a session is the current session status 242 which is changed to another state upon identifying a predetermined event to mark the current session expired or confirmed. There are different parameters or rules for different predetermined events. For example, the predetermined event parameters may include: the maximum amount of time to wait for more signals (session_timeout); target number of sessions to keep in memory (target_sessions); maximum age of session (pension_time); time to wait for processors to confirm (reschedule_timeout); maximum number of times to retry (maximum_unconfirmed_times ; and the like. It will be appreciated that the parameters are tunable, operational, however are not functional. For example, the state is changed from current session state to an expired session state if specific parameters are met, such as pensioning 244 , timeout 246 , or the like. FIG. 10 shows how sessions move from the “current” set into the “expired” set by either being pensioned-off (having an age of start time larger than the pension_time, parameter), or by timing out (having an age of the last time larger than the session_timeout). As soon as the status changes from current session to expired session 248 , the expired session is dispatched to processors 94 in metrics data analyzer 90 , which then confirms the session to change the status to a confirmed session upon dispatch or transmission 248 .
[0054] FIG. 11 is a flow chart 300 of updating session status according to time in accordance with an embodiment of the invention. A counter or “tick” is set to 0 302 . Then, the system waits for an incoming signal 304 . Upon receiving 306 a formatted signal or event data with source id and session id header, the signal is saved 308 as a current session in memory if it is the same source id and session id. If the signal time is not the same as the tick, and the tick is equal to zero 310 , the signal is saved 308 as a current session in memory. If the tick is not equal to zero 310 and the tick is greater khan parameter state change is driven according to time 312 and the tick is incremented 314 . If a session is repeatedly left in the expired state after being dispatched to the processors, the try_maximum_unconfirmed_times parameter is tried before ending the session with a terminal state status for system administrator intervention.
[0055] It will be appreciated that the method and apparatus described in the above embodiments are implemented for a media server, recordation and reporting system that functionally translates signals from a media player into some volume of the signal These principles may be implemented and applied for providing metrics on all types of media content such as advertisements, adverts, games, simulation applications, augmented and/or virtual reality applications, tutorials, online tours, educational material, entertainment applications and the like.
[0056] The methods and apparatus described may be implemented at least in part in software. Those skilled in the art will appreciate that the apparatus described may be implemented using general purpose computers or using bespoke equipment. Those skilled in the art will appreciate that the foregoing has described what is considered to be the best mode and, where appropriate, other modes of performing the invention, the invention should not be limited to the specific configurations and methods disclosed in this description of an embodiment of the invention. Those skilled in the art will recognise that the invention has a broad range of applications, and that the embodiments may take a wide range of modifications without departing from the inventive concept as defined by the appended claims.
[0057] The hardware elements, operating systems and programming languages of such computers are conventional in nature, and it is presumed that those skilled in the art. are adequately familiar therewith. Of course, the server functions may be implemented in a distributed fashion on a number of similar platforms, to distribute the processing load. Hence, aspects of the methods and apparatus described herein can be executed on a mobile station and on a computing device such as a server. Program aspects of the technology may be thought of as “products” or “articles of manufacture” typically in the form of executable code and/or associated data that is carried on or embodied in a type of machine readable medium. “Storage” type media include any or all of the memory of the mobile stations, computers, processors or the like, or associated modules hereof, such as various semiconductor memories, tape drives, disk drives and the like, which may provide storage at any time for the software programming. All or potions of the software may at times be communicated through the Internet or various other telecommunication networks. Such communications, for example, may enable loading of the software from one computer or processor into another computer or processor. Thus, another type of media that may bear the software elements includes optical, electrical and electromagnetic waves, such as used across physical interfaces between local devices, through wired and optical landline networks and over various air-links. The physical elements that carry such waves, such as wired or wireless links, optical links or the like, also may be considered as media bearing the software, As used herein, unless restricted to tangible non-transitory “storage” media, terms such as computer or machine “readable medium” refer to any medium that participates in providing instructions to a processor for execution.
[0058] Hence, a machine readable medium may take many forms, including but not limited to, a tangible storage medium, a carrier wave medium or physical transmission medium. Non-volatile storage media include, for example, optical or magnetic disks, such as any of the storage devices in any computer(s) or the like, such as may be used to implement the data aggregator, the customer communication systems, etc. shown in the drawings, Volatile storage media include dynamic memory, such as main memory of such a computer platform. Tangible transmission media include coaxial cables; copper wire and fiber optics, including the wires that comprise a bus within a computer system. Carrier-wave transmission media can take the form of electric or electromagnetic signals, or acoustic or light waves such as those generated during radio frequency (RF) and infrared (IR) data communications. Common forms of computer-readable media therefore include for example: a floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD OR DVD-ROM, any other optical medium, punch cards paper tape, another physical storage medium with patterns of holes, a RAM, a PROM and EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave transporting data or instructions, cables or links transporting such a carrier wave, or any other medium from which a computer can read programming code and/or data. Many of these forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to a processor for execution.
[0059] While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that the teachings may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all applications, modifications and variations that fall within the true scope of the present teachings. | A metrics data management apparatus and method is disclosed comprising receiving event data of a series of events from a source, processing the event data into a format identifying the source and a session of each event; populating the event data relevant to a series of connected events of a single session into an event repository, and a session build module to determining a complete session from event data relevant to a series of connected events of a single session by a predetermined event. | 6 |
FIELD OF THE INVENTION
The invention relates to an apparatus and method for automatically aligning the top and bottom ends of a pair of fabric panels and maintaining that alignment during sewing.
BACKGROUND OF THE INVENTION
Nearly every type of garment, other than those which are molded or knitted, requires seams. Equally so, nearly every type of garment which has been seamed together requires that there be some type of hem or cuff in the garment as well as a waistline of some sort. Seaming fabric together to form garments is a rather complicated task, and only highly skilled operators, after prolonged training, are used for such operations. It requires even greater skill from the operator to ensure that the bottom edges (cuffs or hems) and top ends (waistband, etc.) are straight and even with respect to each other during and after sewing of the garment's seams.
While there have been a number of machines which have attempted to match the cuff of garments which are sewn together with side seams, by far the most widely used and near accurate method has been to manually match the bottoms and top ends of the fabric by pulling and stretching one piece of the fabric relative to the other piece and then holding the ends together so that the cuff, waist and seams come out even. Notwithstanding the widespread manual method for accomplishing the task of aligning the top and bottom ends of side seams of fabric, there are a number of apparatuses (some semi-automatic) which have been used in an attempt to accomplish this difficult task.
A number of prior art patented devices have been directed toward applying a continuous tension and stretch to both panels of the garment in an attempt to make them even as they approach the sewing station. For example, U.S. Pat. Nos. 3,717,408; 3,905,316; 4,013,025; 4,036,156; 4,062,309; and 4,086,860 are directed to such devices. Each of these references in some way applies an undetermined amount of tension and stretch to the two panels of fabric by gripping them at one end with a clamp or some other means of securing the fabric while tension is applied and then pulls the fabric in the direction opposite the clamp in an effort to stretch the two panel ends even. None of the apparatuses set forth in any of the aforementioned patents discloses a means for monitoring the actual length of two pieces of fabric and then correcting for that discrepancy in conjunction with sewing head feeding, without applying any unnecessary tension, stretch or other pressure on both panels of fabric. Similarly, the prior art devices are not accurate in their manner of correcting the mismatch of fabric lengths and as such necessarily result in a lot of guesswork as well as unnecessary tension being applied to the fabric. These prior art devices are largely dependent on the skill of the worker and thus result in too much variance and chance for error.
Still another common problem in most prior art methods and apparatuses used to match panel ends results from the pull of the bottom panel by the bottom feed dog in typical sewing machines. That is the bottom feed dog pulls the bottom panel more than the top panel is pulled by the smooth non-driven presser foot which comes into contact with the top panel. The presser foot does not have gripping teeth like the bottom feed dog. Thus, a method is needed to match panel ends which recognizes this known problem which results when the bottom feed dog exerts this pull on the bottom panel.
Despite the available patented devices, it is apparent that the most widely used method of matching a pair of fabric workpieces prior to sewing them along their seams is to manually manipulate the workpieces by independently pulling and stretching them, one relative to another, and subsequently feeding both workpieces into the workstation where they are sewn together as tension is continuously applied to them manually to make sure that the cuff and the waist come out even. This manual method is further frustrated by the unequal pull which is exerted on the bottom panel by the bottom feed dog.
SUMMARY OF THE INVENTION
In view of the above disadvantages of the prior art methods and apparatuses for insuring that the top and bottom ends of the seams of two workpieces sewn together come out even after they are sewn together, it is apparent that there is a need in the garment industry for an apparatus and method to monitor the actual discrepancy in the length of the fabric and then correct only that discrepancy in conjunction with sewing head feeding without applying any unnecessary stretch, stress or other tension on both panels of fabric such as when the panels are manually stretched.
Accordingly, we have invented an apparatus and method which overcomes all of the known disadvantages of the prior art methods and/or apparatuses for accomplishing this goal.
The apparatus of this invention utilizes drive rollers positioned between the sewing head and a pair of locking jaw cuff clamps along the transport path of the workpieces to the sewing head. The drive rollers operate in conjunction with the locking jaw cuff clamps to keep the panels tight between the rollers and the cuff clamps by pushing ahead any excess slack where it is pulled forward and sewn by the sewing head or workstation.
The method and apparatus of this invention is used in conjunction with the known tendency of the bottom feed dog to exert a pull on the bottom panel where a predetermined amount of the bottom panel is positioned between the pair of cuff clamps. This preset mismatch provides an unbalanced tension in the panels to offset the uneven sewhead feeding. The drive roller-cuff clamp combination will only match an amount equalled to or less than the preset mismatch amount. If a greater correction is desired, then this preset amount must be increased.
As will be more particularly pointed out hereafter, the torque/drive rollers pull up the mismatch (trapped between the locking jaw cuff clamps) when the first of these clamps are released. The excess length which is in the bottom panel is distributed along the last portion of the garment to assure an even cuff.
Conveyor clamps of the inventive apparatus and method engage both upper and lower panels and pull each forward independently until the trailing edge of each is detected by independent sensors, such as photocells. The photocell stopping point for the upper panel is at a predetermined distance closer to the workstation than that of the lower panel. When both panels have been driven to these sensor points by the drive rollers, the first set of locking jaws closest to the workstation is closed gripping both pieces of fabric together. The set of drive rollers on the lower panel which is stopped at a predetermined distance longer than the upper panel then are reactivated to bring the trailing edge of the lower panel to a position even with the upper panel. At this point, the second set of locking jaws is engaged gripping the two matched ends of the fabric together and trapping a portion of the lower fabric panel between the two jaws. The result of this trailing and engagement system is that a greater resisting tension is applied to the lower panel than the upper panel for sewing at the workstation.
Once the workpieces get trapped by both of the two locked jaws, the conveyor clamp pulls the fabric towards the workstation as tension is constantly being applied to the fabric via the locked jaws, resulting in the fabric being stretched unevenly. As the conveyor feeds toward the workstation, the two panels are carried through two independent torque/drive roller systems, one for the upper and one for the lower panel, and then into the workstation/sewing machine. The torque/drive rollers provide a combination of feeding torque and steering control to provide a combined effect of independent edge guidance of the two panels and tension manipulation to provide even sewing. The workstation/sewing machine presser foot/clamping device is clamped on the leading edge of the panels and sewing initiated. The contour sewing aides/torque motor system is activated to provide edge guidance and provides an equal torque through the rollers to both upper and lower panels independently. The result of this torquing action is that all slack will be removed from both upper and lower panels and the fabric between the torque rollers and the sewing machine is dependent totally on the differences in the length of the fabric.
If the two panels are of equal length, then the lower panel will be under greater tension because of the differential amount of fabric held between the two locked jaws. If the lower panel is shorter, there will be even greater tension on the lower panel because of the shortness plus the differential fabric between the jaws. If the upper panel is shorter by an amount less than the differential between the two panels in the gripper jaws, then the tension on the lower panel will still be greater. If the upper panel is shorter by an amount greater than that held between the two gripper jaws, the tension will be greater on the upper panel.
The basic principle is that the workstation/sewing machine will feed the panel with the least tension the fastest, taking up the differences in length. It is necessary to overcompensate for this effect because of the greater feeding effect of the lower feed dogs on the sewing machine and, hence, the over-tensioning of the lower panel artificially. Even with top feed devices used on the sewing machines of the present designs or state-of-the-art, lower feeding is still more effective than upper feeding.
After approximately two-thirds of the panel has been sewn, the clamping jaw closest to the workstation is opened allowing the artificially added fabric on the lower panel to be released. This allows the sewing machine to act in a normal fashion and end up with cuffs matched or ends matched at the end of sewing. When the cuffs are as close as possible to the sewing machine as determined by mechanical design, the second locking jaw farthest from the workstation is opened and the remaining sewing is continued with no gripping of the trailing edge.
It is therefore an object of this invention to provide an apparatus and method for automatically matching the top and bottom ends of two workpieces regardless of the mismatch and the size of the workpiece.
It is a further object of this invention to provide for an apparatus and method for automatically matching the inseams as well as the outside seams of a garment formed with two workpieces.
The foregoing and other objectives, features and advantages of the invention will be readily understood upon consideration of the following detailed description of the best mode for carrying out the invention, when made in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial schematic of the apparatus of the invention;
FIG. 2 illustrates a pair of pants or trousers with the side seams and congruent bottom ends or hems;
FIG. 3A is a side elevation schematic of the clamping leading edge of a garment's panels;
FIG. 3B illustrates the advancing panels until the shortest panel is detected;
FIG. 3C illustrates the advancing upper and lower panels to a predetermined position with a predetermined mismatch after the shortest panel has been detected;
FIG. 3D illustrates the closing of the first locking jaw;
FIG. 3E illustrates the advancing of the lower panel until the trailing end of both panels are congruent;
FIG. 3F illustrates the closing of the second locking jaw;
FIG. 3G illustrates the path of both panels with both locking jaws closed as the panels are being pulled toward the workstation; and
FIG. 3H illustrates continuous sewing of panels while they are being stretched to take up the excess in fabric and when cuffs are as close as possible to the sewing machine the second locking jaw is opened and the clamp assembly returns to start the process over;
FIGS. 4A through 4C are schematic illustrations of the operation of the apparatus of the invention on two workpieces or panels of the same length;
FIGS. 5A through 5C are schematic illustrations of the operation of the invention on two panels where the top panel is shorter than the bottom panel;
FIGS. 6A through 6C are a schematic illustrating the operation of the invention on two panels where the bottom panel is shorter than the top;
FIG. 7 is a fragmentary plan view of the sensing and clamping station of the apparatus and a rail with clamp opening trips, together with the drive roller used to advance the panels to a pre-determined sensor;
FIG. 8 is a sectional view of the cylinders used to close the locking jaws for clamping the fabric;
FIG. 9 is a sectional view showing the advancing rollers, their drives and how the rollers pinch the panels if fabric against separator plates;
FIG. 10 is an end sectional view of one of the locking jaws in the open position and a compression spring keeping the jaw open;
FIG. 11 is a perspective view of the torque roller steering system, with an arrow indicating the direction of rotation of the roller assemblies;
FIG. 12 is a top plan view of the same torque roller system of FIG. 11; and
FIG. 13 is a side elevational view of the same torque roller steering system of FIG. 11.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Perhaps the apparatus and method of the invention are best understood by considering FIGS. 1 and 3A through 3H together, initially, for an overall explanation of how the apparatus is constructed and how the various parts cooperate with each other to practice the invention and to accomplish the goal of evenly matching the cuffs of panels of fabric. The apparatus is generally illustrated in FIG. 1 by reference numeral 1. A garment 3 (FIG. 2) having workpiece panels 2 and 4 is introduced onto conveyor belts 6a and 6b where the top edges 2f, 4f, 2g and 4g (or the waists) of the panels are gripped by conveyor clamps 8a and 8b. Workpiece panels 2 and 4 are further separated about stationary separator plates 10a and 10b. Conveyor belts 6a and 6b are then energized in a routine manner to transport workpiece panels 2 and 4 in the direction of arrows 5a and 5b towards a workstation 111 (FIG. 3A through 3H) where garment side edges 2a and 4a and 2c and 4c are sewn together, respectively.
As conveyor belts 6a and 6b transport workpieces 2 and 4 in the direction of workstation 111, sensors 13b and 13a (three sensors such as 13a, 13b and 13c are positioned along the path of each leg or panel of a garment having two side edges, thus with a pair of pants there will be six sensors) are positioned along the path of panels 2a and 4a to detect the cuff ends of the panels.
Sensors 13a, 13b and 13c are positioned along the path of panels 2 and 4 upstream of locking jaws 16a, 16b, 18a, and 18b, and workstation 111. As workpiece panels 2 and 4 move towards workstation 111 and one of sensors 13a and 13b is first uncovered by either panel 2 or 4, conveyor belts 6a and 6b are immediately deenergized to halt the movement of panels 2 and 4 and the conveyor at sensor 13a or 13b. Panel 2 or panel 4 which is not yet at sensor 13a or 13b respectively is advanced ahead by drive rollers 12a and 12b or 14a and 14b towards workstation 111. Now the end of top panel 2 is at sensor 13b and the end of bottom panel 4 is at 13aas is illustrated in FIG. 3B. Panel 2 is ahead of panel 4 by a predetermined amount, such as 3/4". It should be pointed out that the above described procedure takes place even if both panels or cuffs are initially even with each other. In such an instance even cuffs are guaranteed.
When cuff ends of top and bottom panels 2 and 4 are at sensors 13b and 13a respectively, drive rollers 12a and 12b and 14a and 14b, are de-energized. Upon the de-energization of the drive rollers 12a and 12b, jaws 16a and 16b are energized with pneumatic cylinders 20a and 20b, causing each of jaws 16a and 16b to firmly grip both workpiece panels 2 and 4 between the locked jaw. Once panels 2 and 4 have been gripped by the first of the two locking jaws, drive rollers 14a and 14b are then energized to engage panel 4, thus advancing panel 4 forward in the direction of workstation 111 until trailing edges 2c and 4c and edges 2d and 4d of each panel 2 and 4 are respectively aligned with each other at sensors 13b and 13c respectively. Once this alignment has been accomplished, jaws 18a and 18b are energized by pneumatic cylinders 22a and 22b, causing the jaws to close gripping both workpieces 2 and 4, thus trapping a slack portion of panel 4 between the two sets of locking jaws. Thereafter, conveyor belts 6a and 6b are again energized to move in the direction of arrow 5a and 5b as conveyor clamp 8a and 8b pull panels 2 and 4 ahead towards workstation 111.
As clamps 8a and 8b pull the two panels toward workstation 111, tension is continuously being applied to panels 2 and 4 by a force restricting the motion of the clamping station as they enter under the sewing head. Tension in the bottom panel 4 is increased because of the slack portion trapped between the two locking jaws.
This compensates for the uneven feed of the sewing machine and creates matched sewing. Once panels 2 and 4 are approximately two thirds (2/3) the distance through the sewing head 111, the first jaw 16a or 16b of FIG. 1 is opened by a cam and is held open by a compression spring (See FIG. 10). As first jaw 16a or 16b 160 is opened, clamp 18a or 18b 18 continues to exert a pull and tension on workpiece panels 2 and 4 and the lower feed dog (a well known and common feature on most sewing machines and not illustrated here) continues to exert a pull and tension on the bottom panel until the cuffs of panels 2 and 4 are as close as possible to the sewing machine as is determined by mechanical design, then the second jaw is opened as the remaining portion of the garment is sewn.
Once both locked jaws 16a and 18a have been returned to their opened position, these jaw assemblies are again returned to a position upstream of workstation 111 (see location of locking jaws 16a, 16b, 18a and 18b of FIG. 1). There, the rollers and jaws are readied to again engage other workpiece panels which are being transported along conveyor belts 6a and 6b in the direction of arrows 5a and 5b toward workstation 111. That is, the locking jaws are returned to their original upstream position via a cable which is attached to the jaw assemblies and which is tensioned by a weight or spring such that when the jaws are released and no longer being pulled by the garment to the workstation, the cable pulls the assembly back to its original home position.
FIGS. 4A through 4C illustrate how the apparatus and method of the invention will operate on panels 2 and 4 to assure that these panels are always equal in length when they are introduced to workstation 111. The apparatus of the invention provides for this guarantee, despite the fact that panels 2 and 4 may be initially equal in length. The same type of forward movement of the panel 2 and panel 4 is accomplished by drive rollers 12a and 14a with an amount of fabric panel 4 being trapped between jaws 16a and 18a (reference numeral 15), despite the fact that neither panel 2 nor panel 4 is any shorter than the other panel. This result is accomplished because sensors 13a and 13b are constantly operating to de-energize conveyor belts 6a and 6b once one of the panels has passed the sensor point. Specifically, sensors 13a, 13b, and 13c are photosensors consisting of a light source 123 and a receiver 125 which remains dark while a panel passes between the light source and the receiver (See FIG. 11). However, when the edge of the panel reaches the sensor, the receiver detects the light and signals the conveyor belt drive motor to stop. But note that where the panels are equal in length, sensor 13a will first be uncovered and the conveyor will stop, thus causing the drive rollers to advance the panel proximate sensor 13b by a predetermined distance dowstream towards the workstation. Locking jaw 16a is then energized to grip both panels and a second set of drive rollers will advance the panel proximate sensor 13b until both trailing edges are equal or even with each other, at which time the second locking jaw 18a will grip both panels of fabric.
A similar situation is true in FIGS. 5A through 5C where panel 4 is initially longer than panel 2. The same type of correction is made for the discrepancy in the length between panels 2 and 4. Similarly, FIGS. 6A through 6B illustrate how the apparatus and method of this invention will operate to correct a discrepancy in length between panels 2 and 4 where panel 4 is shorter than panel 2.
In the instance of FIGS. 5A-5C, where panel 2 is shorter than panel 4, the first one of sensors 13a or sensor 13b to be uncovered will depend upon the difference in lengths of panels 2 and 4. In the example used here, if panel 2 is 3/4 inch or less shorter than panel 4, then sensor 13a will be first uncovered by panel 4 first as it travels along the conveyor belt. If panel 2 is more than 3/4 inch shorter than panel 4, then sensor 13b will be first uncovered as panel 2 travels along the conveyor belt 6a past sensor 13b.
On the other hand, FIGS. 6A-6C illustrate what happens when panel 4 is shorter than panel 2. If the difference in panel lengths is 3/4" or less, sensor 13a is first uncovered. However, if the panels differ in length by more than 3/4" with panel 2 being the longer of the two, sensor 13a will still be uncovered first since panel 4 will always pass sensor 13a first if panel 2 is longer than panel 4 by any amount because of the location and position of the sensors.
FIG. 7 further illustrates by way of a top plan view how sensors 13a, 13b, and 13c are positioned to monitor the fabric workpieces 2 and 4 to determine the shorter of the two pieces (or when a sensor is first uncovered by either workpiece, regardless of the relative lengths of the workpieces) as they move along the conveyor means to become engaged by drive rollers 12a and 14a. Locking jaws 16a and 18a are shown here in their locked positions as they travel along the path of conveyor belts 6a and 6b where jaws 16a and 18a are released from their locked position by cams 17a and 17b, respectively. Cams 17a and 17b are designed to operate on jaws 18a and 16a respectively, when they are nearing the sewing workstation.
Cam followers 24a and 26a ride cams 17a and 17b respectively as locking jaws 18a and 16a approach the sewing workstation 111. Just before the workpiece is passed to and through workstation 111, locking jaw 16a is opened by cam follower 24a and the workpiece proceeds through sewing head 111. Jaw 16a is spring loaded opened by cam follower 24a. Similarly, cam follower 26a spring loads locking jaw 18a opened as the portion of the wordpiece which is gripped by jaw 18a nears sewing head 111. Once the garment is released by both locking jaws 16a and 18a, the garment passes completely through sewing head 111 and locking jaws 16a and 18a are returned via an attached cable to their original upstream positions.
FIG. 8 illustrates pneumatic cylinders 20a and 22a which operate upon each of jaws 16a and 18a, respectively, to lock the jaws about the surface portions of fabric pieces 2 and 4, respectively.
FIG. 9 is intended to illustrate the relative motions of drive rollers 12a and 12b and rollers 14a and 14b as the rollers engage fabric workpieces 2 and 4 being transported along conveyor belts 6a and 6b in the direction of workstation 111.
FIG. 10 illustrates a locking jaw suitably designed for use in the practice of the invention where the locking jaw has a pin 36 for immediately gripping and stabilizing fabric workpieces 2 and 4 as jaw 37 prepares to grip and trap a portion of workpieces 2 and 4 within the jaw.
FIG. 11 illustrates a torque roller steering system, having torque motor 40 and pulley timing belt assembly 42 which is suitably designed for use in the practice of the invention. Upper and lower torque/steering rollers 12a and 14a engage fabric pieces 2 and 4 respectively and transfer any slack in the fabric panels to the area between the torque rollers and the sewing head. Torque motor 40 and the pulley-timing belt assembly 42 operate to rotate drive rollers 12a and 14a about their vertical axis in the direction of arrows A and B, respectively, to move the workpieces along the conveyor belt towards workstation 111.
FIGS. 12 and 13 similarly illustrate the torque roller assemblies having rollers 12a and 14a from two different perspectives, with rollers 117 and 119 not being visible in the FIG. 12 view. The system also provides a guide means 28a and 28b (see FIG. 1) for aligning the edges of the fabric panels to a fixed reference so that they are matched together horizontally when sewn together in the sewing head.
It should be pointed out that in each instance of the inventive apparatus, guide means 28a and guide means 28b (FIG. 1) are situated along the side edges of conveyor belts 6a and 6b. These guide means in each instance cooperate with the torque roller assemblies to align side seam 2a with 4a and side seam 2b with 4b. Guide means 28a and 28b may be any suitable alignment means and any variation of edge guide means is intended to fall within the scope of this invention.
The apparatus of the invention has been described utilizing two units made in accordance with the teachings of this invention so that a garment such as a pair of pants having two seams can be fed to a sewing workstation and have the two seams sewn together simultaneously and also have any discrepancies in the relative length of the two panels forming the garment compensated for just prior to the garment being introduced to the workstation. It is to be understood, however, that the apparatus of the invention is of equal utility where a garment has but one seam and where adjustments or compensation must be made to correct discrepancies in (or to guarantee) the length of two panels forming the garment. Thus, the apparatus of the invention is equally useful in a single seam environment. Similarly, the device of the invention may be used for matching the trailing ends or cuffs of garments or fabric pieces where any other seam (such as inseams) of the garment is being introduced to the workstation.
Likewise, the invention has been described where the discrepancy between panels 2 and 4 have been but three-quarter inch (3/4 inch), but it should be readily understood and recognized that any discrepancy in the lengths of two panels can be compensated for with the apparatus of this invention and can be done within the spirit and scope of this invention.
It should be pointed out that in each instance of the inventive apparatus, means are situated along the path of conveyor belt 6a and 6b for aligning side seams 2a with 4a and side seams 2b with 4b. These means, illustrated as 28a and 28b in FIG. 1, may be any suitable alignment means and any variations in these means is certainly intended to fall within the scope of this invention.
This invention is only limited by the following claims. | An apparatus and method for accurately aligning the top and bottom edges of a garment's workpieces to assure even cuffs after sewing, the apparatus comprising two locking jaw assemblies which cooperate with drive rollers (all of which are located upstream of the sewing head) and the conventional bottom feed action of the lower feed dogs on a sewing machine to capture any excess length or slack of the garment's panels between the locking jaws (to match the cuffs ) and then to drive any excess slack out of the panels as they are fed to the sewing head to be sewn. | 3 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 60/627,736 entitled “Piezoresistive Micro Displacement MEMS Sensing” and filed on 11 Nov. 2004 for Robert K. Messenger, Timothy W. McLain, and Larry L. Howell, and to U.S. Provisional Patent Application No. [App. Number TBD] entitled “Piezoresistive Sensing of Bistable Micro Mechanism State” filed 9 Nov. 2005 for Jeffrey Anderson, Larry L. Howell, Timothy W. McLain, and Robert Messenger. Each of the aforementioned applications is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to micro-electro-mechanical systems (MEMS) and more particularly relates to apparatus, systems, and methods for positional sensing of micromechanical elements.
[0004] 2. Description of the Related Art
[0005] Micro-electro-mechanical systems (MEMS) are typically fabricated using semiconductor processes that etch away and dope selected areas to form electrical and mechanical devices on a common substrate. The integration of electrical and mechanical devices facilitates providing low-cost high performance components. Typical applications include sensors, transducers, accelerometers, optical switching, and multi-colored projection.
[0006] One issue related to controlling the mechanical devices on MEMS chips is sensing the position of various mechanical elements and adjusting their position to achieve a desired position. In particular, the small geometries involved with MEMS systems impose significant challenges to sensing the position of mechanical elements in a cost effective manner. For example, optical techniques used in large scale applications are typically impractical for the small scales involved with MEMS devices. As a result, a need exists for an apparatus, system, and method to sense the positional state of a micromechanical device in a cost effective manner.
SUMMARY OF THE INVENTION
[0007] The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available MEMS devices and methods. Accordingly, the present invention has been developed to provide an apparatus, method, and system to sense a positional state of a micromechanical device that overcome many or all of the above-discussed shortcomings in the art.
[0008] In one aspect of the present invention, an apparatus to sense a positional state of a micromechanical device includes a micromechanical device comprising a piezoresistive material, the micromechanical device configured to have a plurality of positional states, and a sensing circuit configured to sense an electrical resistance of at least a portion of the micromechanical device. In some embodiments, the micromechanical device may be formed entirely of a piezoresistive material such as polysilicon and possess substantially homogenous piezoresistive properties that are leveraged to sense the positional state of the device.
[0009] The micromechanical device may be a compliant device comprised of one or more relatively flexible members such as mechanical beams, strips, or ribbons. In certain embodiments, the micromechanical device is a threshold detector that latches to a particular stable configuration when an applied force exceeds a selected value. The electrical resistance of the micromechanical device (or a selected portion of the micromechanical device) may correspond to the amount of strain within the micromechanical device and therefore the positional state. The positional states may be continuous positional states (such as the position of an actuator) or discreet positional states (such as the positional state of a bistable memory device).
[0010] To increase sensitivity, the sensing circuit may be electrically connected across the longest dimension of the micromechanical device. In one embodiment, the sensing circuit comprises a Wheatstone bridge wherein one branch of the Wheatstone bridge comprises a portion of the micromechanical device.
[0011] In another aspect of the present invention, a method to sense a positional state of a micromechanical device includes providing a micromechanical device comprising a piezoresistive material, the micro-mechanical device configured to have a plurality of positional states, and sensing the electrical resistance of at least a portion of the micromechanical device. The method may also include detecting a positional state of the micromechanical device from the sensed electrical resistance.
[0012] In another aspect of the present invention, a system to sense a positional state of a micromechanical device includes a micromechanical device having piezoresistive properties, a sensing circuit configured to sense an electrical resistance of at least a portion of the micromechanical device, and a processing module configured to receive a signal from the sensing circuit and detect a positional state of the micromechanical device. The positional state of the micromechanical device may be sensitive to various actuation means such as pressure, temperature, force, acceleration, voltage, current, light, magnetic fields, thermal radiation, and the like.
[0013] The present invention facilitates sensing a positional state of a micromechanical device in a non-obtrusive cost effective manner. It should be noted that references to features, advantages, or similar language within this specification does not imply that all of the features and advantages that may be realized with the present invention should be or are in any single embodiment of the invention. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an embodiment is included in at least one embodiment of the present invention. Thus, discussion of the features and advantages, and similar language, throughout this specification may, but do not necessarily, refer to the same embodiment.
[0014] Furthermore, the described features, advantages, and characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize that the invention may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments of the invention.
[0015] The aforementioned features and advantages 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
[0016] To enable the advantages of the invention to be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that 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:
[0017] FIG. 1 is a block diagram depicting one embodiment of a prior art MEMS control system;
[0018] FIG. 2 is a layout diagram depicting one example of a MEMS positional sensor;
[0019] FIG. 3 is a block diagram depicting one embodiment of a MEMS control system of the present invention;
[0020] FIG. 4 is a layout diagram depicting one embodiment of a MEMS positional sensing device of the present invention;
[0021] FIG. 5 is a layout diagram depicting another embodiment of a MEMS positional sensing device of the present invention;
[0022] FIG. 6 is a flow chart diagram depicting one embodiment of a MEMS control method of the present invention;
[0023] FIG. 7 is a layout diagram depicting one embodiment of a MEMS positional sensing device of the present invention integrated with a Wheatstone bridge sensing circuit; and
[0024] FIG. 8 is a layout diagram depicting one embodiment of a peak acceleration sensing array of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Some of the functional units described in this specification have been explicitly labeled as modules, (while others are assumed to be modules) in order to emphasize their implementation independence. For example, a module may be implemented as a hardware circuit comprising custom VLSI circuits, MEMS devices, or gate arrays, off-the-shelf semiconductors such as logic chips, transistors, or other discrete electrical or mechanical components. A module may also be implemented in programmable hardware devices or systems such as field programmable gate arrays, programmable array logic, and programmable logic devices.
[0026] Modules may also be implemented in software for execution by various types of processors such as embedded processing units, microcontrollers, or the like. An identified module of executable code may, for instance, comprise one or more physical or logical blocks of computer instructions which may, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified module need not be physically located together, but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the module and achieve the stated purpose for the module.
[0027] Indeed, a module of executable code may be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices. Similarly, operational data may be identified and illustrated herein within modules, and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices, and may exist, at least partially, merely as electronic signals on a system or network.
[0028] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
[0029] FIG. 1 is a block diagram depicting one embodiment of a MEMS control system 100 . As depicted, the MEMS control system 100 includes a processing module 110 , and a MEMS substrate 120 with one or more control circuits 130 , micromechanical devices 140 , and in some embodiments one or more sensing circuits 150 . The MEMS control system 100 illustrates a typical approach to controlling the micromechanical devices 140 .
[0030] The processing module 110 may receive sensor information and provide control information in the form of digital or analog signals, or other means known to those of skill in the art. The control circuits 130 control the micromechanical devices 140 as directed by the processing module 110 . For example, the control circuits 130 may activate mechanical actuators or switches that control the position and orientation of optical or mechanical elements. In some embodiments, the sensing circuits 150 sense the position of the micromechanical devices 140 and provide feedback information 152 to the control circuits 130 .
[0031] FIG. 2 is a layout diagram depicting one example of a MEMS positional sensing device 200 . As depicted, the positional sensing device 200 includes a thermal actuator 210 and a capacitive sensor 220 . The positional sensing device 200 facilitates providing positional feedback corresponding to the positional state of the thermal actuator 210 .
[0032] The thermal actuator 210 includes a pair of actuation signal pads 212 a and 212 b that receive a differential control signal (not shown) that provides current to a set of beams 214 . The beams 214 may be thermally heated and elongated proportional to the current provided to the signal pads 212 . The elongation of the beams 214 may actuate a movable shuttle 216 to a new position 218 .
[0033] The depicted capacitive sensor 220 includes a lower plate 222 and an upper plate 224 integrally formed with the movable shuttle 216 . As the overlap between the upper plate 224 and the lower plate 222 changes, a change in capacitance may be sensed by an appropriate sensing circuit 150 (see FIG. 1 ) connected to the lower plate 222 . In turn, the control circuits 130 or the processing module 110 (see FIG. 1 ) may receive the capacitance information and estimate the position of the movable shuttle 216 .
[0034] Although the positional sensing device 200 provides valuable feedback, significant circuitry may be required to support the positional sensing device 200 . For example, sensing the capacitance between the upper plate and the lower plate may require generation of an AC signal comprising one or more high frequency components. Furthermore, stray capacitance and other non-linear effects may necessitate significant calibration and/or signal processing to provide an accurate estimate of the position of the movable shuttle 216 . In addition, significant substrate real estate may be consumed by the capacitive sensor 220 and its associated support circuitry. Furthermore, additional layers, processing steps, or materials may be required to properly fabricate the capacitive sensor 220 .
[0035] As subsequently described and claimed herein, various embodiments of the present invention address many of the aforementioned issues. FIG. 3 is a block diagram depicting one embodiment of a MEMS control system 300 of the present invention. In addition to the elements described in conjunction with the MEMS control system 100 or similar elements, the MEMS control system 300 includes one or more piezoresistive elements 345 that may be integrated into the micromechanical devices 140 and/or the sensing circuits 150 . Piezoresistive elements experience changes in electrical resistance in response to changes in strain.
[0036] The piezoresistive elements 345 may be constructed of the same material as the micromechanical devices 140 . In one embodiment, the micromechanical devices 140 are fabricated from one or more layers of polysilicon. By sensing the electrical resistance of the piezoresistive elements 345 (and therefore the mechanical strains within the micromechanical devices 140 ), information and/or feedback corresponding to the positional states of the micromechanical devices 140 may be provided to the controls circuits 130 and/or the processing module 110 . In certain embodiments, the correspondence between the feedback information and the micromechanical states may be substantially linear. In some embodiments, the piezoresistive elements that are measured include primarily those portions of the micromechanical devices (such as beams) that experience significant changes in strain in response to changes in positional state.
[0037] FIG. 4 is a layout diagram depicting one embodiment of a positional sensing device 400 of the present invention. As depicted, the positional sensing device 400 includes a pair of stationary pads 410 a and 410 b , a movable shuttle 420 , and one or more piezoresistive elements 345 . The positional sensing device 400 is one example of a MEMS device that leverages the piezoresistive elements 345 for both mechanical structure and electronic feedback purposes—a concept the applicants consider unique to the present invention.
[0038] The stationary pads 410 a and 410 b may receive a sensing signal from a sensing circuit used to estimate the electrical resistance of the device 400 in general and of the piezoresistive elements 345 in particular. To increase sensitivity, the sensing circuit may be electrically connected across the longest dimension of the device 400 .
[0039] The movable shuttle 420 may be moved by an external force such as acceleration, or by forces imposed by other elements integrated onto the MEMS substrate 120 . Such forces may induce movement on the shuttle 420 and a corresponding strain on the piezoresitive elements 345 and cause the device 400 to assume a particular positional state.
[0040] In certain embodiments, the stable positional states of the device 400 are substantially continuous (for example due to a range of forces imposed on the device 400 ). In other embodiments, the stable positional states are discrete (for example due to a limited number of states having balanced internal forces). The positional state of the micromechanical device 140 may be sensitive to a particular means of actuation such as pressure, temperature, force, acceleration, voltage, current, light, thermal radiation, and the like.
[0041] In certain embodiments, the positional sensing device 400 is a bistable device. For example, the device 400 may be a compliant bistable device that is induced into the stable positional state 440 b when the device is subjected to acceleration that exceeds a selected threshold. In the depicted embodiment, the device 400 has bistable positional states 440 a and 440 b . In another embodiment, the device 400 is a tristable device. For more information on compliant devices and discrete positional states, the reader is referred to the textbook Compliant Mechanisms authored by one of the applicants (Larry L. Howell) and published by John Wiley and Sons, Inc.
[0042] The sensing signal (not shown) provided to the stationary pads may be used to measure the electrical resistance of one or more of the piezoresistive elements 345 . For example, in one embodiment, a pair of DC reference voltages (one of which may be a ground voltage) are applied to the pads 440 and the current flowing through the device 400 is measured to estimate the positional state of the device 400 . The use of DC reference voltages may simplify circuit design and circuit layout.
[0043] FIG. 5 is a layout diagram depicting another embodiment of a positional sensing device of the present invention, namely, the positional sensing device 500 . In addition to the elements of the sensing device 400 or similar elements, the sensing device 500 includes an active device 510 and a reference device 520 . The active device 510 may assume a number of positional states that change the electrical resistance of the device. Use of the reference device 520 may normalize measurement of the electrical resistance of the piezoresistive elements 345 .
[0044] The depicted reference device 520 includes a stationary element 530 that anchors the reference device 520 into a certain positional state. The reference device 520 may also include a set of piezoresistive reference elements 545 that are substantially identical to the piezoresistive elements 345 yet held in a constant positional state. As a result, the depicted sensing device 500 may function as a voltage divider wherein a voltage measured at a measurement pad 410 c may be proportional to the ratio of the resistance of one of the devices to the total resistance of both devices. The use of such a voltage divider may factor out process variations and environmental factors such as humidity, and facilitate more accurate measurement of the positional state of the active device 510 .
[0045] FIG. 6 is a flow chart diagram depicting one embodiment of a MEMS control method 600 of the present invention. As depicted, the MEMS control method 600 includes providing 610 a piezoresistive micromechanical device, sensing 620 an electrical resistance, and deriving 630 a positional state. The MEMS control method 600 may be conducted in conjunction with the MEMS control system 300 depicted in FIG. 3 .
[0046] Providing 610 a piezoresistive micromechanical device may include providing a micromechanical device 140 that includes one or more piezoresistive elements 345 . Sensing 620 an electrical resistance may include measuring a response to a particular measurement signal. Deriving 630 a positional state may include processing the signal response to detect relative changes in resistance and mapping the response values to particular positional states. In certain embodiments, a mapping function is determined by executing a calibration sequence that places a micromechanical device in known positional states.
[0047] FIG. 7 is a layout diagram depicting one embodiment of a MEMS positional sensing device 700 of the present invention integrated with a Wheatstone bridge sensing circuit. As depicted, the sensing device 700 includes a thermal actuator 710 with a moveable shuttle 715 , an active device 720 , and three reference devices 730 . The depicted active device 720 and the reference devices 730 form a Wheatstone bridge circuit that facilitate providing a differential sensing voltage to the differential measurement pads 740 . The use of a differential sensing voltage may increase the sensitivity of the positional sensing device 700 .
[0048] The active device 720 may have an electrical resistance corresponding to the positional state of the movable shuttle 715 . The depicted active device 720 and the reference device 730 a form a voltage divider that is parallel to the voltage divider formed by the reference devices 730 b and 730 c . Each voltage divider should experience substantially similar noise conditions. As a result, the voltages provided to the measurement pads 740 may provide a differential signal that enables detection of small changes in electrical resistance associated with the active device 720 . In certain embodiments, the differential signal is amplified by a differential amplifier (not shown) to provide a larger amplitude feedback signal to the control circuits 130 , or the like. Using a Wheatstone bridge sensing circuit similar to the depicted circuit may be particularly useful for extremely small bistable devices such as MEMS memory devices.
[0049] FIG. 8 is a layout diagram depicting one embodiment of a sensing array 800 of the present invention. As depicted, the sensing array 800 includes a two dimensional array comprising rows 802 and columns 804 of bistable positional sensing devices 810 . The depicted bistable positional sensing devices 810 are similar to the positional sensing device 500 depicted in FIG. 5 . In one embodiment, each bistable sensing device 810 is a MEMS memory device. In another embodiment, each bistable sensing device 810 is a thresholded acceleration detector.
[0050] In addition to the elements described in conjunction with FIG. 5 , the bistable positional sensing devices 810 may include one or more of electrostatic combs 820 attached to the movable shuttle 420 and corresponding combs 830 proximate to the combs 820 . The electrostatic combs 820 and 830 facilitate moving the active device 510 to a selected positional state.
[0051] For example, by applying a sufficiently large voltage to pad 410 d the electrostatic combs 820 a and 830 a may attract each other and induce a primary stable state illustrated with solid lines. Similarly, by applying a sufficiently large voltage to pad 410 e electrostatic combs 820 a and 830 a may attract each other and induce a secondary stable state illustrated with dashed lines. Consequently, the positional state of the active device 510 may be selectively programmed. Furthermore, the positional state of each active device 510 may be detected by applying a voltage difference to pads 410 a and 410 b and measuring the voltage response at pad 410 c.
[0052] In some embodiments, each positional sensing device 810 has a different sized movable shuttle 420 (i.e. shuttles of various masses) that requires a corresponding level of acceleration to move the shuttle from the primary stable state to the secondary stable state 440 b (see FIG. 4 ). In those embodiments, the sensing array 800 may capture and retain a peak acceleration level experienced by the array. Furthermore, since power is only needed to read or reset the sensing devices 810 , the information may be captured and retained without consuming power. In such embodiments, the combs 820 b and 830 b may not be necessary for valid operation and may be omitted from the positional sensing devices 810 .
[0053] The present invention provides improved positional sensing of micromechanical devices. The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A micromechanical device may include one or more piezoresistive elements whose electrical resistance changes in response to externally or internally induced strain. The present invention leverages the piezoresistive properties of such devices to sense the positional state of the device. A sensing circuit may be integrated into the device that senses an electrical resistance of at least a portion of the micromechanical device and provides information regarding the positional state of the micromechanical device. The micromechanical device may be a compliant device that includes relatively flexible members such as mechanical beams or ribbons. The positional states may be continuous positional states (such as the position of an actuator) or discreet positional states (such as the positional state of a bistable memory device). In certain embodiments, the micromechanical device is a threshold detector that latches to a particular stable configuration when an applied force exceeds a selected value. | 6 |
THE FIELD OF THE INVENTION
The present invention relates to solutions for winding cores of dynamoelectric machines by using a needle which dispenses at least one electrical conductor to form coils of a predetermined number of turns. Before and after winding, the needle is used to place termination leads of the coils along predetermined trajectories located around the ends of the core.
DESCRIPTION OF THE RELATED ART
The needle has a passage for guiding the conductor towards the core during winding of the coils and forming of the termination leads. Feeding of the conductor through the needle passage towards the core occurs by using relative motions between the needle and the core. These motions comprise relative translations and relative rotation motions.
For precisely locating the conductor during forming and placement of the termination leads, the needle needs to be relatively moved with respect to the core to deposit the conductor on a predetermined trajectory. At the same time the needle needs to avoid collision with the structure of the core. This requires changing the orientation of the needle with respect to the orientation of the needle used during winding, so that the wire can be deposited correctly and the needle can remain clear of obstacles present on the core.
During winding to form the coils, the needle passage where the wire runs is normally positioned perpendicular to the longitudinal axis of the core. The longitudinal axis of the core can be considered as a reference axis, which is normally central and parallel to the extension of the core slots. The slots are the portions of the core where the coils are placed during the winding operations. The needle needs to be re-oriented by a rotation mechanism, which is actuated when passing between the stages of winding the coils and the stages of forming and placing the termination leads. Mechanisms for rotating the needle between these two orientations have been described in U.S. Pat. No. 6,098,912, JP 2003 169455 and EP 1,759,446, or were previously known.
Certain trajectory configurations where the termination leads can be positioned have been described in EP 1420505.
Mechanisms for rotating the needle need to pass through the interior of the core, or in the spacing existing between external structures of the core. Modern cores need to be compact and therefore allow little room for movement of the needle and the associated rotating mechanisms.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a winding and termination solution having a conductor dispensing nozzle (in the following also referred to as needle) that can be oriented by a mechanism that occupies less space within, or around the core. In this manner smaller and more complex core structures can be wound and terminated
The complicated and multiple routings for placing the termination leads around the core require complex structures assembled on the core for support and termination. With respect to these structures the needle needs to move appropriately to deposit the wire and to avoid collision during termination.
A further object of the present invention is to provide a winding and termination solution having a conductor dispensing nozzle, which is capable of more variable and programmable movements in order to place the leads along more complicated trajectories.
Cores for low voltage applications, like those for automotive applications, are wound with conductors having large section. These conductors require considerable pulling tension on the dispensing nozzle and the related moving mechanism. Consequently, reliable mechanical resistance and low wear of the winding apparatus needs to be guaranteed.
A further object of the present invention is to provide a winding and termination solution having a conductor dispensing nozzle that can wind and position termination leads formed of conductors having large sections.
A further object of the present invention is to provide a winding solution having a conductor dispensing nozzle that can be easily adapted to wind and position termination leads on cores of different configurations. These and other objects of the invention are achieved with the apparatus according to the claims 1 and 27 and the method according to claims 18 and 35 .
Further characteristics of the invention are indicated in the subsequent dependent claims.
The above and other objects, features and advantages of the present invention will become apparent from the following description with reference to the accompanying drawings which illustrate examples of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a perspective view illustrating a previously known apparatus or like that of JP 2003 169455 according to a condition for winding a core of a dynamoelectric machine.
FIG. 1B is a perspective view illustrating the apparatus of FIG. 1A according to another condition for forming and placing termination leads of the coils.
FIG. 2 is a partial section view illustrating the apparatus of the invention as seen from directions 2 of FIG. 3 .
FIG. 2A is a partial section view as seen from view directions 2 A- 2 A of FIG. 2 .
FIG. 3 is a partial section view as seen from view directions 3 - 3 of FIG. 2 illustrating a winding condition of the apparatus.
FIG. 3A is a partial section view similar to FIG. 3 illustrating a termination condition of the apparatus, although without the wire conductor present for reasons of clarity.
FIG. 4 is a perspective view from direction 4 of FIG. 2 illustrating the apparatus of the invention according to a condition for winding a core of a dynamoelectric machine. In FIG. 4 the core is not shown for reasons of clarity.
FIG. 5 is a view similar to the view of FIG. 4 , although illustrating the apparatus of the invention according to a condition for termination of a core of a dynamoelectric machine, therefore in a condition similar to that of FIG. 3A .
FIG. 6 is a partial section view similar to the view of FIG. 2 illustrating an assembly for supporting and positioning the core in the apparatus of the invention.
FIG. 7 is a partial section view from directions 7 - 7 of FIG. 6 .
FIG. 8 is a plan view of FIG. 2 illustrating a position of the conductor dispensing nozzle in relation to the core in the apparatus of the invention.
FIG. 9 is a partial section view from directions 9 - 9 of FIG. 8 .
FIG. 10 is a plan view of FIG. 2 illustrating a further position of the conductor dispensing nozzle in relation to the core in the apparatus of the invention.
FIG. 11 is a partial section view from directions 11 - 11 of FIG. 10 , although with certain parts displaced by a certain quantity of motion
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIGS. 1A and 1B , a previously known mechanism or like that of JP 2003 169455 is shown for supporting and rotating winding needle 10 during the winding and termination stages.
FIG. 1A illustrates the stage in which the needle 10 is oriented for winding the coils C using wire W.
FIG. 1B illustrates the stage in which the needle 10 is re-oriented by 90° for forming and placing leads of wire W during termination.
Wire W comes from a tensioner (not shown), passes through the final passage of needle 10 to reach core 11 . Needle 10 is supported by arm 12 , which is provided with translation motions in directions X, Y and Z for winding and terminating wire W on core 11 .
To wind core 11 , thus to form the coils C of wire W in slots 13 , the tubular passage of needle 10 is oriented perpendicular to the longitudinal axis 11 ′ of the core (as shown in FIG. 1A ). In addition the needle is translated with reciprocation motion in direction X through the core, i.e. parallel to longitudinal axis 11 ′, to deliver wire W in slots 13 . The longitudinal axis 11 ′ of the core is parallel to the extensions of the slots 13 .
The translation of the needle occurs by moving arm portion 12 ′ with reciprocating translation parallel to axis 11 ′ and by passing it through the inside of core 11 . During the winding stage, core 11 can be rotated around longitudinal axis 11 ′ to form the heads of the coils, i.e. the cross over portions of the coils for passing from one slot to another.
For terminating the core, the tubular passage of needle 10 is oriented parallel to the longitudinal axis 11 ′, as shown in FIG. 1B . The change of orientation of the needle occurs by rotating arm 12 around pin 14 for an angle of 90° in direction R′. To return the needle back to the winding orientation of FIG. 1A , arm 12 is reversely rotated around pin 14 for an angle of 90°, therefore arm 12 is rotated in direction R.
In FIGS. 1A and 1B the mechanisms for rotating the needle around pin 14 and for translating the needle in direction X, Y and Z have been omitted for reasons of clarity. Similarly the mechanism for rotating core 11 around axis 11 ′ has been omitted for reasons of clarity. Exit 10 ′ where wire W leaves the needle passage to reach core 11 is aligned with the axis of pin 14 , as shown in FIGS. 1A and 1B . Consequently the needle rotates around the instantaneous position of exit 10 ′ during rotations in directions R and R′. In this way wire W does not leave needle 10 during the rotations in direction R and R′.
This avoids the formation of unwanted lengths of wire during rotations in direction R and R′. The extra lengths of wire would need to be recovered by the tensioner, or would have to be coursed by the needle along specific trajectories to avoid loosing wire tension.
The size and configuration of arm 12 determine the size of the core that can be wound with the solution illustrated in FIGS. 1A and 1B , therefore arm 12 needs to be substituted for winding and terminating certain core sizes. Arm 12 is cantilevered and extends considerably from pin 14 . This produces a considerable inertia with respect to pin 14 . Consequently, rapidity and precision of the movements of the needle for winding and termination are hindered if arm 12 has to be wide and long in portion 12 ′.
With reference to FIGS. 2 and 3 which illustrate an embodiment of the invention, needle 20 is provided with exit 20 ′ where wire W leaves needle passage 21 to reach core 11 . In FIGS. 2 and 3 , the needle 20 can be translating in directions X and X′ with reciprocation motion parallel to the longitudinal axis 11 ′ of core 11 to wind wire W in order to form coil C in slots 13 .
Needle 20 is seated in a bore 22 ′ of support member 22 (see FIG. 3 ). Guide member 23 is screwed on to the end of needle 20 to pull flange portion 24 of needle 20 against member 22 . In this way needle 20 becomes fixed to member 22 . Guide member 23 has a flared portion 23 ′ to smoothly guide wire W into passage 21 of needle 20 . Support member 22 is secured to a second support member 26 by means of bolts (not shown), which are located in bores 22 ′ (see FIG. 5 ). Second support member 26 is assembled to rotate together with pin 25 (see FIG. 3 ). Pin 25 is assembled to rotate in bore 28 . Bore 28 is located on an end portion of support shaft 27 and is aligned with axis 25 ′.
Axis 25 ′ or bore 28 is not inclined at 90° with respect to reference axis 27 ′ of support shaft 27 .
Axis 27 ′ can be parallel and distanced with respect to longitudinal axis 11 ′, like is shown in FIGS. 3 and 3A . Alternatively, axis 27 ′ can be coincident with axis 11 ′ depending on the positioning of needle 20 required for winding and termination.
The incline of axis 25 ′ is more than 0° and less than 90°. In particular, the incline can be 45°, like is shown in FIG. 3 . In addition, axis 25 ′ can intersect the exit 20 ′ of needle 20 , like is shown in FIG. 3 . Second support member 26 is provided with a gear portion 26 ′, like is shown in FIGS. 2-5 . Gear portion 26 ′ meshes with gear portion 29 ′ of drive tube 29 .
Gear portion 26 ′ rotates around axis 25 ′ by rotating gear portion 29 ′ around axis 27 ′. Rotation of drive tube 29 around axis 27 ′ causes gear portion 29 ′ to rotate around axis 27 ′.
A 180° rotation of second support member 26 around axis 25 ′ can occur by rotating drive tube 29 for 180° around axis 27 ′. This causes needle 20 to rotate around axis 25 ′ for 180°. Rotation of needle 20 around axis 25 ′ produces a succession of positions of the section of needle 20 out of the plane of FIG. 3 . The plane of FIG. 3 can be considered as defined by axes 25 ′ and 27 ′ and where the position WP for winding is located as seen in a section view. The full 180° rotation of needle 20 , or of axis 21 ′ of passage 21 , around axis 25 ′ brings the section of needle 20 back into the plane of FIG. 3 to occupy a second position TP (see FIGS. 3A and 5 ), which is required for termination. The second position TP is characterized by the needle being oriented with the section of passage 21 (see axis 21 ′) rotated by 90° in the plane of FIG. 3 (see also FIG. 3A ).
Furthermore, due to the fact that the needle passage 21 has rotated around the instantaneous position of exit 21 ′ no extra wire has been pulled through needle 20 .
Drive tube 29 is coupled to a connection structure 41 of slide 40 (see FIGS. 2 , 2 A and 3 ).
Support shaft 27 is assembled within the interior of drive tube 29 . Bushes like 37 of FIGS. 2A and 3 are interposed between support shaft 27 and drive tube 29 to support rotation of drive tube 29 around support shaft 27 , and therefore the rotation of drive tube 29 around axis 27 ′.
Threaded end 66 of drive tube 29 is screwed onto support 60 . Lock nut 61 is screwed around the end 66 of drive tube 29 to secure that drive tube 29 remains screwed to support 60 . The outer ring of bearing 62 is assembled to be fixed on support 60 . The inner ring of bearing 62 is assembled to be fixed on cylindrical member 63 . The end of support shaft 27 is assembled on cylindrical member 63 . Cylindrical member 63 is secured to connection structure 41 by means of bolt 64 , which screws on to the end of cylindrical member 63 to pull flange portion 63 ′ of member 63 against abutment surface 41 ′ of connection structure 41 , as shown in FIG. 2A .
The end of support shaft 27 which is assembled through member 63 becomes pulled by bolt 65 to abut against member 63 in abutment surface 63 ″. In this way support shaft 27 is secured along axis 27 ′ and is impeded from rotating around axis 27 ′.
Slide 40 is capable of translating with reciprocation motion in directions X and X′ (see FIG. 2 ), and therefore translates parallel to axis 11 ′ of the core, on guides 42 of the apparatus frame 50 . To achieve this motion, motor 43 rotates screw 44 . Screw 44 engages threaded sleeve 45 of slide 40 . Consequently, forward and opposite rotations of motor 43 cause slide 40 to translate with reciprocation motion in directions X and X′.
With reference to FIGS. 2 and 3 , drive tube 29 is assembled to slide through bore 31 of pulley wheel 30 . A key 32 integral with pulley wheel 30 engages key way 34 of drive tube 29 . Pulley wheel 30 is assembled on frame 50 of the apparatus and can be rotated by motor 35 using belt transmission 36 . Motor 43 and 35 are assembled on frame 50 of the apparatus.
Forward and opposite rotations of motor 35 cause rotation of drive tube 29 around axis 27 ′. This causes gear portion 29 ′ to rotate around axis 27 ′. Consequently, second support member 26 rotates around axis 25 ′ for causing needle 20 to rotate around axis 25 ′, like has been described above when passing between the needle orientations for winding and termination.
Wire W reaches needle 20 from a tensioner (not shown) by passing through guide tube 38 , which is fixed to a clamp ring 39 (see FIGS. 2 and 2A ). The clamp ring is fixed to member 60 so that guide tube 38 rotates with drive tube 29 around axis 27 ′. Consequently wire W rotates around axis 27 in synchronism with the rotation of needle passage 21 around axis 25 ′ in order to avoid that wire W remains entangled or hindered in its motion towards the core during winding and termination.
The portion of the apparatus of the invention that is required to travel through the core comprises drive tube 29 , support shaft 27 , needle 20 , member 22 , member 26 and member 23 . As shown in the FIGS. 2-6 , drive tube 29 and support shaft 27 , which are primary members for supporting the needle have a coaxial configuration which can be extremely compact in a transverse direction with respect to the longitudinal axis 11 ′ of the core. This makes it possible to wind cores having interiors of reduced size, therefore cores that are more compact.
The configuration of drive tube 29 and support shaft 27 make it possible to have extremely optimized inertia, therefore these parts can be rapidly and precisely translated and rotated by motors 35 and 43 .
Needle 21 can be easily substituted by releasing and securing guide member 23 where cores requiring different winding and termination specifications need to be processed and therefore require needles of other sizes. Similarly, the entire assembly consisting of drive tube 29 assembled on support shaft 27 , member 26 assembled on support shaft 27 , member 22 assembled on member 26 and needle 20 assembled on member 22 can be disassembled as a unit by disassembly of drive tube 29 and support shaft 27 from connection structure 41 . This entire assembly forming a unit can be substituted with another unit of different size when requiring to wind cores having different configurations, for example when requiring to process significantly different core heights.
Member 22 can be substituted with another similar member of different size to position needle 20 in a required relation with respect to axis 25 ′ or axis 27 ′. In this way the angle between the rotation axis 25 ′ and the reference axis 27 ′, or between the rotation axis 25 ′ and the axis 21 ′ of the passage, can be maintained constant or changed.
The tension exerted on wire W for winding and termination is mainly supported on drive tube 29 and support shaft 27 . Drive tube 29 and support shaft 27 are well supported by bearing 62 and bushes 37 , therefore high tension of wire W can be reliably supported by the apparatus when winding and terminating large size conductors.
By means of programmable rotation of motor 35 , needle passage 21 can rotate around axis 25 ′ as a function, for example of the position of needle 20 during winding and termination. The programmability of the rotation of needle passage 21 around axis 25 ′ can be applied for winding turns or forming termination leads along predetermined trajectories with respect to the core, and also according to predetermined sequences of motion of the apparatus. For example, needle 20 can be rotated around axis 25 ′ so that it remains out of the plane of FIG. 3 for certain stages of termination. The reason can be for allowing the needle to move on predetermined trajectories necessary for coursing the leads and for clearing certain structure that are present on the core. With reference to FIG. 6 , core 11 is shown supported and positioned by means of tubular member 70 . More particularly, core 11 is seated in groove 71 of tubular member 70 for centering core 11 and positioning it with respect to centre axis 70 ′ of tubular member 70 . Therefore longitudinal axis 11 ′ can coincide with centre axis 70 ′. Centre axis 70 ′ can be the axis of symmetry of tubular member 70 .
Arms 72 are hinged in 73 to appendixes of member 70 . Portions 72 ′ of arms 72 are required to press on the external surface of core 11 , as shown in FIG. 6 to firmly press on core 11 when it is seated in groove 71 . Portions 72 ′ are maintained in contact with the core by the pressing action of pressing members 74 on end portions of arms 72 , as shown in FIG. 6 . Pressing members 74 are assembled to slide on tubular member 70 in radial directions 75 ′ to press on end portions of arms 72 by means of the preload force of springs 75 , as shown in FIG. 6 .
By pressing in opposite direction 75 ″ on portion 78 of arms 72 , i.e. against the preload force of springs 75 , arms 72 release the pressing action on the core, and also rotate away to allow core 11 to be moved in direction X′ for extraction of core 11 from tubular member 70 .
Member 70 is supported on the axial end 76 ′ of ring member 76 , as shown in FIG. 6 . A key and slot connection (not shown) between member 70 and ring member 76 (with the key and the slot that extend parallel to axis 70 ′), couples member 70 to ring member 76 for their rotation together around axis 70 ′.
Ring member 76 is supported on radial bearings 77 for rotation around axis 70 ′. Bearings 77 are supported on portion 93 of platform 94
Member 70 is locked to ring member 76 along axis 70 ′ by means of lock mechanism 80 . Lock mechanism 80 is a rapid lock and release coupling mechanism that allows member 70 to be easily and rapidly disassembled and reassembled with respect to ring member 76 .
Member 70 can be substituted when requiring to seat cores of different configuration that need to be wound and terminated.
Mechanism 80 is provided with a shaft member 81 , which is assembled to pass through an end bore of member 70 , as shown in FIG. 6 . Shaft member 81 is normally pressed in direction X′ by the preload of spring 81 ′, which presses on the upper portion of member 81 .
Portion 80 ′ of shaft member 81 is threaded and screws into a threaded bore of plate member 82 , as shown in FIG. 6 . Pin 83 is fixed in a cross manner near an end of member 80 , as shown in FIGS. 6 and 7 .
With reference to FIG. 7 , plate member 82 can be rotated between a position 80 a and a position 80 b (shown with dashed line representation) and vice versa around axis 70 ′. In position 80 a , plate member 82 secures member 70 to ring member 76 . In position 80 b of plate member 82 , member 70 results unlocked and therefore member 70 can be disassembled from ring member 76 .
By screwing shaft member 81 on plate member 82 (by means of the rotation in direction 85 ), plate member 82 is pulled against shelf 84 of member 70 to secure member 70 to ring member 76 ; see position 80 a of plate member 82 in FIGS. 6 and 7 .
By unscrewing shaft member 81 (by means of a rotation in direction 86 ), plate member 82 is released and rotated to the position 80 b . More particularly, plate member 82 is rotated to the position 80 b after having unscrewed shaft member 81 until pin 83 is brought against plate member 82 and moved into slot 87 of plate member 82 (see FIG. 7 ). When pin 83 is seated in slot 87 , rotation 86 rotates member 82 to position 80 b.
When member 70 is reassembled on ring member 76 , pin 83 can be brought out of slot 87 by screwing shaft member 81 using rotation in direction 85 . The initial effect of the rotation in direction 85 is that of bringing plate member 82 to position 80 a for locking. By pressing shaft member 81 in direction X″, therefore against the pushing action of spring 81 ′, pin 83 is brought out of slot 87 . Continuing with the rotation in the direction 85 , shaft member 81 is screwed into the threaded bore of plate member 82 so that plate member 82 is pulled against shelf 84 of member 70 to secure member 70 to ring member 76 . Extension 88 of member 70 acts as an abutment surface to maintain position of plate member 82 and react during the screwing rotation of shaft member 81 . The action of spring 81 ′ maintains a certain pull on the thread existing between shaft member 81 and plate member 82 to maintain pin 83 secure in slot 87 , when member 70 is removed for substitution.
Shaft 90 of motor 91 is coupled to ring member 76 by means of a conventional conical coupling 92 . Motor 91 is flanged to portion 93 of platform 94 . Platform 94 is assembled on guides 95 to translate in directions Y and Y′ by means of a programmable motor drive (not shown). Guides 95 are assembled on a second platform 96 , which move on guides 98 towards and away with respect to an observer view of FIG. 6 , therefore perpendicular to directions Y and Y′. The second platform 96 accomplishes this movement by means of a programmable motor drive (not shown) which turns screw 97 .
Motions of platform 94 in directions Y and Y′ and motions of second platform 96 towards and away with respect to an observer view of FIG. 6 can be used to position core 11 during termination operations. Motions of second platform 96 towards and away with respect to an observer view of FIG. 6 can also be used to position core 11 during winding, for example to stratify wire W when winding the coils.
The motion of the second platform 96 towards and away with respect to an observer view of FIG. 6 can be used to carry away the finished core, or for positioning the new core in relation to the work area of the apparatus. During this motion, portions 78 of arms 72 can come in contact with a cam surface (not shown) having a profile for moving arms 72 away from the core and therefore freeing the core so that it can be unloaded and substituted with another core to be processed.
With reference to FIGS. 8 and 9 at the end of winding a coil portion C 1 , needle 20 has wire W extending to the coil. Wire W can be extending from core 11 along an extension line 105 that is parallel to the longitudinal axis 11 ′ of the core, as shown in FIG. 9 . In FIGS. 8 and 9 needle 20 is oriented in a first orientation 103 with respect to core 11 , in which exit 20 ′ can be positioned within the perimeter of the core 11 and facing in a direction 102 away from the axis 11 ′ of the core. Successively, wire W may need to be laid as a termination lead like 100 on core 11 (shown with dashed line representation in FIG. 8 ), i.e. along an external portion 101 , which can be a channel, like is shown in FIGS. 9 and 11 .
To place the lead like 100 , needle 20 can be kept stationary and core 11 can be rotated around wire extension line 105 . The result reached is shown in FIG. 10 where needle 20 has become oriented according to a second orientation 104 with respect to core 11 , i.e. with exit 20 ′ facing in a direction 102 ′ towards axis 11 ′ of the core and a portion of needle 20 is positioned external to the core. In certain cases this second condition may not be with the needle external to the core, for example when the lead needs to be positioned on a wide axial face of the core.
The rotation of core 11 around extension line 105 can be achieved by a combination of translating platform 94 in directions Y Y′, translating second platform 96 towards and away with respect to the observer view of FIG. 6 , i.e. perpendicular to the movement in directions Y and Y′, and rotation of motor 91 , i.e. rotating core 11 around axis 11 ′.
After the condition shown in FIG. 10 is reached, needle 11 can be translated in direction X″ to align exit 20 ′ with external portion 101 of core 11 , as shown in FIG. 11 . FIG. 11 shows that exit 20 ′ can be very near to portion 101 to achieve that wire W can be deposited with accuracy and without pulling an excessive amount of wire from needle 20 during a successive rotation Z 1 of the core 11 around axis 11 ′ for laying the lead like 100 . The phantom line representation 107 of needle 20 and support members 22 and 26 shown in FIG. 9 illustrates how there can be interference with a termination tang 106 of the core when moving the needle in direction X″ for termination. The previously described rotation around an extension line like 105 avoids such interferences.
It should be contemplated that instead of moving core 11 as described above for rotation around an extension line like 105 , needle 11 could be rotated around an extension line like 105 to reach the relative position of needle 20 with respect to core 11 as shown in FIGS. 9 and 10
It will be understood that the foregoing is only illustrative of the principles of this invention, and that various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention. | Apparatus and method for winding coils C of at least one electrical conductor W for at least one core ( 11 ) of a dynamoelectric machine and for forming termination leads of the coils, the core having a longitudinal axis (H′), the apparatus and method using a dispensing member ( 20 ) and rotation of the dispensing member ( 20 ) around a rotation axis ( 25 ′) to re-orient the dispensing member between an orientation for winding the coils and an orientation for forming the termination leads. An axis of reference ( 21 ′) for the relative translation of the dispensing member ( 20 ) is positioned parallel and shifted with respect to the longitudinal axis (H′) of the core or coincident with the longitudinal axis (H′) of the core. The rotation axis ( 25 ′) is inclined with an angle that is not at 90° with respect to the dispensing member. In particular the rotation axis ( 25 ′) is inclined by an angle of 45 degrees with respect to the dispensing member ( 20 ) and the rotation axis ( 25 ′) intersects the exit of the conductor during the rotation. | 7 |
This invention relates to discs and associated equipment for cleaners of liquid-containing vessels and more particularly to automatic pool cleaners having finned discs for improved maneuverability in swimming pools.
BACKGROUND OF THE INVENTION
U.S. Pat. Nos. 4,351,077 to Hofmann and 4,642,833 to Stoltz, et al., incorporated herein in their entireties by this reference, disclose automatic, water-interruption-type suction swimming pool cleaners having flexible annular discs. These discs are typically mounted near the inlets of the suction cleaners and designed to contact pool surfaces when in use. By doing so, the discs decrease the tendency of the cleaners to disengage from pool surfaces, particularly when the cleaners are negotiating transition regions between walls and floors.
U.S. Pat. No. 4,193,156 to Chauvier, also incorporated herein in its entirety by this reference, describes (at column 4, lines 5-55) an annular disc having numerous "concertina-like," "circumferentially spaced folds." These folds extend when their associated swimming pool cleaner encounters a transition region, purportedly "keeping the inflow of water into the mouth opening to a minimum." The underside of the disc is grooved, moreover, according to the Chauvier patent, to assist in removing dust from the floors and walls of swimming pools.
Other existing swimming pool cleaner discs, including one provided by Jandy Industries, Inc., contain upwardly-extending protrusions about their peripheries. The protrusions of the Jandy disc are truncated so that they do not extend beyond the disc's periphery, however, and the periphery itself is wholly circular. Another disc distributed outside the United States combines the upwardly-extending protrusions with a scalloped periphery. Again, however, the protrusions are truncated and thereby do not extend beyond the periphery of the disc. The vertical peripheral faces of the truncated protrusions of this disc function as stops, causing the disc to move around certain obstacles extending from internal pool surfaces rather than, for example, lodging under them or moving over them.
SUMMARY OF THE INVENTION
The present invention provides alternative flexible discs for devices such as automatic swimming pool cleaners. Unlike the discs described above, the present invention incorporates upwardly-extending, non-truncated fins protruding radially from the peripheries of the discs. The serpentine peripheries themselves, moreover, define a plurality of tongues, providing increased flexibility over even existing scalloped discs. Concurrently, the fins supply sufficient rigidity to the discs of the present invention to enable them to ride over various objects, including many drains, lights, valves, and nozzles, projecting from internal surfaces of pools.
Additional features of the present invention include a curved radius between the fins and the lower surface of the disc, providing a smooth transition therebetween. The disc underside also contains an integrally-formed ramped segment surrounding its (nominally circular) central aperture. This ramp assists the pool cleaner in negotiating obstacles, supplying a smooth progression from the disc bottom to the bottom of the cleaner footpad (which the disc surrounds in use), which too may include a ramp. Multiple openings through the disc enable fluid to pass from one surface of the disc to the other, maintaining a boundary fluid layer between the lower surface of the disc and the adjacent surface of the pool. These openings facilitate movement of the disc relative to the pool cleaner and allow dirt and debris to be entrained in the flow of fluid through the openings and in the boundary layer.
It is therefore an object of the present invention to provide a disc incorporating upwardly-extending, non-truncated fins protruding beyond its periphery.
It is another object of the present invention to provide a disc having a serpentine periphery forming a plurality of tongues for increased flexibility.
It is a further object of the present invention to provide a disc facilitating movement of an automatic swimming pool cleaner over various objects projecting from internal surfaces of pools.
It is an additional object of the present invention to provide a disc having a curved radius between fins and its lower surface.
It is yet another object of the present invention to provide a disc having an underside containing a ramped segment surrounding its central aperture.
It is, moreover, an object of the present invention to provide a disc including multiple openings therethrough, enabling fluid to pass from one surface of the disc to the other.
It is a further object of the present invention to provide a ramped footpad for use in connection with an automatic swimming pool cleaner.
Other objects, features, and advantages of the present invention will become apparent with reference to the remainder of the text and the drawings of this application.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of a disc (and footpad) of the present invention.
FIG. 2 is a perspective view of a portion of the disc of FIG. 1.
FIG. 3 is a bottom plan view of the disc and footpad of FIG. 1.
FIG. 4 is a cross-sectional view of the disc and footpad of FIG. 1 taken along lines 4--4 of that figure.
FIG. 5 is a top plan view of an alternate disc of the present invention.
FIG. 6 is a cross-sectional view of the disc of FIG. 5 taken along lines 6--6 of that figure.
DETAILED DESCRIPTION
FIGS. 1-4 illustrate disc 10 of the present invention. Disc 10 defines a central aperture 14, nominally circular, in which a footpad 16 of an automatic swimming pool cleaner may be received, for example. Disc 10 also defines a generally planar upper surface 18, a periphery 20 and, as shown in FIG. 3, a lower surface 22. Extending upward from and spaced about upper surface 18 are fins 26, which assist disc 10 in maneuvering over many objects (such as drains, lights, valves, and nozzles) projecting from internal surfaces of pools. Fins 26 additionally extend beyond periphery 20, causing them to contact most projections before the remainder of disc 10.
FIGS. 1-3 also detail the serpentine nature of periphery 20. The shape of periphery 20 defines multiple tongues 30, increasing the flexibility of disc 10 and on which an equivalent number of fins 26 are positioned. Although forty-eight tongues are shown in FIG. 1, such number of tongues (and fins) is not required and may vary as necessary or desired. Openings 34 through disc 10 enable fluid to pass between upper and lower surfaces 18 and 22 of disc 10 when in use, maintaining a boundary fluid layer between the lower surface 22 of disc 10 and the adjacent surface of the pool or other structure to be cleaned.
Shown in FIGS. 2-4 is ramp 38, projecting from lower surface 22 of disc 10 and positioned concentrically about central aperture 14. Ramp 38 promotes a smooth transition between lower surface 22 and the bottom of footpad 16 (or other component) received by central aperture 14, facilitating unobstructed movement of a swimming pool cleaner associated with the footpad 16. FIGS. 2 and 4 similarly disclose radius 42 existing between fins 26 and lower surface.22 of disc 10, providing a smooth transition therebetween.
In an embodiment of the invention consistent with FIGS. 1-4, fins 26 are spaced approximately every 7.5° about periphery 20. This spacing of fins 26 precludes sufficiently small-diameter objects from becoming entangled between adjacent fins 26 as an associated swimming pool cleaner moves about the surfaces of a pool. Instead, fins 26, including radii 42 and the remainders of their curved leading edges 46, are designed to ride over the objects, thereby carrying the associated swimming pool cleaner over the obstacles as well. Evenly spacing fins 26 about periphery 20 and having them extend radially from periphery 20 cause disc 10 to be more flexible than, for example, having the entirety of its periphery 20 raised (like a dinner plate). Fins 26 additionally assist in bending disc 10 to remain in contact with vertical or angled walls extending from the bottom surface of the swimming pool.
FIG. 4 details various angular and distance relationships between a fin 26 and disc 10. As shown in FIG. 4, leading edge 46 of fin 26 forms an angle "φ" with axis 48, an extension of a radius of lower surface 22, while "D" describes the distance between the uppermost portion 49 of fin 26 and axis 48. In at least one embodiment of the invention, φ is approximately 45° and D equals 1.06 inches. Fins 46 may be made of plastic or other flexible material and integrally molded with disc 10, facilitating uniformity of these angular and distance relationships between fins 26 of a disc 10 and between discs 10 themselves. In some embodiments, disc 10 has an approximate diameter of fourteen inches measured from the center of central aperture 14 to the outermost extension of fins 46.
FIGS. 5-6 illustrate an alternate disc 50 of the present invention. Although including tongues 54 and fins 58 similar to disc 10, the number of each is not identical. Rather, twice as many tongues 54 as fins 58 are present for disc 50. Consequently, fins 58 are positioned (at approximately 15° intervals) about the periphery 62 of disc 50 on alternating tongues 54. The increased spacing between fins 58 permits larger leaves and other debris to pass between them to the inlet of the swimming pool cleaner to which disc 50 may be attached in use. At the same time, tongues 54 lacking associated fins 58 remain sufficiently flexible so that they bend when encountering obstacles, enabling the adjacent fins 58 and tongues 54 to continue passing over the obstacles.
Although discs 10 and 50 can be attached to existing footpads, footpad 16 shown in FIGS. 1, 3, and 4 provides an alternative device for connecting a disc to an automatic swimming pool cleaner. Like ramp 38 of lower surface 22, the outer surfaces 64 of footpad 16 are sloped to continue the smooth transition from lower surface 22 to the mouth of an automatic swimming pool cleaner. Rear interior surface 66 is similarly ramped or sloped to facilitate dislodging a swimming pool cleaner from small diameter obstacles extending from the pool surface. Footpad 16 additionally includes slots 68 and 70 through which water and entrained debris may flow. As illustrated in FIGS. 3 and 4, slots 68 are spaced approximately 45° about footpad 16, with larger slog 70 occupying the rear of the footpad 16.
The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of the present invention. Modifications and adaptations to these embodiments will be apparent to those of ordinary skill in the art and may be made without departing from the scope or spirit of the invention. | Discs and a footpad for devices such as automatic swimming pool cleaners are disclosed. The discs incorporate upwardly-extending, non-truncated fins protruding radially from their peripheries. The peripheries themselves, moreover, define a plurality of tongues for increased flexibility, and both the discs and footpad may include ramped segments facilitating movement over obstacles extending from swimming pool surfaces. | 4 |
This application is the U.S. national phase of International Application No. PCT/CN2013/087736 Filed on 24 Nov. 2013 which designated the U.S. and claims priority to Chinese Application Nos. CN201210504310.8 filed on 30 Nov. 2012, the entire contents of each of which are hereby incorporated by reference.
BACKGROUND
Technical Field
The present invention relates to the field of medicinal chemistry, and in particular, to a 2-aryl selenazole compound and application thereof. The present invention further relates to a method for preparing the compound, a pharmaceutical composition including the compound, and medical uses thereof, especially application as a xanthine oxidase inhibitor in treatment of gout and hyperuricemia.
Related Art
Gout is a disease caused by deposition of sodium urate in vivo when an excessively great amount of uric acid is generated due to disorder of purine metabolism in vivo. Gout is a second largest metabolism disease following diabetes, and has been listed by UN as one of the twenty most chronic and stubborn diseases in 21 st century. According to epidemiological studies at home and abroad, with improvement of living level and increase of average lifetime of human beings, the incidence of hyperuricemia and gout shows an increasing tendency. It was reported that, during ten years from 1990 to 1999, the incidence of gouty arthritis in U.S. was increased from 0.29% to 0.52% (Arthur L. Weaver. Epidemiology of gout [J]. Cleveland Clinic Journal of Medicine 2008, 75 (Suppl 5): S9-S12); in a national health investigation carried out between 2007 and 2008, 8.3 million Americans reported that they were informed by their doctors that they suffered from gout; and the incidence thereof in UK and German was 1.4% during a period from 2000 to 2005 (L. Annemans, E Spaepen, M Gaskin, et al. Gout in the UK and Germany: prevalence, comorbidities, and management in general practice 2000-2005 [J]. Ann Rheum Dis, 2008, 67: 960-966). From an epidemiological study for 3978 urban persons aged 40 to 74, which was carried out in China in 2010, it was shown that 25% of investigated persons suffered from hyperuricemia (Raquel Villegas, Yong bing Xiang, Qiu yin Cai, et al. Prevalence and Determinants of Hyperuricemia in Middle-Aged, Urban Chinese Men [J]. Metabolic Syndrome and Related Disorders, 2010, 8(3):263-270); and the incidence thereof in inland regions was lower than that in coastal regions, while the incidence thereof in undeveloped areas was lower than that in developed areas (Hairong Nan, Qing Qiao, Yanhu Dong, et al. The prevalence of hyperuricemia in a population of the coastal city of Qingdao, China [J]. The Journal of Rheumatology, 2006, 33(7):1346-1350.). According to an analysis report from the Chinese Center for Diseases and Health Investigation in 2004, the number of hyperuricemia patients had then reached 0.12 billion in China, including more than 75 million gout patients, and in addition, the number was increasing at an annual growth rate of 0.97%, which seriously endangers people's life and health.
The occurrence of gout is caused by hyperuricemia due to constant increase of uric acid level in vivo. With supersaturation of uric acid level, sodium urate is crystallized and deposited in such sites as joints and soft tissues. When the uric acid level in vivo changes rapidly, and a partial wound leads to release of microcrystals or change of urate crystal protein coating, an inflammatory reaction of gout is caused, and then gout is induced. Uric acid is an end product of purine metabolism in nucleic acid (including nucleic acid in foods) in vivo. The content thereof is related with catabolism rate of nucleic acid in vivo and renal excretory function. When the generation of uric acid increases or excretion of uric acid reduces, it may both lead to deposition of uric acid and occurrence of hyperuricemia. It is generally believed that hyperuricemia occurs when the content of uric acid in serum is >420 μmol/L (70 mg/L) for male and >360 μmol/L (60 mg/L) for female at 37° C.
Gout may also cause many complications. According to statistics, for 90% gout patients, impotence, nephritis, calculus and the like will be induced, and complications such as chronic nephrosis and heart diseases may also be caused; for 50% patients, serious deformation of joints easily occurs and then causes disability; and for 30% patients, diseases such as uremia and renal failure are easily induced and then cause death (Grobner W, Walter-Sack I. Treatment of hyperuricemia and gout [J]. Med Monatsschr Pharm. 2005, 28(5): 159-164). Gout is also related with multiple diseases such as hypertension, metabolic syndrome, hyperlipidaemia, diabetes and insulin resistance (Terkeltaub R A. Clinical practice. Gout [J]. N Engl J Med. 2003, 349: 1647-1655) (Schlesinger N, Schumacher H R Jr. Gout: can management be improved ? [J]. Curr Opin Rheumatol. 2001, 13: 240-244).
Currently, medicines used for gout treatment mainly include anti-inflammatory agents, uricosuric drugs and uric acid production inhibitors.
Some anti-inflammatory agents such as colchicines, non-steroidal anti-inflammatory drugs (NSAIDS), adrenocorticotrophic hormone (ACTH), and glucocorticoid are mainly used for treatment of acute gouty arthritis, which can relieve patients from temporary pains. Colchicines is often accompanied by common adverse reactions such as diarrhea, emesis, and a spasm of abdominal pain; and non-steroidal anti-inflammatory drugs can relieve pains within a short period, but most of the non-steroidal anti-inflammatory drugs are accompanied by a serious gastrointestinal reaction. Adrenocorticotrophic hormone and glucocorticoid can inhibit infective inflammation, reduce hyperemia and edema, inhibit movement of inflammatory cells, and reduce individual immune level, which are used for treatment of severe acute gout patients accompanied with constitutional symptoms. However, such drugs have a strong rebound effect.
The uric acid level in vivo shall be reduced radically so as to better cure gout. The uric acid level in vivo is reduced mainly by two means of promoting uric acid excretion and reducing uric acid generation. Currently, drugs for promoting uric acid excretion in vivo mainly include probenecid, anturan, benzbromarone and the like. These drugs can inhibit reabsorption of uric acid by kidney tubules, and act on urate transporters of renal proximal tubules, thereby inhibiting reabsorption of uric acid, increasing excretion thereof, and consequently reducing the concentration of uric acid in vivo. Probenecid is developed by Merck Corp. (U.S.), with main side-effects of erythra, severe gastrointestinal stimulation, drug fever and the like. Benzbromarone (Narcaricin) developed by Sanofi-Synthelabo Ltd (France) and marketed since 1976, and anturan developed by Navatris Corp. (U.S.) and marketed since 1959, have the same action principle as probenecid. It was found through researches that due to main side-effects of such drugs, urine shall be alkalized when the drugs are administered to patients, and the drugs cannot be applied in patients with renal insufficiency. In addition, it was reported according to researches that benzbromarone has a very great hepatotoxicity, and so has been withdrawn from most of the European market (Jansen T L, Reinders M K, van Roon E N, et al. Benzbromarone with drawn from the European market: another case of “absence of evidence is evidence of absence”? [J]. Clin Exp Rheumatol, 2004, 22 (5):651).
Another type of drugs used for gout treatment are uric acid production inhibitors. Researches indicated that such drugs mainly inhibits transformation of purine to uric acid through inhibiting the activity of xanthine oxidase (XO) required in the procedure of purine metabolism, so as to radically reduce generation of uric acid, thereby taking effect of gout treatment. Allopurinol marketed in 1960s, as an analogue of hypoxanthine, is a competitive inhibitor of xanthine oxidase. Allopurinol is mainly applied in patients with renal insufficiency. Although allopurinol has been applied for half a century, patients are often accompanied with fever, allergic eruption, abdominal pain, diarrhea, and reduction of leukocytes and platelets, and it even has side-effects such as hepatic function damage. It was found through researches that oxipurinol, a metabolite of allopurinol, can also inhibit the activity of xanthine oxidase, but it was also found that toxic and side effects of allopurinol are also resulted from a metabolite thereof such as oxipurinol.
Febuxostat is a new generation of xanthine oxidase inhibitor, which is applied clinically in prevention and treatment of hyperuricemia and induced gout. Teijin (Japan) applied for marketing of febuxostat at the beginning of 2004, EU approved marketing thereof in May, 2008 and FDA (U.S.) approved marketing thereof in February 2009. Febuxostat can inhibit oxidation and reduction states of xanthine oxidase. By comparison, allopurinol has a weak capability of inhibiting oxidation state of xanthine oxidase. Febuxostat is metabolized mainly though hepar, while allopurinol is metabolized and excreted mainly through kidney, which can better avoid adverse effects of allopurinol caused by renal metabolism and excretion (Takano Y, Hase-Aoki K, Horiuchi H et al. Selectivity of febuxostat, a novel non-purine inhibitor of xanthine oxidase/xanthine dehydrogenase [J]. Life Sci. 2005, 76: 1835-1847) (Becker M A, schumacher H R Jr, Wortman R L. Febuxostat compared with allopurinol in patients with hyper-uricemia and gout [J]. N Engl J Med. 2005, 353: 2450-2461). According to a Phase III clinical test report, compared with a control group, the uric acid level of plasma in a treatment group is lower than 60 mg/L after completion of treatment. Patients sensitive to allopurinol can better adapt to febuxostat. Compared with a dosage of 300 mg/d allopurinol, a dosage of 80 mg/d to 120 mg/d febuxostat can more effectively reduce the urate level of plasma (Pohar S, Murphy G. Febuxostat for prevention of gout attacks [J]. Issues Emerg Health Technol. 2006, 87:1-4).
Xanthine oxidase inhibitors with a target spot of xanthine oxidase are all almost heterocyclic compounds till now, and are mostly nitrogen heterocyclic aromatic compounds, for example, phenyl pyrazole derivatives (WO9818765, JP10310578), 2-phenyl thiazole derivatives (WO9631211, JP2002105067), 3-phenyl isothiazole derivatives (JP6211815), C-fused pyridine derivatives (WO2005121153), 2-phenyl thiophene derivatives (WO2006022375), 2-phenyl pyridine derivatives (WO2006022374), aryltriazole compounds (Nakazawa T, Miyata K, Omura K, et al. Metabolic profile of FYX-051 (4-(5-pyridin-4-yl-1H-[1,2,4]triazol-3-yl)pyridine-2-carbonitrile) in the rat, dog, monkey, and human: identification of N-glucuronides and N-glucosides [J]. Drug Metab Dispos, 2006, 34(11): 1880-1886), triaryl formic acid derivatives (WO2007043457), and the like as reported. Because such drugs can radically reduce generation of uric acid and take effect of gout treatment, great importance is attached to development of the drugs. With further research on a target spot of xanthine oxidase, and constant development of computers and the like, crystal structure of xanthine oxidase is completely analyzed, so as to further identify function mechanism of the drugs, thereby establishing a necessary basis for research on these drugs.
In last decades, the development of xanthine oxidase inhibitors was slow, which is related with a small proportion of hyperuricemia and gout patients. However, the incidence of hyperuricemia and gout showed an increasing tendency in recent years, which attracted great attention of researchers on anti-gout drug studies. Meanwhile, with further research on xanthine oxidase and reductase, it was found that inhibition of the activity of xanthine oxidase and reductase can contribute to treatment of hyperuricemia, and has a certain treatment effect of ischemia/ischemia-reperfusion injury and especially heart failure, which indicates that a xanthine oxidase inhibitor with high efficiency and low toxicity has huge development potentials and application values. With respect to the chronic and stubborn disease of gout, design of new drugs with an action target of xanthine oxidase has attracted great attention widely. Multiple compounds with high activity have gone through clinical tests. However, there are many problems faced such as great toxic and side effects, which need to be researched more deeply.
SUMMARY
An objective of the present invention is to provide a 2-aryl selenazole compound based on the prior art.
Another objective of the present invention is to provide application of the 2-aryl selenazole compound in terms of preparing a xanthine oxidase inhibitor, or preparing a drug used for prevention or treatment of hyperuricemia, gout, diabetic nephropathy, an inflammatory disease, a neurological disease and the like.
The objectives of the present invention can be achieved by the following measures:
A 2-aryl selenazole compound represented by formula (I) or a pharmaceutically acceptable salt thereof is provided,
where,
X is selected from C 1-2 alkyl or substituted C 1-2 alkyl;
Y is selected from —COOR a or —CONHR a ;
R 1 is selected from halogen, —CN, C 1-2 alkyl, substituted C 1-2 alkyl, C 1-3 alkoxy, or substituted C 1-3 alkoxy;
R 2 is selected from H, D, halogen, C 1-2 alkyl, substituted C 1-2 alkyl, C 1-3 alkoxy, or substituted C 1-3 alkoxy; and
R 3 is selected from —(CH 2 ) n —O—R b , —(CH 2 ) n —S—R b , —C(O)R b , —NR c R d , —S(O)CHR c R d , —S(O) 2 CHR c R d , —(CH 2 ) n C(O)NR c R d , aryl, substituted aryl, a heterocyclic radical, a substituted heterocyclic radical, a heteroaryl radical, or a substituted heteroaryl radical, where,
n is 0 to 2;
R a is selected from H, C 1-6 alkyl or substituted C 1-6 alkyl;
R b is selected from H, C 1-8 alkyl, substituted C 1-8 alkyl, aryl, substituted aryl, a heterocyclic radical, a substituted heterocyclic radical, a heteroaryl radical, or a substituted heteroaryl radical; and
R c and R d are respectively independently selected from H, C 1-8 alkyl, or substituted C 1-8 alkyl; or R c and R d are cyclized to form a cycloalkyl, a substituted cycloalkyl, a heteroaryl radical, or a substituted heteroaryl radical; and
A substituent in groups X, Y, R 1 , R 2 , R 3 , R a , R b , R c or R d is selected from one or more of D, —OH, —CN, —NH 2 , acyl, acylamino, halogen, C 1-4 alkyl, halogenated C 1-4 alkyl, deuterated C 1-4 alkyl, C 1-2 alkoxy, or C 1-2 aminoalkyl.
In a preferred solution, the 2-aryl selenazole compound of the present invention may further be a compound with the structure of formula (II) or a pharmaceutically acceptable salt thereof.
In a preferred solution, X is C 1-3 alkyl, or halogenated or hydroxy-substituted C 1-3 alkyl.
Further, X is —CH 3 , —CH 2 CH 3 , —CH 2 OH or —CF 3 .
Further, X is —CH 3 .
In a preferred solution, Y is —COOR a , and R a is H, C 1-3 alkyl, or substituted C 1-3 alkyl.
Further, Y is —COOH.
In a preferred solution, R 1 is selected from halogen, —CN, C 1-2 alkyl, halogenated C 1-2 alkyl, C 1-2 alkoxy, or halogenated C 1-2 alkoxy.
Further, R 1 is selected from halogen, —CN, —CH 3 , —CH 2 CH 3 , —CHF 2 , —CF 3 , —OCHF 2 , or —OCF 3 .
Further, R 1 is selected from Cl, Br, —CN, or —CF 3 .
In a preferred solution, R 2 is selected from H or D.
In a preferred solution, the compound of the present invention may be a compound represented by formula (III) or a pharmaceutically acceptable salt thereof.
In a preferred solution, R 3 is selected from —OR b , —SR b , —C(O)R b , —NR c R d , —S(O)CHR c R d , —S(O) 2 CHR c R d , —C(O)NR c R d , phenyl, substituted phenyl, pyridyl, substituted pyridyl, naphthyl, substituted naphthyl, phenoxy, substituted phenoxy, thiophenyl, substituted thiophenyl, morpholinyl, substituted morpholinyl, N-ethyl morpholinyl, substituted N-ethyl morpholinyl, piperazinyl, substituted piperazinyl, 4,5,6,7-tetrahydrothieno[3,2-c]pyridyl, methylphenyl sulfonyl, or substituted methylphenyl sulfonyl.
Further, R 3 is selected from —OR b , —SR b , —C(O)R b , —NR c R d , —S(O) 2 CHR c R d , —C(O)NR c R d , phenyl, substituted phenyl, pyridyl, substituted pyridyl, naphthyl, substituted naphthyl, quinolyl, substituted quinolyl, thiophenyl, substituted thiophenyl, phenoxy, substituted phenoxy, pyridylthio, morpholinyl, piperazinyl, substituted piperazinyl, or 4,5,6,7-tetrahydrothieno[3,2-c]pyridyl.
In a preferred solution, R b is C 1-8 alkyl, substituted C 1-8 alkyl, phenyl or substituted phenyl; R c or R d is independently selected from H, C 1-8 alkyl, or substituted C 1-8 alkyl; or R c and R d are cyclized to form cycloalkyl, substituted cycloalkyl, a heteroaryl radical, or a substituted heteroaryl radical.
In a preferred solution, the substituent is selected from one or more of D, —OH, —NH 2 , —CN, acyl, halogen, C 1-4 alkyl, halogenated C 1-4 alkyl, deuterated C 1-4 alkyl, or C 1-2 alkoxy.
Further, the substituent is selected from one or more of D, —OH, —NH 2 , —CN, —NHCH 3 , —F, —Cl, —Br, —CH 3 , —CH 2 CH 3 , —CHDCH 2 D, —CF 3 , —OCH 3 , or —OCH 2 CH 3 .
In another preferred solution, R 3 is selected from —OCH 2 CH 3 , —OCH(CH 3 ) 2 , —OCH 2 CH(CH 3 ) 2 , —OCH 2 CH 2 CH(CH 3 ) 2 , —OCH 2 C 6 H 11 , —OCH 2 C 3 H 5 , —SCH(CH 3 ) 2 , —SCH 2 CH(CH 3 ) 2 , —S(O) 2 CH(CH 3 ) 2 , —CH 2 SCH(CH 3 ) 2 , —N(CH 3 ) 2 , phenyl, methoxyphenyl, dimethoxyphenyl, trimethoxyphenyl, methoxyfluorophenyl, trifluoromethoxyphenyl, chlorophenyl, difluorophenyl, pentadeuterophenyl, methylpiperazinylphenyl, aniline formyl, benzylthio, benzyloxy, naphthyl, pyridyl, pyridylthiophenyl, dideuteroethylpyridyl, thiophenyl, chlorothiophenyl, (trifluoromethyl)phenyl, (trifluoromethylthio)phenyl, morpholinyl, methylpiperazinyl, or 4,5,6,7-tetrahydrothieno[3,2-c]pyridyl.
The 2-aryl selenazole compound of the present invention may further be selected from the following compounds or pharmaceutically acceptable salts thereof:
2-(3-cyano-4-ethoxyphenyl)-4-methyl-selenazole-5-carboxylic acid, 2-(3-cyano-4-isobutoxyphenyl)-4-methyl-selenazole-5-carboxylic acid, 2-(3-cyano-4-isopropoxyphenyl)-4-methyl-selenazole-5-carboxylic acid, 2-[3-cyano-4-(3-methyl-butoxy)phenyl]-4-methyl-selenazole-5-carboxylic acid, 2-[3-cyano-4-(cyclohexylmethoxy)phenyl]-4-methyl-selenazole-5-carboxylic acid, 2-[3-cyano-4-(benzyloxy)phenyl]-4-methyl-selenazole-5-carboxylic acid, 2-[3-cyano-4-(cyclopropylmethoxy)phenyl]-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-biphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-3′,4′-dimethoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-3′-fluoro-4′-methoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-3′,4′,5′-trimethoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-4′-methoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-3′-methoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-3′-trifluoromethoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-4′-chlorobiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-3′,4′-difluorobiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-2′,3′,4′,5′,6′-pentadeuterobiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-2′-methoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-2′,4′-dimethoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-[3-cyano-4-(1-naphthyl)-phenyl]-4-methyl-selenazole-5-carboxylic acid, 2-[3-cyano-4-(4-pyridyl)-phenyl-4-yl]-4-methyl-selenazole-5-carboxylic acid, 2-[3-cyano-4-(3-pyridyl)-phenyl-4-yl]-4-methyl-selenazole-5-carboxylic acid, 2-[2-cyano-4′-(1,2-deuteroethyl)-biphenyl-4-yl]-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-6-deuterobiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(3-cyano-4-isopropylthiophenyl)-4-methyl-selenazole-5-carboxylic acid, 2-(3-cyano-4-isobutylthiophenyl)-4-methyl-selenazole-5-carboxylic acid, 2-[3-cyano-4-(4-chrolophenylthio)-phenyl]-4-methyl-selenazole-5-carboxylic acid, 2-[3-cyano-4-(3-trifluoromethylthiophenyl)-phenyl]-4-methyl-selenazole-5-carboxylic acid, 2-[3-cyano-4-(2-pyridylthio)-phenyl]-4-methyl-selenazole-5-carboxylic acid, 2-(3-cyano-4-benzylthio-phenyl)-4-methyl-selenazole-5-carboxylic acid, 2-(3-cyano-4-isopropyl sulfone-phenyl)-4-methyl-selenazole-5-carboxylic acid, 2-(3-cyano-4-morpholinyl-4-yl-phenyl)-4-methyl-selenazole-5-carboxylic acid, 2-[3-cyano-4-(4-methylpiperazine-1-yl)phenyl]-4-methyl-selenazole-5-carboxylic acid, 2-{3-cyano-4-(6,7-dihydro-4H-thieno[3,2-c]pyridyl)-phenyl}-4-methyl-selenazole-5-carboxylic acid, 2-(3-cyano-4-dimethylamino-phenyl)-4-methyl-selenazole-5-carboxylic acid, 2-(3-chloro-4-isobutoxyphenyl)-4-methyl-selenazole-5-carboxylic acid, 2-(3-trifluoromethyl-4-isobutoxyphenyl)-4-methyl-selenazole-5-carboxylic acid, 2-[3-cyano-4-(isopropylthiomethyl)-phenyl]-4-methyl-selenazole-5-carboxylic acid, 2-[3-bromo-4-(aniline formyl)-phenyl]-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-4′-trifluoromethylbiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-3′-trifluoromethylbiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(2-cyano-2′-trifluoromethylbiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid, 2-(3-cyano-4-isobutoxyphenyl)-4-hydroxymethyl-selenazole-5-carboxylic acid, 2-(3-bromo-4-isobutoxyphenyl)-4-methyl-selenazole-5-carboxylic acid, 2-(3-cyano-4-isopropylthiophenyl)-4-methyl-selenazole-5-carboxylic acid-(2-N-acetyl)ethyl ester, 2-(3-cyano-4-tertbutylthiophenyl)-4-methyl-selenazole-5-carboxylic acid, 2-(3-cyano-4-cyclohexylthiophenyl)-4-methyl-selenazole-5-carboxylic acid, 2-(3-trifluoromethylphenyl)-4-methyl-selenazole-5-carboxylic acid.
A compound of the present invention, 2-(3-cyano-4-isopropylthiophenyl)-4-methyl-selenazole-5-carboxylic acid-(2-N-acetyl)ethyl ester may be a prodrug of 2-(3-cyano-4-isopropylthiophenyl)-4-methyl-selenazole-5-carboxylic acid.
The compound of the present invention has the following synthesis routes:
Synthesis Route 1:
Synthesis Route 2:
The compound of the present invention may be prepared by using the foregoing methods or similar methods, and corresponding raw materials are selected according to different substituents and different positions of a substituent. Special preparation methods will be described in detail with reference to embodiments.
Unless otherwise stated, the following terms as used in the claims and specification are defined below:
“Hydrogen” refers to protium (1H), a primary stable isotope of hydrogen element.
“Deuterium” refers to a stable form of hydrogen, also called heavy hydrogen, with an element symbol of D.
“Alkyl” refers to a saturated aliphatic alkyl group having 1 to 20 carbon atoms, including a straight chain and a branched chain group (a numerical range mentioned herein, for example, “1 to 20”, indicates that the group (an alkyl group here) may contain 1 carbon atom, 2 carbon atoms, 3 carbon atoms, and so forth, till 20 carbon atoms). An alkyl group containing 1 to 4 carbon atoms is called lower alkyl. When a lower alkyl has no substituent, it is called unsubstituted lower alkyl. More preferably, the alkyl is an alkyl group of a moderate size having 1 to 10 carbon atoms, for example, methyl, ethyl, propyl, 2-propyl, butyl, isobutyl, tertiary butyl, amyl, and the like. Most preferably, the alkyl is a lower alkyl group having 1 to 4 carbon atoms, for example, methyl, ethyl, propyl, 2-propyl, butyl, isobutyl, tertiary butyl, or the like. The alkyl may be substituted or unsubstituted.
“Cycloalkyl” in the present invention refers to a group of an all-carbon single or fused ring (the “fused” ring means that each ring in a system shares an adjacent pair of carbon atoms with another ring in the system), where one or more rings have no fully-connected π electron system, and the group generally has 3 to 10 carbon atoms. Embodiments of the cycloalkyl include (but are not limited to) cyclopropane, cyclobutane, cyclopentane, cyclopentene, cyclohexane, adamantane, cyclohexadiene, cycloheptane and cycloheptatriene. The cycloalkyl may be substituted or unsubstituted.
“Heterocyclic radical” in the present invention includes “heterocyclic alkyl” and “heterocyclic aryl”. The “heterocyclic alkyl” refers to a group of a single ring or saturated fused ring containing at least one heteroatom (the “fused” ring means that each ring in a system shares an adjacent pair of carbon atoms with another ring in the system), where one or more rings have no fully-connected π electron system, and the group generally has 3 to 10 carbon atoms. The “heterocyclic aryl” in the present invention refers to a group of a single or fused ring having 5 to 12 annular atoms, which contains 1, 2, 3 or 4 heterocyclic atoms selected from N, O or S in addition to other carbon atoms, and also has a fully conjugated π electron system. Embodiments of unsubstituted heterocyclic aryl include but are not limited to pyrrole, furan, thiophene, imidazole, oxazole, thiazole, pyrazole, pyridine, quinoline, isoquinoline, purine, tetrazole, triazine and carbazole. The heterocyclic aryl may be substituted or unsubstituted.
“Aryl” in the present invention refers to a group of an all-carbon single ring or a polycyclic fused ring containing 6 to 12 carbon atoms, which has a fully conjugated it electron system. Embodiments of the aryl include but are not limited to phenyl, naphthyl and naphthyl. The alkyl may be substituted or unsubstituted.
“Hydroxyl” refers to a —OH group.
“Alkoxy” refers to a —O-(unsubstituted alkyl) group and a —O-(unsubstituted cycloalkyl) group, and further represents a —O-(unsubstituted alkyl) group. Typical embodiments thereof include but are not limited to methoxyl, ethoxyl, propoxyl, butoxyl, cyclopropoxyl, cyclobutoxyl, cyclopentyloxy, cyclohexyloxyl, and the like.
“Phenyl” refers to a group of a benzene ring
with any position thereon connected with another group.
“Thiophenyl” refers to a —S-phenyl group.
“Phenoxyl” refers to a —O-phenyl group.
“Alkylcarbonyl” refers to a group of (unsubstituted alkyl)-C(═O)— and a group of (unsubstituted cycloalkyl)-C(═O)—, and further refers to the former.
“Halogen” refers to fluorine, chlorine, bromine or iodine, and is preferably fluorine, chlorine, or bromine.
“Cyano” refers to a —CN group.
“Nitryl” refers to a —NO 2 group.
“Acyl” refers to a —C(O)Q group, where Q may be hydrogen (then the acyl formed is formyl), and may also be alkyl, aminoalkyl, aryl and aminoaryl, for example, acetyl, propionyl, phenylcarbamoyl, benzoyl, and the like.
“Amino” refers to a —NH 2 group.
“Aminoalkyl” refers to a —NH-alkyl group.
“Deuterated alkyl” refers to a group where one or more hydrogen atoms of an alkyl group are substituted by deuterium atoms.
“Naphthyl” refers to a group of a naphthalene ring
with any position thereon connected with another group.
“Pyridyl” refers to a group of a pyridine ring
with any one of positions 2 to 6 thereon connected with another group.
“Thiopyridyl” refers to a —S-pyridyl group.
“Morpholinyl” refers to a group of a morpholine ring
with any one (including N—) of positions 2 to 6 thereon connected with another group.
“Piperazinyl” refers to a group of a piperazine ring
with any position (including N—) thereon connected with another group.
“Methylphenyl sulfonyl” refers to a group of methyl phenyl sulfone
with CH 3 —thereon connected with another group.
“4,5,6,7-Tetrahydrothieno[3,2-c]pyridyl” refers to a group of 4,5,6,7-tetrahydrothieno[3,2-c]pyridine ring
with any one (including N—) of positions available for connection with another group being connected with another group.
“C 3-8 ” and “C 1-8 ” in a group of “C 1-8 alkoxy substituted by C 3-8 cycloalkyl” in the present invention only restricts the number of carbon atoms of an adjacent group thereof, rather than the number of carbon atoms of the whole group.
“Pharmaceutically acceptable salt” refers to a salt formed by a compound of formula (I) or (II) and an organic or inorganic acid, representing salts that maintain the bio-availability and properties of a parent compound. The salts include:
(1) a salt formed by reaction with an acid, that is, obtained from reaction of free alkali of a patent compound and an inorganic or organic acid, where the inorganic acid includes (but is not limited to) hydrochloric acid, hydrobromic acid, nitric acid, phosphoric acid, metaphosphoric acid, sulfuric acid, sulphurous acid, and perchloric acid; and the organic acid includes (but is not limited to) acetic acid, propionic acid, acrylic acid, oxalic acid, D- or L-malic acid, fumaric acid, maleic acid, hydroxybenzoic acid, γ-hydroxybutyric acid, methoxybenzoic acid, phthalic acid, methanesulfonic acid, ethanesulfonic acid, naphthalene-1-sulfonic acid, naphthalene-2-sulfonic acid, p-toluenesulfonic acid, salicylic acid, tartaric acid, citric acid, lactic acid, mandelic acid, succinic acid, or malonic acid.
(2) a salt generated by an acidic proton present in a parent compound being substituted by a metal ion, or coordinated with an organic alkali, where the metal ion is, for example, an alkali metal ion, an alkaline-earth metal ion, or an aluminum ion; and the organic alkali is, for example, ethanol amine, diethanol amine, triethanol amine, trometamol, N-methyloctanamide, or the like.
“Pharmaceutical composition” refers to one or more compounds described herein or a pharmaceutically acceptable salt thereof, a prodrug, and another chemical composition, for example, a mixture of a pharmaceutically acceptable carrier and excipient. The pharmaceutical composition is used to promote administration of a compound to an organism.
“Prodrug” refers to a compound that takes a pharmacological effect only after being transformed in vivo. The prodrug itself has no or low bioactivity, and is transformed to an active substance through metabolism in vivo. This process aims to increase the bio-availability of drugs, enhance targeting, and reduce the toxicity and side effects of drugs.
The present invention provides a pharmaceutical composition, including any compound or pharmaceutically acceptable salt thereof in the present invention as an active ingredient.
The compound of the present invention or a pharmaceutically acceptable salt thereof can be applied in terms of preparing a xanthine oxidase inhibitor drug.
The compound of the present invention or a pharmaceutically acceptable salt thereof can be applied in terms of preparing a drug used for prevention or treatment of hyperuricemia, gout, diabetic nephropathy, an inflammatory disease or a neurological disease.
BRIEF DESCRIPTION OF THE DRAWINGS
DETAILED DESCRIPTION
The following preparation examples and embodiments are provided so that a person skilled in the art can more clearly understand and implement the present invention. They shall not be construed as a limitation on the scope of the present invention, but are merely used for illustration and representation thereof.
SYNTHESIS EMBODIMENTS
Embodiment 1
Synthesis of 2-(3-cyano-4-ethoxyphenyl)-4-methyl-selenazole-5-carboxylic acid (6)
Step A: Anhydrous ethanol (540 mL) was added dropwise into a mixture of selenium powder (50.0 g, 0.633 mol) and sodium borohydride (26.4 g, 0.698 mol) within 3 h to 4 h under the protection of nitrogen in an ice-water bath, then heated to room temperature, and stirred for 1 h. The mixture was then added with pyridine solution (126 mL) containing 4-cyanophenol (18.84 g, 0.158 mol), and heated until reflux occurred. After 2M hydrochloric acid solution (320 mL) was added dropwise slowly for no less than 4 h, the resulting solution was stirred overnight under reflux. A TLC analysis indicated that the reaction was completed. The solution was distilled under reduced pressure to remove most of ethanol, added with water (400 mL) for dilution, and extracted with ethyl acetate (200 mL×2). The combined organic phase was washed with 2M hydrochloric acid (100 mL), and then washed with saturated saline solution (100 mL). After the solvent was removed by means of reduced pressure distillation, the resulting product was recrystallized with petroleum ether/ethyl acetate, to obtain p-hydroxy-seleno-benzamide (1) (25.0 g), with a yield of 79.1%.
Step B: The compound 1 (25.0 g, 0.125 mol) and ethyl 2-chloroacetoacetate (24.7 g, 0.150 mol) were added into anhydrous ethanol (500 mL), heated, and stirred under reflux for 3 h. A TLC analysis indicated that the reaction was completed. The reaction solution was cooled to room temperature. After suction filtration under reduced pressure, the filter cake was collected and dried, to obtain 2-(4-hydroxyphenyl)-4-methyl-selenazole-5-ethyl formate (2) (32.7 g), with a yield of 84.3%.
1 H NMR (DMSO-d 6 , 400 MHz) δ 7.81 (dd, J=2.0, 6.8 Hz, 2H), 6.87 (dd, J=2.0, 6.8 Hz, 2H), 4.26 (q, J=6.8 Hz, 2H), 2.64 (s, 3H), 1.28 (t, J=6.8 Hz, 3H).
Step C: The compound 2 (17.6 g, 56.7 mmol) and hexamethylene tetramine (HMTA) (9.8 g, 69.9 mmol) were added into trifluoroacetic acid (85 mL). The reaction solution was heated to 85° C. and stirred for 42 h. A TLC analysis indicated that the reaction was completed. The solution was distilled under reduced pressure to remove most of the solvent, then added with water (300 mL), stirred for 60 min and filtered. The filter cake was dissolved in ethyl acetate (200 mL), separated from residual water, and dried with anhydrous sodium sulfate. After the solvent was removed by means of reduced pressure distillation, the resulting product was separated and purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/8 for elution), so as to obtain 2-(3-formyl-4-hydroxyphenyl)-4-methyl-selenazole-5-ethyl formate (3) (8.7 g), with a yield of 45.3%.
Step D: The compound 3 (8.7 g, 25.7 mmol), hydroxylamine hydrochloride (2.6 g, 37.4 mmol) and sodium formate (2.5 g, 36.7 mmol) were added into formic acid (90 mL), and the resulting solution was heated and stirred under reflux for 42 h. A TLC analysis indicated that the reaction was completed. The reaction solution was cooled to room temperature and added with water (270 mL) to separate out abundant solids, and was then further cooled to 0-5° C., stirred for 30 min and filtered. The filter cake was washed with abundant water and vacuum-dried to obtain a light yellow solid. The solid was recrystalized with petroleum ether/ethyl acetate, to obtain 2-(3-cyano-4-hydroxyphenyl)-4-methyl-selenazole-5-ethyl formate (4) (7.0 g), with a yield of 81.2%.
Step E: The compound 4 (70 mg, 0.209 mmol) was dissolved in DMF (5 mL), and added with potassium iodide (7 mg, 0.042 mmol), anhydrous potassium carbonate (34.7 mg, 0.251 mmol) and ethyl bromide (32 mg, 0.293 mmol). The resulting mixture was stirred overnight at 70° C. The mixture was cooled to room temperature, added with water for dilution, and then filtered. The filter cake was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/20 for elution), so as to obtain a product, 2-(3-cyano-4-ethyoxyphenyl)-4-methyl-selenazole-5-ethyl formate (5), which was directly used for the next step reaction.
Step F: The compound 5 obtained from the last step reaction was dissolved in THF (4 mL) and methanol (11 mL), and added with 2M sodium hydroxide solution (3 mL). The resulting mixture was heated to 55° C. and stirred for 0.5 h. After the reaction was completed, about half of the solvent was removed by means of reduced pressure distillation. The solution was added with water (20 mL) and then with diluted hydrochloric acid so as to adjust the pH value to 5-6, filtered and dried to obtain 2-(3-cyano-4-ethyoxyphenyl)-4-methyl-selenazole-5-carboxylic acid (6).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.23 (s, 1H), 8.17 (d, J=8.4 Hz, 1H), 7.32 (d, J=8.4 Hz, 1H), 4.27 (q, J=6.8 Hz, 2H), 2.67 (s, 3H), 1.39 (t, J=6.4 Hz, 3H). MS (EI, m/z): 335.1 [M−H] − .
Embodiment 2
Synthesis of 2-(3-cyano-4-isobutoxyphenyl)-4-methyl-selenazole-5-carboxylic acid (7)
The compound 4 was reacted with 1-bromo-2-methylpropane according to step E in Embodiment 1, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(3-cyano-4-isobutoxyphenyl)-4-methyl-selenazole-5-carboxylic acid (7).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.26 (d, J=2.4 Hz, 1H), 8.18 (dd, J=2.0, 9.2 Hz, 1H), 7.34 (d, J=9.2 Hz, 1H), 4.00 (d, J=6.8 Hz, 2H), 2.63 (s, 3H), 2.14-2.04 (m, 1H), 1.02 (d, J=6.8 Hz, 6H). MS (EI, m/z): 363.2 [M−H] − .
Embodiment 3
Synthesis of 2-(3-cyano-4-isopropoxyphenyl)-4-methyl-selenazole-5-carboxylic acid (8)
The compound 4 was reacted with isopropyl bromide according to step E in Embodiment 1, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(3-cyano-4-isopropoxyphenyl)-4-methyl-selenazole-5-carboxylic acid (8).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.29 (d, J=2.4 Hz, 1H), 8.20 (dd, J=2.4, 8.8 Hz, 1H), 7.38 (d, J=8.8 Hz, 1H), 4.94-4.88 (m, 1H), 2.65 (s, 3H), 1.36 (d, J=6.0 Hz, 6H). MS (EI, m/z): 349.1 [M−H] − .
Embodiment 4
Synthesis of 2-[3-cyano-4-(3-methyl-butoxy)phenyl]-4-methyl-selenazole-5-carboxylic acid (9)
The compound 4 was reacted with 3-methyl-1-bromobutane according to step E in Embodiment 1, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[3-cyano-4-(3-methyl-butoxy)phenyl]-4-methyl-selenazole-5-carboxylic acid (9).
1 H NMR (DMSO-d 6 , 400 MHz) δ 13.28 (s, 1H), 8.30 (d, J=1.6 Hz, 1H), 8.22 (dd, J=1.6, 8.8 Hz, 1H), 7.38 (d, J=8.8 Hz, 1H), 4.26-4.25 (m, 2H), 2.65 (s, 3H), 1.86-1.78 (m, 1H), 1.70-1.68 (m, 2H), 0.96 (d, J=6.8 Hz, 6H). MS (EI, m/z): 377.2 [M−H] − .
Embodiment 5
Synthesis of 2-[3-cyano-4-(cyclohexylmethoxy)phenyl]-4-methyl-selenazole-5-carboxylic acid (10)
The compound 4 was reacted with cyclohexylmethyl bromide according to step E in Embodiment 1, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[3-cyano-4-(cyclohexylmethoxy)phenyl]-4-methyl-selenazole-5-carboxylic acid (10).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.18 (d, J=2.4 Hz, 1H), 8.12 (dd, J=2.0, 8.8 Hz, 1H), 7.32 (d, J=8.8 Hz, 1H), 4.01 (d, J=6.0 Hz, 2H), 2.64 (s, 3H), 1.91-1.65 (m, 5H), 1.29-1.07 (m, 6H). MS (EI, m/z): 403.2 [M−H] − .
Embodiment 6
Synthesis of 2-[3-cyano-4-(benzyloxy)phenyl]-4-methyl-selenazole-5-carboxylic acid (11)
The compound 4 was reacted with benzyl bromide according to step E in Embodiment 1, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[3-cyano-4-(benzyloxy)phenyl]-4-methyl-selenazole-5-carboxylic acid (11).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.34 (d, J=2.4 Hz, 1H), 8.24 (dd, J=2.4, 8.8 Hz, 1H), 7.52-7.38 (m, 6H), 5.38 (s, 2H), 2.65 (s, 3H). MS (EI, m/z): 397.2 [M−H] − .
Embodiment 7
Synthesis of 2-[3-cyano-4-(cyclopropylmethoxy)phenyl]-4-methyl-selenazole-5-carboxylic acid (12)
The compound 4 (100 mg, 0.298 mmol) was dissolved in THF (5 mL), added with cyclopropyl methanol (35 mg, 0.485 mmol) and triphenylphosphine (130 mg, 0.496 mmol), and then added dropwise with diethyl diazodicarboxylate (85 mg, 0.488 mmol). The resulting mixture was stirred overnight at room temperature. The solvent was removed by means of reduced pressure distillation, and the resulting product was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/20 for elution). The product was then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[3-cyano-4-(cyclopropylmethoxy)phenyl]-4-methyl-selenazole-5-carboxylic acid (12).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.30 (t, J=1.2 Hz, 1H), 8.22-8.19 (m, 1H), 7.33 (d, J=8.8 Hz, 1H), 4.09 (d, J=7.2 Hz, 2H), 2.65 (s, 3H), 1.30-1.28 (m, 1H), 0.65-0.61 (m, 2H), 0.42-0.40 (m, 2H). MS (EI, m/z): 361.2 [M−H] − .
Embodiment 8
Synthesis of 2-(2-cyano-biphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (14)
Step A: The compound 4 (7.0 mg, 20.9 mmol) was suspended in anhydrous dichloromethane (100 mL), and then added with DMAP (262 mg, 2.14 mmol) and pyridine (7.0 mL). The resulting mixture was stirred until becoming clear, then cooled by means of an ice-salt bath, and added with trifluoromethanesulfonic anhydride (10.8 mL), and then stirred for 1 h in the ice-salt bath. A TLC analysis indicated that the reaction was completed. The solution was distilled under reduced pressure to remove dichloromethane, then added with a proper amount of water and extracted with ethyl acetate (70 mL×3). The combined organic phase was respectively washed with diluted hydrochloric acid (50 mL) and saturated saline solution (50 mL), and dried with anhydrous sodium sulfate. The solvent was removed by means of reduced pressure distillation, so as to obtain 2-(3-cyano-4-trifluoromethanesulfonyl-phenyl)-4-methyl-selenazole-5-ethyl formate (13) (9.7 g), with a yield of 99%.
Step B(1): A mixture of the compound 13 (110 mg, 0.235 mmol), phenylboronic acid (52.7 mg, 0.422 mmol) and anhydrous potassium carbonate (20 mg, 0.017 mmol) was added with methylbenzene (10 mL) and tetrakis(triphenylphosphine)platinum (20 mg, 0.017 mmol). The resulting mixture was heated to 110° C. under the protection of nitrogen, and stirred overnight. The reaction solution was cooled to room temperature, and filtered with a diatomite pad. The filtrate was purified by using a silica column (200 to 300 mesh silica, ethyl acetate/petroleum ether=1/15 for elution), to obtain 2-(2-cyano-biphenyl-4-yl)-4-methyl-selenazole-5-ethyl formate.
1 H NMR (CDCl 3 , 400 MHz) δ 8.50 (d, J=1.6 Hz, 1H), 8.33 (dd, J=1.6, 8.0 Hz, 1H), 7.64-7.61 (m, 3H), 7.57-7.51 (m, 3H), 4.37 (q, J=6.4 Hz, 2H), 2.82 (s, 3H), 1.42 (t, J=6.4 Hz, 3H).
Step B(2): The ester obtained in step B(1) was hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-biphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (14).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.50 (d, J=1.6 Hz, 1H), 8.33 (dd, J=1.6, 8.4 Hz, 1H), 7.77-7.54 (m, 6H), 2.70 (s, 3H). MS (EI, m/z): 367.1 [M−H] − .
Embodiment 9
Synthesis of 2-(2-cyano-3′,4′-dimethoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (15)
The compound 13 was reacted with 3,4-dimethoxyphenylboronic acid according to step B(1) in Embodiment 8, and was then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-3′,4′-dimethoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (15).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.46 (d, J=2.0 Hz, 1H), 8.30 (dd, J=2.0, 8.4 Hz, 1H), 7.77 (d, J=8.4 Hz, 1H), 7.27-7.22 (m, 2H), 7.14 (d, J=8.4 Hz, 1H), 3.85 (s, 6H), 2.70 (s, 3H). MS (EI, m/z): 427.2 [M−H] − .
Embodiment 10
Synthesis of 2-(2-cyano-3′-fluoro-4′-methoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (16)
The compound 13 was reacted with 3-fluoro-4-methoxyphenylboronic acid according to step B(1) in Embodiment 8, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-3′-fluoro-4′-methoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (16).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.47 (d, J=2.0 Hz, 1H), 8.31 (dd, J=2.0, 8.4 Hz, 1H), 7.75 (d, J=8.4 Hz, 1H), 7.60 (dd, J=2.4, 12.0 Hz, 1H), 7.49-7.47 (m, 1H), 7.37 (t, J=8.8 Hz, 1H), 3.94 (s, 3H), 2.69 (s, 3H). MS (EI, m/z): 415.2 [M−H] − .
Embodiment 11
Synthesis of 2-(2-cyano-3′,4′,5′-trimethoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (17)
The compound 13 was reacted with 3,4,5-trimethoxyphenylboronic acid according to step B(1) in Embodiment 8, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-3′,4′,5′-trimethoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (17).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.46 (d, J=1.6 Hz, 1H), 8.29 (dd, J=1.6, 8.4 Hz, 1H), 7.81 (d, J=8.4 Hz, 1H), 6.97 (s, 2H), 3.86 (s, 6H), 3.76 (s, 3H), 2.69 (s, 3H). MS (EI, m/z): 457.2 [M−H] − .
Embodiment 12
Synthesis of 2-(2-cyano-4′-methoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (18)
The compound 13 was reacted with 4-methoxyphenylboronic acid according to step B(1) in Embodiment 8, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-4′-methoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (18).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.45 (d, J=2.0 Hz, 1H), 8.28 (dd, J=2.0, 8.0 Hz, 1H), 7.71 (d, J=8.4 Hz, 1H), 7.62 (dd, J=2.0, 6.8 Hz, 2H), 7.13 (dd, J=2.0, 6.8 Hz, 2H), 3.85 (s, 3H), 2.69 (s, 3H). MS (EI, m/z): 397.2 [M−H] − .
Embodiment 13
Synthesis of 2-(2-cyano-3′-methoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (19)
The compound 13 was reacted with 3-methoxyphenylboronic acid according to step B(1) in Embodiment 8, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-3′-methoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (19).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.50 (d, J=2.0 Hz, 1H), 8.32 (dd, J=2.0, 8.0 Hz, 1H), 7.77 (d, J=8.4 Hz, 1H), 7.48 (t, J=8.0, 1H), 7.22-7.12 (m, 2H), 7.10-7.09 (m, 1H), 3.85 (s, 3H), 2.70 (s, 1H). MS (EI, m/z): 397.2 [M−H] − .
Embodiment 14
Synthesis of 2-(2-cyano-3′-trifluoromethoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (20)
The compound 13 was reacted with 3-trifluoromethoxyphenylboronic acid according to step B(1) in Embodiment 8, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-3′-trifluoromethoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (20).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.52 (s, 1H), 8.34 (dd, J=2.0, 8.0 Hz, 1H), 7.81-7.69 (m, 4H), 7.55 (d, J=2.4 Hz, 1H), 2.69 (s, 3H). MS (EI, m/z): 451.2 [M−H] − .
Embodiment 15
Synthesis of 2-(2-cyano-4′-chlorobiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (21)
The compound 13 was reacted with 4-chlorophenylboronic acid according to step B(1) in Embodiment 8, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-4′-chlorobiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (21).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.51 (d, J=2.0 Hz, 1H), 8.33 (dd, J=2.0, 8.0 Hz, 1H), 7.76 (d, J=8.0, 1H), 7.71-7.64 (m, 4H), 2.69 (s, 3H). MS (EI, m/z): 401.1 [M−H] − .
Embodiment 16
Synthesis of 2-(2-cyano-3′,4′-difluorobiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (22)
The compound 13 was reacted with 3.4-difluorophenylboronic acid according to step B(1) in Embodiment 8, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-3′,4′-difluorobiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (22).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.45 (s, 1H), 8.28 (dd, J=2.0, 8.0 Hz, 1H), 7.84-7.74 (m, 2H), 7.69-7.62 (m, 1H), 7.55-7.51 (m, 1H), 2.68 (s, 3H). MS (EI, m/z): 403.1 [M−H] − .
Embodiment 17
Synthesis of 2-(2-cyano-2′,3′,4′,5′,6′-pentadeuterobiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (23)
The compound 13 was reacted with 2,3,4,5,6-pentadeuterophenylboronic acid according to step B(1) in Embodiment 8, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-2′,3′,4′,5′,6′-pentadeuterobiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (23).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.50 (d, J=1.6 Hz, 1H), 8.33 (dd, J=1.6, 8.4 Hz, 1H), 7.76 (d, J=8.4 Hz, 1H), 2.69 (s, 3H). MS (EI, m/z): 372.2 [M−H] − .
Embodiment 18
Synthesis of 2-(2-cyano-2′-methoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (24)
The compound 13 was reacted with 2-methoxyphenylboronic acid according to step B(1) in Embodiment 8, where potassium carbonate was replaced with cesium carbonate. The product was then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-2′-methoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (24).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.44 (d, J=2.0 Hz, 1H), 8.30 (dd, J=2.0, 8.4 Hz, 1H), 7.63 (d, J=8.0 Hz, 1H), 7.53-7.48 (m, 1H), 7.34 (dd, J=2.0, 7.2 Hz, 1H), 7.21 (d, J=8.0 Hz, 1H), 7.13-7.09 (m, 1H), 3.80 (s, 3H), 2.69 (s, 3H). MS (EI, m/z): 397.1 [M−H] − .
Embodiment 19
Synthesis of 2-(2-cyano-2′,4′-dimethoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (25)
The compound 13 was reacted with 2.4-dimethoxyphenylboronic acid according to step B(1) in Embodiment 8, where potassium carbonate was replaced with cesium carbonate. The product was then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-2′,4′-dimethoxybiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (25).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.40 (d, J=1.6 Hz, 1H), 8.26 (dd, J=1.6, 8.0 Hz, 1H), 7.59 (d, J=8.4 Hz, 1H), 7.27 (d, J=8.4 Hz, 1H), 6.75-6.68 (m, 2H), 3.85 (s, 3H), 3.80 (s, 3H), 2.69 (s, 3H). MS (EI, m/z): 427.2 [M−H] − .
Embodiment 20
Synthesis of 2-[3-cyano-4-(1-naphthyl)-phenyl]-4-methyl-selenazole-5-carboxylic acid (26)
The compound 13 was reacted with 1-naphthaleneboronic acid according to step B(1) in Embodiment 8, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[3-cyano-4-(1-naphthyl)-phenyl]-4-methyl-selenazole-5-carboxylic acid (26).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.60 (d, J=2.0 Hz, 1H), 8.40 (dd, J=2.0, 8.0 Hz, 1H), 8.13-8.07 (m, 2H), 7.76-7.54 (m, 6H), 2.72 (s, 3H). MS (EI, m/z): 417.3 [M−H] − .
Embodiment 21
Synthesis of 2-[3-cyano-4-(4-pyridyl)-phenyl-4-yl]-4-methyl-selenazole-5-carboxylic acid (27)
A mixture of the compound 13 (110 mg, 0.235 mmol), 4-pyridineboronic acid (86.8 mg, 0.706 mmol), lithium bromide (102 mg, 1.17 mmol) and sodium carbonate (40 mg, 0.377 mmol) was added with 1,4-dioxane (8 mL) and water (2 mL), and then added with tetrakis(triphenylphosphine)platinum (20 mg, 0.017 mmol). The reaction solution was heated under the protection of nitrogen until reflux occurred, and stirred overnight. After being cooled to room temperature, the solution was filtered with a diatomite pad, and the filtrate was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/15 for elution). The resulting product was then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[3-cyano-4-(4-pyridyl)-phenyl-4-yl]-4-methyl-selenazole-5-carboxylic acid (27).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.81 (s, 2H), 8.58 (d, J=2.0 Hz, 1H), 8.40 (dd, J=2.0, 8.0 Hz, 1H), 7.84 (d, J=8.0 Hz, 1H), 7.71 (d, J=5.6 Hz, 2H), 2.70 (s, 3H). MS (EI, m/z): 368.1 [M−H] − .
Embodiment 22
Synthesis of 2-[3-cyano-4-(3-pyridyl)-phenyl-4-yl]-4-methyl-selenazole-5-carboxylic acid (28)
The compound 13 was reacted with 1-naphthaleneboronic acid according to the operation procedure in Embodiment 21, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[3-cyano-4-(3-pyridyl)-phenyl-4-yl]-4-methyl-selenazole-5-carboxylic acid (28).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.74 (s, 1H), 8.73 (d, J=5.2 Hz, 1H), 8.55 (d, J=1.6 Hz, 1H), 8.36 (dd, J=2.0, 8.0 Hz, 1H), 8.14-8.11 (m, 1H, 7.83 (d, J=8.0 Hz, 1H), 7.61 (dd, J=4.8, 8.0 Hz, 1H), 2.70 (s, 3H). MS (EI, m/z): 368.1 [M−H] − .
Embodiment 23
Synthesis of 2-[2-cyano-4′-(1.2′-deuteroethyl)-biphenyl-4-yl]-4-methyl-selenazole-5-carboxylic acid (30)
Step A: A mixture of the compound 13 (110 mg, 0.235 mmol), 4-vinylphenylboronic acid (39 mg, 0.264 mmol) and anhydrous potassium carbonate (53 mg, 0.384 mmol) was added with methylbenzene (10 mL) and tetrakis(triphenylphosphine)platinum (20 mg, 0.017 mmol). The reaction solution was heated to 110° C. under the protection of nitrogen, and stirred overnight. The solution was cooled to room temperature, and filtered with a diatomite pad. The filtrate was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/20 for elution), to obtain 2-(2-cyano-4′-vinyl-biphenyl-4-yl)-4-methyl-selenazole-5-ethyl formate (29).
Step B: the compound 29 was dissolved in THF (10 mL) and heavy water (1 mL), and added with 5% palladium carbon (20 mg). The mixture was deuterated in deuterium gas under normal pressure for 24 h. After being filtered with diatomite, the filtrate was distilled under reduced pressure so as to remove the solvent. The product was then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[2-cyano-4′-(1.2′-deuteroethyl)-biphenyl-4-yl]-4-methyl-selenazole-5-carboxylic acid (30).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.48 (d, J=2.0 Hz, 1H), 8.31 (dd, J=2.0, 8.4 Hz, 1H), 7.75 (d, J=8.4 Hz, 1H), 7.58 (d, J=8.4 Hz, 2H), 7.41 (d, J=8.4 Hz, 2H), 2.70-2.68 (m, 4H), 1.23 (t, J=4.0 Hz, 2H). MS (EI, m/z): 397.2 [M−H] − .
Embodiment 24
Synthesis of 2-(2-cyano-6-deuterobiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (35)
Step A: A mixture of the compound 4 (250 mg, 0.745 mmol), methanol (8 mL) and triethylamine (1 mL) was added with NBS (160 mg, 0.898 mmol) in batches in an ice-water bath, and then the resulting mixture was stirred for reaction over 1 h. The solvent was removed by reduced pressure distillation, and the resulting product was dissolved in ethyl acetate (25 mL), filtered to remove insoluble substances, washed with water until the pH value was adjusted to 2-3, and then filtered. The collected solid was directly used for the next step reaction.
Step B: The product obtained in the last step reaction was dissolved in DMF (3 mL), and added with anhydrous potassium carbonate (240 mg, 1.739 mmol) and benzyl bromide (159 mg, 0.930 mmol). The resulting mixture was heated to 60° C. for reaction over about 20 min, and then added with DMF (5 mL) for reaction at constant temperature over 2 h. After being cooled to room temperature, the solution was diluted with water (45 mL), and filtered. The filter cake was dried and then directly used for the next step reaction.
Step C: The product obtained from the last step reaction was dissolved in DMF (10 mL) and heavy water (1 mL), and added with 5% palladium carbon (30 mg). The resulting mixture was deuterated in deuterium gas under normal pressure for 24 h, and filtered with a diatomite pad. The filtrate was distilled under reduced pressure to remove the solvent, so as to obtain 2-(3-cyano-4-hydroxyl-5-deutero-phenyl)-4-methyl-selenazole-5-ethyl formate (33) (102 mg), with a total yield of 40.6% in the three steps of reactions.
Step D: The compound 33 (102 mg, 0.302 mmol) was dissolved in dichloromethane (10 mL), added with DMAP (4 mg, 0.033 mmol) and pyridine (0.1 mL), and then added with trifluoromethanesulfonic anhydride (257 mg, 0.910 mmol) in an ice-water bath. The reaction solution was stirred for 1 h in the ice-water bath. Most of dichloromethane was removed by means of reduced pressure distillation. The solution was then added with water (10 mL) and extracted with ethyl acetate (10 mL×3). The combined organic phase was washed with 2M diluted hydrochloric acid (10 mL), and dried with anhydrous sodium sulfate. After the solvent was removed by means of reduced pressure distillation, the product was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/20 for elution), to obtain 2-(3-cyano-4-trifluoromethanesulfonyl-5-deuterophenyl)-4-methyl-selenazole-5-ethyl formate (34) (70 mg), with a yield of 49.5%.
Step E: A mixture of the compound 34 (70 mg, 0.149 mmol), phenylboronic acid (33.5 mg, 0.275 mmol) and anhydrous potassium carbonate (33.7 mg, 0.244 mmol) was added with methylbenzene (10 mL) and tetrakis(triphenylphosphine)platinum (20 mg, 0.017 mmol). The reaction solution was heated to 110° C. under the protection of nitrogen, and stirred overnight. After being cooled to room temperature, the reaction solution was filtered with a diatomite pad, and the filtrate was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/20 for elution). The resulting product was then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[2-cyano-6-deuterobiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (35).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.50 (s, 1H), 8.33 (s, 1H), 7.69-7.56 (m, 5H), 2.69 (s, 3H). MS (EI, m/z): 368.2 [M−H] − .
Embodiment 25
Synthesis of 2-(3-cyano-4-isopropylthiophenyl)-4-methyl-selenazole-5-carboxylic acid (37)
Step A: Under the protection of nitrogen, a three-mouth flask A was successively added with 1,4-dioxane (4 mL), isopropyl mercaptan (27 mg, 0.355 mmol), and diisopropylethylamine (61 mg, 0.472 mmol). The mixed solution was stirred for 40 min at room temperature. Another three-mouth flask B was added with 1,4-dioxane (6 mL), the compound 13 (110 mg, 0.235 mmol), Pd 2 (dba) 3 (11 mg, 0.012 mmol) and 4,5-diphenylphosphine-9,9-dimethylxanthene (13.7 mg, 0.0236 mmol). The mixed solution in the three-mouth flask B was stirred for 20 min under the protection of nitrogen, and then transferred to the aforementioned three-mouth flask A by using a syringe. The resulting mixture was stirred under reflux overnight. After being cooled to room temperature, the reaction solution was added with ethyl acetate (40 mL), washed with water (10 mL×2), and dried with anhydrous sodium sulfate. The solution was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/20 for elution), to obtain 2-(3-cyano-4-isopropylthiophenyl)-4-methyl-selenazole-5-ethyl formate (36).
1 H NMR (CDCl 3 , 400 MHz) δ 8.17 (d, J=2.0 Hz, 1H), 8.03 (dd, J=2.0, 8.4 Hz, 1H), 7.51 (d, J=8.4 Hz, 1H), 4.36 (q, J=7.2 Hz, 2H), 3.71-3.63 (m, 1H), 2.79 (s, 3H), 1.43-1.39 (m, 9H).
Step B: The compound 36 was hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(3-cyano-4-isopropylthiophenyl)-4-methyl-selenazole-5-carboxylic acid (37).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.36 (d, J=1.6 Hz, 1H), 8.19 (dd, J=1.6, 8.4 Hz, 1H), 7.71 (d, J=8.4 Hz, 1H), 3.88-3.81 (m, 1H), 2.67 (s, 3H), 1.35 (d, J=6.4 Hz, 6H). MS (EI, m/z): 365.1 [M−H] − .
Embodiment 26
Synthesis of 2-(3-cyano-4-isobutylthiophenyl)-4-methyl-selenazole-5-carboxylic acid (38)
The compound 13 was reacted with isobutyl mercaptan according to step A in Embodiment 25, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(3-cyano-4-isobutylthiophenyl)-4-methyl-selenazole-5-carboxylic acid (38).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.33 (d, J=2.0 Hz, 1H), 8.16 (dd, J=2.0, 8.4 Hz, 1H), 7.64 (d, J=8.4 Hz, 1H), 3.09 (d, J=6.4 Hz, 2H), 2.67 (s, 3H), 1.94-1.86 (m, 1H), 1.04 (d, J=6.8 Hz, 6H). MS (EI, m/z): 379.2 [M−H] − .
Embodiment 27
Synthesis of 2-[3-cyano-4-(4-chrolophenylthio)-phenyl]-4-methyl-selenazole-5-carboxylic acid (39)
The compound 13 was reacted with 4-chlorothiophenol according to step A in Embodiment 25, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[3-cyano-4-(4-chrolophenylthio)-phenyl]-4-methyl-selenazole-5-carboxylic acid (39).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.44 (d, J=2.0 Hz, 1H), 8.15 (dd, J=2.0, 8.4 Hz, 1H), 7.85-7.84 (m, 4H), 7.24 (d, J=8.4 Hz, 1H), 2.65 (s, 3H). MS (EI, m/z): 433.1 [M−H] − .
Embodiment 28
Synthesis of 2-[3-cyano-4-(3-trifluoromethylphenylthio)-phenyl]-4-methyl-selenazole-5-carboxylic acid (40)
The compound 13 was reacted with 3-trifluoromethylthiophenol according to step A in Embodiment 25, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[3-cyano-4-(3-trifluoromethylphenylthio)-phenyl]-4-methyl-selenazole-5-carboxylic acid (40).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.49 (d, J=2.0 Hz, 1H), 8.20 (dd, J=2.0, 8.4 Hz, 1H), 7.91 (s, 1H), 7.86-7.71 (m, 3H), 7.36 (d, J=8.4 Hz, 1H), 2.66 (s, 3H). MS (EI, m/z): 467.1 [M−H] − .
Embodiment 29
Synthesis of 2-[3-cyano-4-(2-pyridylthio)-phenyl]-4-methyl-selenazole-5-carboxylic acid (41)
The compound 13 was reacted with 2-mercaptopyridine according to step A in Embodiment 25, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[3-cyano-4-(2-pyridylthio)-phenyl]-4-methyl-selenazole-5-carboxylic acid (41). 1 H NMR (DMSO-d 6 , 400 MHz) δ 8.54 (s, 1H), 8.45-8.43 (m, 1H), 8.29 (dd, J=2.0, 8.0 Hz, 1H), 7.85-7.77 (m, 2H), 7.39 (d, J=8.0 Hz, 1H), 7.31-7.27 (m, 1H), 2.69 (s, 3H). MS (EI, m/z): 400.3 [M−H] − .
Embodiment 30
Synthesis of 2-(3-cyano-4-benzylthio-phenyl)-4-methyl-selenazole-5-carboxylic acid (42)
The compound 13 was reacted with 2-mercaptomethyl benzene according to step A in Embodiment 25, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(3-cyano-4-benzylthio-phenyl)-4-methyl-selenazole-5-carboxylic acid (42). 1 H NMR (DMSO-d 6 , 400 MHz) δ 8.35 (d, J=2.0 Hz, 1H), 8.16 (dd, J=2.0, 8.4 Hz, 1H), 7.73 (d, J=8.4 Hz, 1H), 7.47-7.29 (m, 5H), 4.51 (s, 2H), 2.65 (s, 3H). MS (EI, m/z): 413.3 [M−H] − .
Embodiment 31
Synthesis of 2-(3-cyano-4-isopropyl sulfone-phenyl)-4-methyl-selenazole-5-carboxylic acid (43)
The compound 36 (80 mg, 0.203 mmol) was dissolved in acetic acid (5 mL), and the resulting solution was added with hydrogen peroxide (1.5 mL), and then stirred overnight at room temperature. The reaction solution was added with water (20 mL) for dilution and filtered. The filter cake was then collected. The obtained product was hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(3-cyano-4-isopropyl sulfone-phenyl)-4-methyl-selenazole-5-carboxylic acid (43).
1 H NMR (DMSO-d 6 , 400 MHz) δ 13.56 (s, 1H), 8.71 (d, J=2.0 Hz, 1H), 8.52 (dd, J=2.0, 8.4 Hz, 1H), 8.17 (d, J=8.4 Hz, 1H), 3.65 (t, J=6.8 Hz, 1H), 2.71 (s, 3H), 1.26 (d, J=6.8 Hz, 6H). MS (EI, m/z): 397.1 [M−H] − .
Embodiment 32
Synthesis of 2-(3-cyano-4-morpholinyl-4-yl-phenyl)-4-methyl-selenazole-5-carboxylic acid (44)
The compound 13 (100 mg, 0.214 mmol) was added into morpholine (3 mL). The resulting reaction solution was heated to 80° C., stirred for 15 min, then cooled to room temperature, and added with water (20 mL) for dilution. After filtration, the filter cake was collected. The obtained product was hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(3-cyano-4-morpholinyl-4-yl-phenyl)-4-methyl-selenazole-5-carboxylic acid (44).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.24 (d, J=2.0 Hz, 1H), 8.13 (dd, J=2.0, 8.8 Hz, 1H), 7.22 (d, J=8.8 Hz, 1H), 3.78 (d, J=4.0 Hz, 4H), 3.31 (d, J=4.0 Hz, 4H), 2.64 (s, 3H). MS (EI, m/z): 367.2 [M−H] − .
Embodiment 33
Synthesis of 2-[3-cyano-4-(4-methylpiperazin-1-yl)phenyl]-4-methyl-selenazole-5-carboxylic acid (45)
The compound 13 was reacted with methylpiperidine according to the experimental procedure in Embodiment 32, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[3-cyano-4-(4-methylpiperazin-1-yl)phenyl]-4-methyl-selenazole-5-carboxylic acid (45).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.30 (d, J=2.0 Hz, 1H), 8.16 (dd, J=2.0, 8.8 Hz, 1H), 7.32 (d, J=8.8 Hz, 1H), 3.65-3.14 (m, 8H), 2.81 (s, 3H), 2.64 (s, 3H). MS (EI, m/z): 389.1 [M−H] − .
Embodiment 34
Synthesis of 2-{3-cyano-4-(6,7-dihydro-4H-thieno[3,2-c]pyridyl)-phenyl}-4-methyl-selenazole-5-carboxylic acid (46)
4,5,6,7-4H-thieno[3,2-c]pyridine hydrochloride (173 mg, 0.984 mmol) was dissolved in DMF (5 mL). The resulting solution was added with the compound 13 (100 mg, 0.214 mmol) and diisopropylethylamine (138 mg, 1.067 mmol), then heated to 90° C. and stirred for 40 min. After being cooled to room temperature, the solution was poured into water (30 mL), and then extracted with ethyl acetate (15 mL×3). The organic phase was washed with water (10 mL×2), and the solvent was removed by means of reduced pressure distillation. The product was purified by using a silica column (200 to 300 mesh silica, ethyl acetate/petroleum ether=1/15 for elution). The obtained product was hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-{3-cyano-4-(6,7-dihydro-4H-thieno[3,2-c]pyridyl)-phenyl}-4-methyl-selenazole-5-carboxylic acid (46).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.25 (d, J=2.4 Hz, 1H), 8.11 (d, J=2.4, 8.8 Hz, 1H), 7.39 (d, J=5.2 Hz, 1H), 7.26 (d, J=5.2 Hz, 1H), 6.93 (d, J=5.2 Hz, 1H), 4.45 (s, 2H), 3.78 (t, J=5.2 Hz, 2H), 3.03 (t, J=5.2 Hz, 2H), 2.64 (s, 3H). MS (EI, m/z): 428.2 [M−H] − .
Embodiment 35
Synthesis of 2-(3-cyano-4-dimethylamino-phenyl)-4-methyl-selenazole-5-carboxylic acid (47)
The compound 13 (150 mg, 0.321 mmol) was dissolved in DMF (4.5 mL), and then added with 30% dimethylamine aqueous solution (1.5 mL). The reaction solution was stirred for 2 h at room temperature, then added with water (20 mL) for dilution, and extracted with ethyl acetate (10 mL×3). The organic phase was washed with water (10 mL×2), and distilled under reduced pressure to remove the solvent. The product was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/15 for elution). The obtained product was hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(3-cyano-4-dimethylamino-phenyl)-4-methyl-selenazole-5-carboxylic acid (47).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.10 (d, J=2.4 Hz, 1H), 7.98 (dd, J=2.4, 9.2 Hz, 1H), 7.03 (d, J=9.2 Hz, 1H), 3.15 (s, 6H), 2.63 (s, 3H). MS (EI, m/z): 334.2 [M−H] − .
Embodiment 36
Synthesis of 2-(3-chloro-4-isobutoxyphenyl)-4-methyl-selenazole-5-carboxylic acid (51)
Step A: At 0-10° C., anhydrous ethanol (36 mL) was slowly added into a mixture of selenium powder (3.3 g, 41.8 mmol) and sodium borohydride (1.73 g, 45.8 mmol), then heated to room temperature and stirred for 30 min, and then added with pyridine solution (8.3 mL) containing 3-chloro-4-hydroxybenzonitrile (1.6 g, 10.4 mmol). The reaction solution was heated until reflux occurred, then slowly added dropwise with 2M hydrochloric acid (21 mL), and stirred under reflux for 1 h. A TLC analysis indicated that the reaction was completed. The reaction solution was cooled to room temperature, added with water (100 mL) for dilution and extracted with ethyl acetate (30 mL×3). The combined organic phase was respectively washed with 2M hydrochloric acid (15 mL×2) and saturated saline solution (20 mL). The solvent was removed by means of reduced pressure distillation, so as to obtain 3-chloro-4-hydroxy selenobenzamide (49) (2.4 g), with a yield of 98.1%.
Step B: The compound 49 (2.4 g, 10.2 mmol) was dissolved in ethanol (25 mL), and added with ethyl 2-chloroacetoacetate (2.04 g, 12.4 mmol). The mixed solution was heated until reflux occurred, and stirred for 2 h. A TLC analysis indicated that the reaction was completed. The reaction solution was cooled to room temperature, and was dried after suction filtration to obtain 2-(3-chloro-4-hydroxyphenyl)-4-methyl-selenazole-5-ethyl formate (50) (3.1 g), with a yield of 88.1%.
Step C: The compound 50 (80 mg, 0.232 mmol) was dissolved in DMF (5 mL), and then added with potassium iodide (8.0 mg, 0.048 mmol), anhydrous potassium carbonate (42.6 mg, 0.309 mmol), and 1-bromo-2-methylpropane (49.4 mg, 0.361 mmol). The resulting mixture was heated to 70° C. and stirred overnight. After being cooled to room temperature, the mixture was added with water (20 mL) for dilution and filtered. The filter cake was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/15 for elution). The obtained product was hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(3-chloro-4-isobutoxyphenyl)-4-methyl-selenazole-5-carboxylic acid (51).
1 H NMR (DMSO-d 6 , 400 MHz) δ 13.24 (s, 1H), 7.99 (s, 1H), 7.88 (d, J=8.8 Hz, 1H), 7.24 (d, J=8.8 Hz, 1H), 3.93 (d, J=6.4 Hz, 2H), 2.64 (s, 3H), 2.12-2.05 (m, 1H), 1.02 (d, J=6.8 Hz, 6H). MS (EI, m/z): 372.1 [M−H] − .
Embodiment 37
Synthesis of 2-(3-trifluoromethyl-4-isobutoxyphenyl)-4-methyl-selenazole-5-carboxylic acid (55)
A compound 3-trifluoromethyl-4-hydroxybenzonitrile was used to prepare selenoamide according to step A in Embodiment 32, then cyclized according to step B in Embodiment 32 and reacted with 1-bromo-2-methylpropane according to step C in Embodiment 32, and finally hydrolyzed according to step F in Embodiment 1 and acidized to obtain 2-(3-trifluoromethyl-4-isobutoxyphenyl)-4-methyl-selenazole-5-carboxylic acid (55).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.18 (dd, J=2.4, 8.8 Hz, 1H), 8.13 (d, J=2.4 Hz, 1H), 7.36 (d, J=9.2 Hz, 1H), 3.99 (d, J=6.0 Hz, 2H), 2.65 (s, 3H), 2.10-2.03 (m, 1H), 1.01 (d, J=6.8 Hz, 6H). MS (EI, m/z): 406.3 [M−H] − .
Embodiment 38
Synthesis of 2-[3-cyano-4-(isopropylthiomethyl)-phenyl]-4-methyl-selenazole-5-carboxylic acid (62)
Step A: Concentrated sulfuric acid (20 mL) was added into water (20 mL) to prepare sulfuric acid solution, and the resulting solution was then added with 4-methylbenzonitrile (5.86 g, 50.0 mmol) and NBS (8.9 g, 50.0 mmol). The resulting mixture was stirred overnight at room temperature while being protected from light. After filtration, the filter cake was dissolved in ethyl acetate (150 mL), respectively washed with water (30 mL×2), sodium bicarbonate aqueous solution (30 mL) and saturated saline solution (20 mL), and dried with anhydrous sodium sulfate. The solvent was removed by means of reduced pressure distillation, so as to obtain 3-bromo-4-methylbenzonitrile (57) (6.78 g), with a yield of 69.2%.
1 H NMR (CDCl 3 , 400 MHz) δ 7.84 (d, J=1.6 Hz, 1H), 7.52 (dd, J=1.6, 8.0 Hz, 1H), 7.35 (d, J=8.0 Hz, 1H).
Step B: The compound 57 (804 mg, 4.04 mmol) was dissolved in carbon tetrachloride (8 mL), and then added with NBS (730 mg, 4.10 mmol) and benzoyl peroxide (7 mg, 0.0289 mmol). The resulting mixture was heated under the protection of nitrogen until reflux occurred, and was stirred overnight. The mixture was cooled to room temperature, filtered to remove insoluble substances and distilled under reduced pressure to remove the solvent, then dissolved in ethyl acetate (30 mL) and respectively washed with water (10 mL) and saturated saline solution (10 mL). After the solvent was removed by means of reduced pressure distillation, the resulting product was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/35 for elution) to obtain 3-bromo-4-cyanobenzyl bromide (58) (583 mg), with a yield of 52.5%.
Step C: The compound 58 (275 mg, 1.0 mmol) was dissolved in DMF (5 mL), cooled to 0-10° C., and added with cesium carbonate (652 mg, 2.0 mmol) and isopropyl mercaptan (114 mg, 1.5 mmol), heated to room temperature and stirred for 2 h. A TLC analysis indicated that the reaction was completed. The reaction solution was added with water (30 mL), and extracted with ethyl acetate (15 mL×3). The combined organic phase was then washed with water (10 mL×2) and dried with anhydrous sodium sulfate. The solvent was removed by means of reduced pressure distillation, so as to obtain an oily substance, 3-bromo-4-isopropyl cyanobenzyl sulfide (59) (278 mg), with a yield of 100%.
Step D: At 0-10° C., anhydrous ethanol (10 mL) was slowly added into selenium powder (340 mg, 4.306 mmol) and sodium borohydride (178 mg, 4.709 mmol), then heated to room temperature and stirred for 30 min. The resulting mixture was then added with pyridine solution (1.5 mL) containing the compound 59 (270 m, 1.0 mmol), heated until reflux occurred, and slowly added dropwise with 2M hydrochloric acid solution (10 mL). After addition, the solution was stirred under reflux for 1 h. A TLC analysis indicated that the reaction was completed. The solution was cooled to room temperature, added with water (30 mL) for dilution, and extracted with ethyl acetate (15 mL×3). The combined organic phase was respectively washed with 2M hydrochloric acid (15 mL) and saturated saline solution (15 mL). The solvent was removed by means of reduced pressure distillation, so as to obtain a product, 3-bromo-4-isopropylthiomethyl selenobenzamide (60), which was directly used for the next step reaction.
Step E: The compound 60 was dissolved in ethanol (10 mL), added with ethyl 2-chloroacetoacetate (248 mg, 1.506 mmol), then heated until reflux occurred and stirred for 2 h. After ethanol was removed by means of reduced pressure distillation, the resulting product was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/20 for elution), to obtain 2-[3-bromo-4-(isopropylthiomethyl)phenyl]-4-methyl-selenazole-5-ethyl formate (61) (118 mg), with a yield of 25.6%.
Step F: The compound 61 (115 mg, 0.249 mmol) was dissolved in N-methylpyrrolidone (6 mL), added with cuprous cyanide (40 mg, 0.446 mmol), then heated under the protection of nitrogen until reflux occurred, and stirred for 6 h. After the solvent was removed by means of reduced pressure distillation, the resulting product was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/15 for elution), to obtain 2-[3-cyano-4-(isopropylthiomethyl)phenyl]-4-methyl-selenazole-5-ethyl formate.
1 H NMR (CDCl 3 , 400 MHz) δ 8.16 (d, J=1.6 Hz, 1H), 7.83 (dd, J=1.6, 8.0 Hz, 1H), 7.50 (d, J=8.0 Hz, 1H), 4.36 (q, J=6.8 Hz, 2H), 3.90 (s, 2H), 2.95-2.89 (m, 1H), 2.81 (s, 3H), 1.40 (t, J=2.8 Hz, 3H), 1.30 (d, J=10.0 Hz, 6H).
The ester was hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[3-cyano-4-(isopropylthiomethoxy)phenyl]-4-methyl-selenazole-5-carboxylic acid (62).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.38 (d, J=2.0 Hz, 1H), 8.22 (dd, J=2.0, 8.4 Hz, 1H), 7.70 (d, J=8.4 Hz, 1H), 3.98 (s, 2H), 2.90-2.83 (m, 1H), 2.67 (s, 3H), 1.23 (d, J=6.8 Hz, 6H). MS (EI, m/z): 379.1 [M−H] − .
Embodiment 39
Synthesis of 2-[3-bromo-4-(aniline formyl)-phenyl]-4-methyl-selenazole-5-carboxylic acid (67)
Step A: The compound 58 (2.6 g, 9.46 mmol) was dissolved in 1,4-dioxane (20 mL) and water (20 mL), then added with calcium carbonate (4.3 g, 43 mmol), heated until reflux occurred and stirred overnight. The solution was cooled to room temperature, added with water (40 mL) and extracted with ethyl acetate (30 mL×3). The combined organic phase was filtered with a short silicone pad. The solvent was removed by means of reduced pressure distillation, so as to obtain 3-bromo-4-hydroxymethyl benzonitrile (63) (1.8 g), with a yield of 89.7%.
Step B: At 0-10° C., anhydrous ethanol (27 mL) was slowly added dropwise into a mixture of selenium powder (2.7 g, 34.2 mmol) and sodium borohydride (1.57 g, 41.5 mmol), then heated to room temperature and stirred for 30 min, and then added with pyridine solution (7.2 mL) containing 3-bromo-4-isopropylthiomethyl benzonitrile (63) (1.8 g, 8.49 mmol). The reaction solution was heated until reflux occurred, slowly added dropwise with 2M hydrochloric acid solution (18 mL) and then stirred under reflux for 1 h. A TLC analysis indicated that the reaction was completed. The solution was cooled to room temperature, added with a proper amount of water and then extracted with ethyl acetate (30 mL×3). The organic phase was respectively washed with 2M hydrochloric acid (20 mL) and saturated saline solution (20 mL), and dried with anhydrous sodium sulfate. The solvent was removed by means of reduced pressure distillation, so as to obtain pink 3-bromo-4-hydroxymethyl selenobenzamide (64) (1.98 g), with a yield of 79.6%.
Step C: The compound 64 (293 mg, 1.0 mmol) was dissolved in ethanol (10 mL), added with ethyl 2-chloroacetoacetate (197 mg, 1.20 mmol), and then heated under reflux for 1.5 h. A TLC analysis indicated that the reaction was completed. The solution was cooled to room temperature, added with a proper amount of water, and filtered to obtain a compound 2-(3-bromo-4-hydroxymethylphenyl)-4-methyl-selenazole-5-ethyl formate (65) (340 mg), with a yield of 84.3%.
Step D: The compound 65 (200 mg, 0.496 mmol) was dissolved in acetone (5 mL), and then added with potassium permanganate (158 mg, 1.0 mmol). After being stirred at room temperature for 2 h, the resulting mixture was quenched with sodium hydrogen sulfite aqueous solution, added with a proper amount of water, and filtered to remove insoluble substances. The filtrate was extracted with ethyl acetate (20 mL×2), and the water phase was added with 2M hydrochloric acid to adjust the pH value to 3-4. After filtration, 2-(3-bromo-4-carboxylphenyl)-4-methyl-selenazole-5-ethyl formate (66) (168 mg) was obtained, with a yield of 81.2%.
Step E: The compound 66 (147 mg, 0.352 mmol) was dissolved in dichloromethane (10 mL), and then added with thionyl chloride (168 mg, 1.41 mmol). The resulting solution was heated until reflux occurred, then stirred for 3 h, and distilled under reduced pressure to remove the solvent. The product was then added with dichloromethane (10 mL), and added with triethylamine (107 mg, 1.059 mmol) and aniline (33 mg, 0.354 mmol) while being cooled in an ice-water bath. After the ice-water bath was removed, the solution was stirred at room temperature for 1 h. The reaction solution was washed with a proper amount of water and dried with anhydrous sodium sulfate. The solvent was removed by means of reduced pressure distillation, and the product was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/15 for elution). The obtained product was hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-[3-bromo-4-(aniline formyl)-phenyl]-4-methyl-selenazole-5-carboxylic acid (67).
1 H NMR (DMSO-d 6 , 400 MHz) δ 10.62 (s, 1H), 8.26 (d, J=1.6 Hz, 1H), 8.07 (dd, J=1.6, 8.0 Hz, 1H), 7.73-7.67 (m, 3H), 7.37 (t, J=8.0 Hz, 2H), 7.14 (d, J=8.0 Hz, 1H), 2.69 (s, 3H). MS (EI, m/z): 435.1 [M+H] + .
Embodiment 40
Synthesis of 2-(2-cyano-4′-trifluoromethylbiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (68)
The compound 13 was reacted with 4-trifluoromethoxyphenylboronic acid according to step B(1) in Embodiment 8, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-4′-trifluoromethylbiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (68).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.55 (d, J=2.0 Hz, 1H), 8.38 (dd, J=2.0, 8.0 Hz, 1H), 7.95 (d, J=8.0 Hz, 2H), 7.89 (d, J=8.4 Hz, 2H), 7.82 (d, J=8.4 Hz, 1H), 2.66 (s, 3H). MS (EI, m/z): 434.8 [M−H] − .
Embodiment 41
Synthesis of 2-(2-cyano-3′-trifluoromethylbiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (69)
For the experimental operation, refer to step B in Embodiment 8, where potassium carbonate was replaced with cesium carbonate in the reaction (1).
The compound 13 was reacted with 3-trifluoromethoxyphenylboronic acid according to step B(1) in Embodiment 8, where potassium carbonate was replaced with cesium carbonate. The product was then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-3′-trifluoromethylbiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (69).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.55 (d, J=2.0 Hz, 1H), 8.37 (dd, J=2.0, 8.4 Hz, 1H), 8.03-7.81 (m, 5H), 2.70 (s, 3H). MS (EI, m/z): 434.8 [M−H] − .
Embodiment 42
Synthesis of 2-(2-cyano-3′-trifluoromethylbiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (70)
The compound 13 was reacted with 2-trifluoromethoxyphenylboronic acid according to step B(1) in Embodiment 8, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(2-cyano-3′-trifluoromethylbiphenyl-4-yl)-4-methyl-selenazole-5-carboxylic acid (70).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.34 (dd, J=1.6, 8.0 Hz, 1H), 8.32 (d, J=2.0 Hz, 1H), 7.95 (d, J=8.0 Hz, 1H), 7.86-7.56 (m, 4H), 2.70 (s, 3H). MS (EI, m/z): 434.8 [M−H] − .
Embodiment 43
Synthesis of 2-(3-cyano-4-isobutoxyphenyl)-4-hydroxymethyl-selenazole-5-carboxylic acid (74)
Step A: The compound 4 (1.0 g, 2.983 mmol) was dissolved in DMF (10 mL), and added with anhydrous potassium carbonate (1.2 g, 8.70 mmol) and 1-bromo-2-methylpropane (0.82 g, 5.985 mmol), and the resulting mixture was stirred overnight at 80° C. The mixture was cooled to room temperature, added with water for dilution, and then filtered. The filter cake was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/20 for elution), to obtain 2-(3-cyano-4-isobutoxyphenyl)-4-methyl-selenazole-5-ethyl formate (71) (1.10 g), with a yield of 94.2%.
Step B: The compound 71 (1.1 g, 2.811 mmol) was dissolved in carbon tetrachloride (25 mL), and then added with NBS (0.55 g, 3.090 mmol) and benzoyl peroxide (0.40 g, 1.65 mmol). The resulting mixture was heated under the protection of nitrogen until reflux occurred, and then stirred overnight. After the solvent was removed by means of reduced pressure distillation, the product was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/5 for elution), to obtain 2-(3-cyano-4-isobutoxyphenyl)-4-bromomethyl-selenazole-5-ethyl formate (72) (0.91 g), with a yield of 68.8%.
Step C: The compound 72 (0.90 g, 1.914 mmol) was dissolved in 1,4-dioxane (15 mL) and water (15 mL), then added with calcium carbonate (0.80 g, 8.0 mmol), heated until reflux occurred and stirred overnight under reflux. The solution was cooled to room temperature, added with water (30 mL) and extracted with ethyl acetate (30 mL×3). The organic solvent was removed by means of reduced pressure distillation, and the product was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate/petroleum ether=1/5 for elution), so as to obtain 2-(3-cyano-4-isobutoxyphenyl)-4-hydroxymethyl-selenazole-5-ethyl formate (73) (0.20 g), with a yield of 25.7%.
Step D: The compound 73 was hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(3-chloro-4-isobutoxyphenyl)-4-hydroxymethyl-selenazole-5-carboxylic acid (74).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.36 (d, J=2.0 Hz, 1H), 8.25 (dd, J=2.0, 8.8 Hz, 1H), 7.37 (d, J=8.8 Hz, 1H), 4.81 (s, 2H), 4.02 (d, J=6.4 Hz, 2H), 2.15-2.05 (m, 1H), 1.02 (d, J=6.4 Hz, 6H). MS (EI, m/z): 379.0 [M−H] − .
Embodiment 44
Synthesis of 2-(3-bromo-4-isobutoxyphenyl)-4-methyl-selenazole-5-carboxylic acid (78)
A compound 3-bromo-4-hydroxybenzonitrile was used to prepare selenoamide according to step A in Embodiment 36, then cyclized according to step B in Embodiment 32 and reacted with 1-bromo-2-methylpropane according to step C in Embodiment 32, and finally hydrolyzed according to step F in Embodiment 1 and acidized to obtain 2-(3-bromo-4-isobutoxyphenyl)-4-methyl-selenazole-5-carboxylic acid (78). 1 H NMR (DMSO-d 6 , 400 MHz) δ 8.13 (d, J=2.0 Hz, 1H), 7.91 (dd, J=2.4, 8.8 Hz, 1H), 7.19 (d, J=8.8 Hz, 1H), 3.92 (d, J=6.4 Hz, 2H), 2.64 (s, 3H), 2.11-2.03 (m, 1H), 1.02 (q, J=6.8 Hz, 6H). MS (EI, m/z): 416.0 [M−H] − .
Embodiment 45
Synthesis of 2-(3-cyano-4-isopropylthiophenyl)-4-methyl-selenazole-5-carboxylic acid-(2-N-acetyl)ethyl ester (79)
A mixture of the compound 37 (120 mg, 0.328 mmol), N-(2-hydroxyethyl)acetamide (50.8 mg, 0.493 mmol), N-methylmorpholine (99.7 mg, 0.985 mmol), HOBT (66.6 mg, 0.493 mmol) and DMF (5 mL) was added with EDCI in an ice-water bath, and then stirred overnight at room temperature. The reaction solution was added with water (20 mL), and extracted with ethyl acetate (15 mL×3). The combined organic phase was then washed with water (15 mL) once more. After the solvent was removed by means of reduced pressure distillation, the product was purified by using a silica column (200 to 300 mesh silica gel, ethyl acetate for elution), to obtain 2-(3-cyano-4-isopropylthiophenyl)-4-methyl-selenazole-5-carboxylic acid-(2-N-acetyl)ethyl ester (79).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.39 (d, J=2.0 Hz, 1H), 8.22-8.19 (m, 1H), 8.07-8.04 (m, 1H), 7.72 (dd, J=4.0, 8.4 Hz, 1H), 4.24 (t, J=5.2 Hz, 2H), 3.89-3.82 (m, 1H), 3.41-3.29 (m, 2H), 2.68 (s, 3H), 1.87 (s, 3H), 1.37-1.36 (m, 6H). MS (EI, m/z): 449.9 [M−H] − .
The compound 79 may be a prodrug of the compound 37.
Embodiment 46
Synthesis of 2-(3-cyano-4-tertbutylthiophenyl)-4-methyl-selenazole-5-carboxylic acid (81)
The compound was reacted with tert-butyl mercaptan according to step A in Embodiment 25, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(3-cyano-4-tertbutylthiophenyl)-4-methyl-selenazole-5-carboxylic acid (81).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.47 (d, J=2.0 Hz, 1H), 8.26 (dd, J=2.0, 8.4 Hz, 1H), 7.86 (d, J=8.4 Hz, 1H), 2.68 (s, 3H), 1.36 (s, 9H). MS (EI, m/z): 381.4 [M+H] + .
Embodiment 47
Synthesis of 2-(3-cyano-4-cyclohexylthiophenyl)-4-methyl-selenazole-5-carboxylic acid (83)
The compound was reacted with cyclopentyl mercaptan according to step A in Embodiment 25, then hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(3-cyano-4-cyclohexylthiophenyl)-4-methyl-selenazole-5-carboxylic acid (83).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.34 (d, J=2.0 Hz, 1H), 8.18 (dd, J=2.0, 8.4 Hz, 1H), 7.69 (d, J=2.0 Hz, 1H), 4.01-3.96 (m, 1H), 2.66 (s, 3H), 2.22-2.17 (m, 2H), 1.76-1.74 (m, 2H), 1.67-1.64 (m, 4H). MS (EI, m/z): 393.1 [M+H] + .
Embodiment 48
Synthesis of 2-(3-trifluoromethylphenyl)-4-methyl-selenazole-5-carboxylic acid (86)
Step A: Anhydrous ethanol (30 mL) was added dropwise into a mixture of selenium powder (1.84 g, 23.3 mmol) and sodium borohydride (0.97 g, 25.6 mmol) under the protection of nitrogen in an ice-water bath, then heated to room temperature, and stirred for 30 min. The resulting mixture was then added with pyridine solution (6 mL) containing 3-(trifluoromethyl)benzonitrile (1.0 g, 5.84 mmol), heated until reflux occurred, and slowly added dropwise with 2M hydrochloric acid solution (4 mL) and then stirred under reflux for 1 h. A TLC analysis indicated that the reaction was completed. Most of ethanol was removed by means of reduced pressure distillation. The resulting product was added with water (30 mL) for dilution, and extracted with ethyl acetate (20 mL×3). The combined organic phase was washed with 2M hydrochloric acid (10 mL) and then with saturated saline solution (15 mL). The solvent was removed by means of reduced pressure distillation, so as to obtain a compound 3-trifluoromethyl selenobenzamide (84) (1.6 g), which was directly used for the next step reaction without being purified.
Step B: the compound 84 (1.0 g, NMT 3.65 mmol) and ethyl 2-chloroacetoacetate (653 mg, 3.97 mmol) were added into anhydrous ethanol (10 mL), heated, and stirred under reflux for 2 h. A TLC analysis indicated that the reaction was completed. The reaction solution was cooled to room temperature. After suction filtration under reduced pressure, the filter cake was collected and dried, to obtain 2-(3-trifluoromethylphenyl)-4-methyl-selenazole-5-ethyl formate (85) (930 mg), with a total yield of 70.3% in the two steps of reactions.
Step C: The compound 85 was hydrolyzed according to step F in Embodiment 1, and acidized to obtain 2-(3-trifluoromethylphenyl)-4-methyl-selenazole-5-carboxylic acid (86).
1 H NMR (DMSO-d 6 , 400 MHz) δ 8.26-8.23 (m, 2H), 7.92 (d, J=8.0 Hz, 1H), 7.77-7.73 (m, 1H), 2.68 (s, 3H).
Embodiment 49
Test for Inhibition of the Activity of Xanthine Oxidase
I. Principle
The inhibition of the activity of xanthine oxidase (XO) is tested through a coupled enzymatic reaction of xanthine oxidase, horseradish peroxidase (HRP) and a substrate thereof. First, xanthine oxidase oxidizes hypoxanthine to produce xanthine and hydrogen peroxide, and further oxidizes xanthine to produce uric acid and hydrogen peroxide. Then, hydrogen peroxide reacts with 10-acetyl-3,7-dihydroxyphenoxazine (Ampliflu Red) under catalytic action of horseradish peroxidase so as to produce resorufin, a compound with strong fluorescence. The fluorescence intensity of resorufin is determined by using a fluorescence microplate, which is in direct proportion to the activity of xanthine oxidase.
II. Test Compound and Preparation of Reaction Solutions
A certain amount of a test compound and a control compound, febuxostat (by Beijing Lianben Pharm-chemicals Tech. Co., Ltd.) were dissolved in DMSO (by Sinopharm Chemical Reagent Co., Ltd.). A 2.5-fold serial dilution of the test compound was diluted with DMSO in a 96-well polypropylene reaction plate (by Greiner Bio One), so as to obtain a 200-fold dilution. The solution was further diluted in ultrapure water to obtain a 3-fold serial dilution.
Reaction solution A: 6 mU/mL xanthine oxidase (sourced from milk, by Sigma) was prepared in 0.1 M Tris-HCl (pH 7.5) buffer solution.
Reaction solution B: A mixed solution of 0.6 U/mL horseradish peroxidase (by Shanghai Yuanye Biological Technology Co., Ltd.), 0.15 mM Ampliflu Red (by Sigma), and 0.3 mM hypoxanthine (by Sigma) was prepared in 0.1 M Tris-HCl (pH 7.5) buffer solution. The solution was placed away from light at 4° C., and used immediately after preparation.
III. Determination Method
9 μL reaction solution A and 9 μL 3-fold serial dilution of the test compound were mixed in a 96-well test plate (by Greiner Bio One), placed on a flat plate type oscillator, and mixed at 30° C. for 30 min at 100 rpm. 9 μL reaction solution B was then added. A enzymatic reaction was carried out for 30 min at 30° C. The fluorescence intensity at 530 nm exciting light and 590 nm emitted light was determined by using a fluorescence microplate (Perkin Elmer Vitor X4). The fluorescence intensity without xanthine oxidase for comparison is 0%, and the fluorescence intensity without the test compound for comparison is 100%, according to which 50% inhibition concentration (IC 50 ) of the test compound and control compound febuxostat was calculated.
For the test results, refer to Table 1. It can be shown from Table 1 that, the compound of the present invention exhibited an excellent effect of xanthine oxidase inhibition in a pharmacological test in vitro.
TABLE 1
Xanthine Oxidase Inhibition Activity (IC 50 ) of Compounds
Compound No.
IC 50 (nM)
Compound 6
2.29
Compound 7
2.05
Compound 8
2.40
Compound 9
3.28
Compound 10
12.43
Compound 11
2.85
Compound 12
2.97
Compound 14
1.70
Compound 15
3.25
Compound 16
2.99
Compound 17
3.79
Compound 18
2.70
Compound 19
4.61
Compound 20
3.92
Compound 21
2.61
Compound 22
3.24
Compound 23
2.37
Compound 24
1.67
Compound 25
3.47
Compound 26
2.78
Compound 27
2.53
Compound 28
2.67
Compound 30
4.84
Compound 35
2.63
Compound 37
1.32
Compound 38
2.56
Compound 39
3.58
Compound 40
12.06
Compound 41
5.19
Compound 42
3.07
Compound 43
13.89
Compound 44
2.30
Compound 45
9.13
Compound 46
4.11
Compound 47
2.52
Compound 51
10.25
Compound 55
3.06
Compound 62
8.56
Compound 67
>100
Compound 68
2.84
Compound 69
6.01
Compound 70
31.07
Compound 74
10.08
Compound 81
2.29
Compound 83
2.43
Compound 86
25.45
Febuxostat
2.78 | A 2-aryl selenazole compound and a pharmaceutical composition are disclosed, wherein the 2-aryl selenazole compound is a compound represented by formula (I) or a pharmaceutically acceptable salt thereof. The 2-aryl selenazole compound has the activity of inhibiting xanthine oxidase. The compound or a pharmaceutically acceptable salt thereof can be applied in terms of preparing a drug used for prevention or treatment of hyperuricemia, gout, diabetic nephropathy, an inflammatory disease or a neurological disease. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit under 35 U.S.C. 119(e) from U.S. provisional patent application Ser. No. 60/533,306, filed Dec. 30, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The methods, apparatus and articles described herein are generally related to tracking and/or awarding third parties who originate or otherwise provide leads that may consummate in a consumer transaction, and facilitating timely responses to the referral of leads.
[0004] 2. Description of the Related Art
[0005] The Internet allows the providers of goods and/or services the ability to reach potential consumers directly in unprecedented ways. Conversely, the Internet provides potential consumers new ways to research and shop for goods and/or services, and to find providers of such goods and/or services. This new medium gives rise to new consumer behaviors, resulting in new demands upon the providers who serve such consumers.
[0006] One example of the many possible examples may be instructive. The consumer may, for example, be brought into the “door” of one provider (e.g., the provider's Website or Webpage), then led to the “door” of another provider (e.g., via a link to a second provider's Website or Webpage), and then led to the “door” of yet another provider, while all the time maintaining complete freedom to “browse” and research. In this example, the originator of the consumer inquiry (i.e., lead) will in most cases not be the service provider of the lead or the ultimate provider of the purchased goods and/or services.
[0007] When a potential consumer is interested in more information on a particular good and/or service, the consumer may desire immediate assistance or may request assistance at some later time. The consumer commonly expects more knowledgeable assistance when they indicate they are ready for help and/or more information.
[0008] In order for businesses to keep pace with the demands of the consumer, businesses must adapt or evolve the way in which they conduct business. Specifically, businesses must change the way they obtain, distribute, and manage their consumer inquiries.
[0009] One way these demands can be met is through the creation of new business relationships by the providers of goods and/or services. One of the many possible examples of such a relationship is a group of real estate companies, or offices, and/or agents affiliating themselves into a network of other real estate companies, or offices, and/or agents to combine their collective resources and people, to the mutual benefit of each other. The affiliation of these third party entities within a network is synergistic for these entities.
[0010] Another way these demands can be met is through the creation of new people and financial processes used by the providers of goods and/or services to capture revenue from these consumer inquiries. As an example, currently, the multi-billion dollar real estate industry is experiencing revolutionary change. The use of the Internet, and particularly the World Wide Web portion of the Internet, as a shopping tool for home buyers (consumers) is exploding. According to statistics from the National Association of Realtors® (NAR), 38% of home buyers used the Internet as a research tool just a few years ago; while today 72% of home buyers use the Internet as a research tool. Home buyers who do not use the Internet look at an average of 18 to 20 homes with an Agent before purchasing, while home buyers who use the Internet look at an average of 6 to 7 homes with an Agent before purchasing. Home buyers who use the Internet expect convenience in searching for homes, and researching schools, communities and areas. Home buyers who use the Internet also demand a fast and professional response when they are ready to look at a home. The providers that adapt to the consumer trends such examples represent, will be those who will prosper and grow in this new market place. Such adaptation must include serving the changes in consumer behavior and the naturally resulting needs.
[0011] A common approach has been for company/agent A to place a call to company/agent B to refer a prospective consumer. Company/agent B then pays company/agent A for the lead, or an agreed upon portion of the resulting sale or commission of the sale. As online systems came to the market, there have been many creative proposals for automating portions of the referral procedure. For example, company/agent A enters a lead into the system where company/agent B picks the lead up and updates the system with the follow through results after contacting the consumer, etc. What is inherent with these partially automated systems is the manual entry of the leads into the system, allowing such leads to be tracked.
BRIEF SUMMARY OF THE DISCLOSURE
[0012] One previously unrecognized problem in successfully realizing the above described approaches is the inability or difficulty in compensating or otherwise awarding the lead originator for their investment of time, money and/or goodwill in generating the consumer inquiries (i.e., leads). Another previously unrecognized problem in successfully realizing the above described approaches is the inability or difficulty of ensuring timely distribution of the leads to the best suited and available agents, providing the most timely response possible by that Agent, and ensuring that the consumer is satisfied that their needs were met by the Agent who serviced the lead.
[0013] Without a way to compensate the actual originator across the various possible scenarios, the collective benefit of sharing resources and/or network affiliation amongst one another for lead creation, distribution, and management, is minimized or lost altogether. In addition, without timely and independently confirmed follow through of the leads generated by the network, the percentage of leads that are successfully converted to actual sales remains very small, resulting in the lack of sufficient profit to implement the quality model needed to meet the evolving needs and demands of consumers using the Internet and/or other networks such as extranets and intranets. For example, statistics reported by the NAR show that only 50% of all leads generated in the real estate industry are responded to within 48 hours. The consumers who rely on the Internet typically want contact to occur no later than one hour after they make a request for more information.
[0014] One result of the issues raised above is a low conversion ratio of leads to sales, which may in some instance be under 10%. A low conversion ratio places at risk the current local agent's role in benefiting from leads generated by this new medium. Now with over 72% of all home buyers using the Internet to search for homes, it places their future viability in this changing market place at risk. This competitive obsolescence adversely affects the companies that the agents work for, and place these companies at risk of being unable to compete, and thus their very existence is uncertain, particularly as their agents go to work for their larger competitors who have invested in the costly adaptations needed to allow the agent to compete for the business of Internet using consumers. This allows the larger providers to grow, servicing the sophisticated consumers that the smaller providers leave behind.
[0015] Thus, one previously unrecognized problem with prior approaches is that such approaches do not identify the initial or original source of a lead. The previous approaches track the lead originator as the last Company the consumer came from, not the first Company the consumer visited. This leaves the originator of the actual lead unable to depend on compensation through a referral fee, thus breaking the model as an automated solution.
[0016] Another previously unrecognized problem with the prior approaches is the time and effort it takes on the part of the originating company/agent to record the referral, thus, many do not take the effort needed to do so.
[0017] Additionally, another previously unrecognized problem of prior approaches is that while such approaches provide for the lead being delivered to an agent, there is no agent's follow through confirmation or quality of service assessment. Such prior approaches provide for delivery of a lead to the agent, but lack the confirmation of the follow through in a timely and satisfactory fashion sufficient to redistribute the lead to another agent who can remedy the failed follow through by the Agent or in situations where the consumer has not been happy with the agent. Prior approaches also fail to ensure timely contact by an agent with the consumer because they distribute the lead to the agents in a linear or serial fashion, i.e., one at a time. This causes delays in response time, waiting for contact to be made to each Agent, one after the other, until a suitable agent is found who is available to service the lead. Ultimately these approaches do not resolve the failed follow through by the Agents because they stop at delivery only. These prior approaches do not ensure timely follow through; but only ensure timely delivery of the lead.
[0018] In one aspect, a method, system and article captures and tracks events. An event, for example, may take the form of a prospective consumer moving from company/agent A's product and/or service offerings, to company/agent B's product and/or service offerings. Other events may apply which may be distilled to a thumb-print image and tracked as the prospective consumer navigates between various goods and/or service offerings of a network of affiliated third party entities, for example, by Hyperlinking using the World Wide Web aspect of the Internet. The “event” becomes a point of entry for customized tracking, allowing an eventual consumer transaction to be automatically tracked back to the “event” and thus, tracked back to the originating entity (e.g., advertiser or company, etc.) which initially drew the consumer to the network of entities. This allows the originating party to be adequately and timely rewarded or compensated for driving the “lead” to the network of affiliated third parties.
[0019] In another aspect, a method, system and article automates the referral process by ensuring the delivery of the lead to the best suited agent who is available at the time. Such may be accomplished, for example, by transmitting the lead simultaneously to a number of agents (i.e., broadcasting), each of who have criteria in a profile that satisfies one or more particular search criteria. Broadcasting the lead in a multi-threaded fashion may achieve response times typically in the order of a few minutes, resulting in a “near time” response to the consumer. Once the lead is delivered, the potential consumer is contacted (e.g., phone call, email), if they have given permission to do so, and asked if the agent contacted them within the time required. The potential consumer may also be asked one more questions regarding the quality of service provided by the agent. The quality question may inquire directly or indirectly regarding whether the consumer was satisfied with the service they received by the agent who contacted them. If not, the consumer may elect to be contacted by another agent. The broadcast is then run again, omitting the previous agent from the agents notified by the broadcast. The agent is also omitted from any subsequent broadcasts made with respect to the particular lead and/or consumer. Following each broadcast, the same or a similar follow through inquiry of the consumer is made until the consumer is satisfied or requests that their inquiry be retired.
[0020] Current approaches are based on revenue models which do not yield sufficient profit to make an enterprise viable if they were to provide as complete and detailed of a solution as is possible using the approach disclosed herein. If existing approaches were to provide the service, processes, and technology disclosed herein, such approaches would be un-profitable with their current un-modified revenue models.
[0021] Unlike other approaches, the timely and satisfactory follow through with the consumer is independently ensured. This goes beyond just the timely delivery of the lead to the agent, since the current approach positively confirms that the consumer's needs are being met, rather than simply assuming such or never even appreciating that such an issue exists. If the consumer's needs are not met, this is addressed before the distribution of the lead is considered complete. Once a sale is made, compensation of the originator of the lead is achieved, regardless of how many intervening sites or contacts the consumer may have visited, thereby fostering a cooperative relationship between independent service providers affiliated into an online network. Collectively, the resulting profitable affiliation of like entities delivers a competitive advantage only previously available to the largest of competitors within the market. It delivers a unique affiliation and lead distribution model not available by any other known approach.
[0022] While the affiliation model and the distribution model can stand on their own as unique solutions, together they provide a unique synergistic approach to the above described problems.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0023] In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not drawn to scale, and some of these elements are arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not intended to convey any information regarding the actual shape of the particular elements, and have been solely selected for ease of recognition in the drawings.
[0024] FIG. 1 is a schematic diagram of a networked environment in which at least one exemplary embodiment may operate.
[0025] FIG. 2 is a functional block diagram of a computing system suitable for use in the networked environment of FIG. 1 , according to one illustrated embodiment.
[0026] FIG. 3 is a flow diagram showing a high level method of facilitating lead referral, and distributing leads according to one illustrated embodiment.
[0027] FIG. 4 is a flow diagram showing an intermediate level method of processing leads according to one illustrated embodiment.
[0028] FIG. 5 is a flow diagram of a low level method of processing leads according to one illustrated embodiment.
[0029] FIGS. 6A-6C are a flow diagram of a low level method of distributing the lead to the best matching agents according to one illustrated embodiment.
[0030] FIG. 7 is a flow diagram of a low level method of handling a lead referral with a backlog queue and a referral queue according to one illustrated embodiment.
[0031] FIG. 8 is a flow diagram of a low level method of determining whether the agent contacted the lead and determining consumer satisfaction according to one illustrated embodiment.
DETAILED DESCRIPTION
[0032] In the following description, certain specific details are set forth in order to provide a thorough understanding of various embodiments of the invention. However, one skilled in the relevant art will recognize that the invention may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures associated with networks, servers, clients, databases and computing systems have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the embodiments of the invention.
[0033] Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is as “including, but not limited to.”
[0034] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Further more, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0035] The headings provided herein are for convenience only and do not interpret the scope or meaning of the claimed invention.
[0036] FIGS. 1 and 2 , and the following discussion, provide a brief, general description of a suitable computing environment in which embodiments may be implemented. Although not required, embodiments will be described in the general context of computer-executable instructions, such as program application modules, objects, or macros being executed by a personal computer. Those skilled in the relevant art will appreciate that the invention can be practiced with other computing system configurations, including handheld devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, network PCs, minicomputers, mainframe computers, and the like. Embodiments can be practiced in distributed computing environments where tasks or modules are performed by remote processing devices, which are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
[0037] In particular, FIG. 1 shows a networked environment 10 comprising a tracking computing system 12 , and a number of third party computing systems 14 a - 14 e, and a consumer computing system 15 , all communicatively coupled via a Wide Area Network (WAN) such as the Internet 16 . While represented as the Internet 16 , the WAN may take the form of one or more extranets or intranets, or other types of networks, and can employ any of a variety of network architectures.
[0038] As described in more detail below, the tracking computing system 12 may take the form of a computer such as a server computer 18 , and may optionally include a monitor 20 and one or more user input devices such as a keyboard, keypad, mouse, trackball, digitizing tablet 22 , and/or touch screen display. The tracking computing system 12 may also include one or more data storage devices 24 storing one or more databases of information. While illustrated as being external to a housing of the server computer 18 , one or more of the data storage devices 24 may be located internally in the housing of the server computer 18 .
[0039] The third party computing systems 14 a - 14 e may take the form of a computer 26 configured to function as a server and/or client, and may optionally include a monitor 28 , and one or more user input devices such as a keyboard, keypad, mouse, trackball, digitizing tablet 30 , and/or touch screen display. Some of the third party computing systems 14 a - 14 c may be communicatively coupled to via a local or a wide area network 32 , with access to the Internet 16 provide by a server 34 . Such may be operated by or comprise a first third party affiliate with a respective Website/Webpage A. The third party computing system 14 d may be operated or comprises a second third party affiliate with a respective Website/Webpage B. The third party computing system 14 e may be operated by or comprises an originating third party affiliate with a respective Website/Webpage O. While only five third party computing systems 14 a - 14 e are illustrated, typical environments 10 would provide an almost unlimited number of third party computing systems 15 , since almost every business operated computing system in the world having access to the Internet could operate as a third party computing system 14 a - 14 e.
[0040] The consumer computing system 15 may take the form of a computer such as a client computer 31 , and may optionally include a monitor 33 , and one or more user input devices such as a keyboard, keypad, mouse, trackball, digitizing tablet 35 , and/or touch screen display. While only a single consumer computing system 15 is illustrated, typical environments 10 would provide an almost unlimited number of consumer computing systems 15 , since almost every computing system in the world having access to the Internet could operate as a consumer computing system 15 .
[0041] In particular FIG. 2 shows a conventional personal computer referred to herein as a computing system 46 that may be appropriate configured to function as either the tracking computing system 10 ( FIG. 1 ), as one of the third party computing systems 14 a - 14 e, or the consumer computing system 15 .
[0042] In the computing system 46 includes a processor unit 48 , a system memory 50 and a system bus 52 that couples various system components including the system memory 50 to the processing unit 48 . The processing unit 48 may be any logical processing unit, such as one or more central processing units (CPUs), digital signal processors (DSPs), application-specific integrated circuits (ASIC), etc. Unless described otherwise, the construction and operation of the various blocks shown in FIG. 2 are of conventional design. As a result, such blocks need not be described in further detail herein, as they will be understood by those skilled in the relevant art.
[0043] The system bus 52 can employ any known bus structures or architectures, including a memory bus with memory controller, a peripheral bus, and/or a local bus. The system memory 50 includes read-only memory (“ROM”) 54 and random access memory (“RAM”) 56 . A basic input/output system (“BIOS”) 58 , which can form part of the ROM 54 , contains basic routines that help transfer information between elements within the computing system 46 , such as during startup.
[0044] The computing system 46 also includes one or more spinning media memories such as a hard disk drive 60 for reading from and writing to a hard disk 61 , and an optical disk drive 62 and a magnetic disk drive 64 for reading from and writing to removable optical disks 66 and magnetic disks 68 , respectively. The optical disk 66 can be a CD-ROM, while the magnetic disk 68 can be a magnetic floppy disk or diskette. The hard disk drive 60 , optical disk drive 62 and magnetic disk drive 64 communicate with the processing unit 48 via the bus 52 . The hard disk drive 60 , optical disk drive 62 and magnetic disk drive 64 may include interfaces or controllers coupled between such drives and the bus 52 , as is known by those skilled in the relevant art, for example via an IDE (i.e., Integrated Drive Electronics) interface. The drives 60 , 62 and 64 , and their associated computer-readable media 61 , 66 and 68 , provide nonvolatile storage of computer-readable instructions, data structures, program modules and other data for the computing system 46 . Although the depicted computing system 46 employs hard disk 61 , optical disk 66 and magnetic disk 68 , those skilled in the relevant art will appreciate that other types of spinning media memory computer-readable media may be employed, such as, digital video disks (“DVD”), Bernoulli cartridges, etc. Those skilled in the relevant art will also appreciate that other types of computer-readable media that can store data accessible by a computer may be employed, for example, non-spinning media memories such as magnetic cassettes, flash memory cards, RAMs, ROMs, smart cards, etc.
[0045] Program modules can be stored in the system memory 50 , such as an operating system 70 , one or more application programs 72 , other programs or modules 74 , and program data 76 . The applications programs 72 may include one or more programs for tracking lead origination, locating and/or notifying suitable agents, tracking the status of leads, and maintaining information about agents and other third party affiliates. The system memory 50 also includes one or more communications programs 77 for permitting the computing system 46 to access and exchange data with sources such as websites of the Internet, corporate intranets, or other networks, as well as other server applications on server computers. The communications program 77 may take the form of a server program, particularly where the computing system 46 implements the server computer 18 ( FIG. 1 ) or third party computer 26 . Alternatively, or additionally, the communications program may take the form of a browser program, particularly where the computing system 46 implements the consumer computer 31 ( FIG. 1 ). The communications program 77 may be markup language based, such as hypertext markup language (“HTML”), and operate with markup languages that use syntactically delimited characters added to the data of a document to represent the structure of the document.
[0046] While shown in FIG. 2 as being stored in the system memory 50 , the operating system 70 , application programs 72 , other program modules 74 , program data 76 and communications program 77 can be stored on the hard disk 61 of the hard disk drive 60 , the optical disk 66 and the optical disk drive 62 and/or the magnetic disk 68 of the magnetic disk drive 64 .
[0047] A user can enter commands and information to the computing system 46 through input devices such as a keyboard 78 and a pointing device such as a mouse 80 . Other input devices can include a microphone, joystick, game pad, scanner, etc. These and other input devices are connected to the processing unit 48 through an interface 82 such as a serial port interface that couples to the bus 52 , although other interfaces such as a parallel port, a game port or a universal serial bus (“USB”) can be used. A monitor 84 or other display devices may be coupled to the bus 52 via video interface 86 , such as a video adapter. The computing system 46 can include other output devices such as speakers, printers, etc.
[0048] The computing system 46 can operate in a networked environment 10 ( FIG. 1 ) using logical connections to one or more remote computers. The computing system 46 may employ any known means of communications, such as through a local area network (“LAN”) 88 or a wide area network (“WAN”) or the Internet 90 . Such networking environments are well known in enterprise-wide computer networks, intranets, extranets, and the Internet.
[0049] When used in a LAN networking environment, the computing system 46 is connected to the LAN 88 through an adapter or network interface 92 (communicatively linked to the bus 52 ). When used in a WAN networking environment, the computing system 46 often includes a modem 93 or other device for establishing communications over the WAN/Internet 90 . The modem 93 is shown in FIG. 2 as communicatively linked between the interface 82 and the WAN/Internet 90 . In a networked environment, program modules, application programs, or data, or portions thereof, can be stored in a server computer (not shown). Those skilled in the relevant art will readily recognize that the network connections shown in FIG. 2 are only some examples of establishing communication links between computers, and other communications links may be used, including wireless links.
[0050] The computing system 46 may include one or more interfaces such as slot 94 to allow the addition of devices 96 , 98 either internally or externally to the computing system 46 . For example, suitable interfaces may include ISA (i.e., Industry Standard Architecture), IDE, PCI (i.e., Personal Computer Interface) and/or AGP (i.e., Advance Graphics Processor) slot connectors for option cards, serial and/or parallel ports, USB ports (i.e., Universal Serial Bus), audio input/output (i.e., I/O) and MIDI/joystick connectors, and/or slots for memory.
[0051] The term “computer-readable medium” as used herein refers to any medium that participates in providing instructions to processor unit 48 for execution. Such a medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, hard, optical or magnetic disks 61 , 66 , 68 , respectively. Volatile media includes dynamic memory, such as system memory 50 . Transmission media includes coaxial cables, copper wire and fiber optics, including the wires that comprise system bus 52 . Transmission media can also take the form of acoustic or light waves, such as those generated during radio wave and infrared data communications.
[0052] Common forms of computer-readable media include, for example, floppy disk, flexible disk, hard disk, magnetic tape, or any other magnetic medium, CD-ROM, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, RAM, PROM, EPROM, EEPROM, FLASH memory, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read.
[0053] Various forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to processor unit 48 for execution. For example, the instructions may initially be carried on a magnetic disk of a remote computer. The remote computer can load the instructions into its dynamic memory and send the instructions over a telephone line using a modem. A modem 93 local to computer system 46 can receive the data on the telephone line and use an infrared transmitter to convert the data to an infrared signal. An infrared detector coupled to the system bus 52 can receive the data carried in the infrared signal and place the data on system bus 52 . The system bus 52 carries the data to system memory 50 , from which processor unit 48 retrieves and executes the instructions. The instructions received by system memory 50 may optionally be stored on storage device either before or after execution by processor unit 48 .
[0054] FIG. 3 is a flow diagram of a high level method 100 according to one illustrated embodiment.
[0055] At 102 , a consumer browses the Internet, perhaps looking to purchase a good or service, perhaps looking for some piece of information or perhaps simply passing time. At 104 , the consumer arrives at a Website/Webpage A of a first third party affiliate. The consumer may arrive at the Website/Webpage A from a previous Website/Webpage O operated by an originating third party affiliate that has invested in advertising their Webpage or Website O or that has other goodwill that initially attracted the consumer. The tracking computing system 12 causes a unique session identifier of the consumer browser session to be saved for later use, for example, in the database of data storage device 24 or as a cookie on the consumer's computing system 15 or the third party affiliate's computing system 14 a - 14 e. Storing the unique session identifier at the database of data storage device 24 provides an enhanced level of security over the other options. Storing the unique session identifier on the third party affiliate's computing system 14 a - 14 e, or even on the consumer's computing system 15 reduces the amount of network traffic, and allows the entity operating the tracking computing system 12 to offload the storage function which would otherwise be monumental.
[0056] At 106 , the consumer continues browsing, reaching a Website/Webpage B operated by a second third party affiliate. The consumer may locate a good and/or service offered on the Website/Webpage B, for which the third party affiliate is a specialist in providing or which is competitively priced or has other desirable qualities. The browser session is automatically changed to Website/Webpage B, thus the consumer may, or may not, notice the change from Website/Webpage A to Website/Webpage B. This transfer of Websites/Webpages constitutes an “event” which is managed and tracked by the tracking computing system 12 and/or third party affiliate computing system 14 a - 14 e within this example. This event is saved for later use, for example in the database of data storage device 24 or as a cookie on the consumer's computing system 15 or the third party affiliate's computing system 14 a - 14 e. As discussed above, storing the information at the database of data storage device 24 provides an enhanced level of security over the other options. Storing the information at the third party affiliate's computing system 14 a - 14 e, or even on the consumer's computing system 15 reduces the amount of network traffic, and allows the entity operating the tracking computing system 12 to offload the storage function which would otherwise be monumental.
[0057] At 108 , the consumer requests more information, for example, via email, chat request or phone call. The request includes the capture by the tracking computing system 12 of the unique browser session identifier stored at 104 . This unique browser session identifier links the online session and the tracked events resulting from it to this request. This is accomplished whether the request by the consumer is an online request or an offline request (e.g., via a phone call). At this point all tracked browser history is available for reporting as desired. The tracking computing system 12 may also capture additional information, such as contact information for the consumer, which can be used below at 110 to link those steps back to the unique browser session identifier.
[0058] At 110 , the captured lead is fed into a lead distribution system via any number of means of communications means, for example, broadcasting or point casting using various communications channels such as wired or wireless communications including but not limited to email, telephone calls and/or messages, pager, and/or instant text messaging.
[0059] At 112 , the lead is distributed to the available agent having criteria that best matches selected criteria as determined by the distribution process. As discussed in more detail below, the agent is selected by one or more criteria specified by the referring third party affiliate (originating and/or intervening third party affiliate), the entity for which the agent works, the entity providing the tracking service, and/or consumer. Consequently, the best matching agent is selected to assist the consumer with the request for more information, based on the details of the lead.
[0060] At 114 , the consumer purchases product and/or service from Website/Webpage B associated with the second third party affiliate. The consumer may make the purchase in a conventional manner, for example, by entering requested data and making the desired selections typical of checkout procedures commonly encountered on retail Websites/Webpages.
[0061] At 116 , the Website/Webpage B reports the sale to the tracking computing system 12 , providing any one of the unique identifying data elements previously gathered, for example at 104 or 108 . In this example those elements are either the unique browser session identifier and/or the additional information provided by the consumer at 108 .
[0062] At 118 , the tracking computing system 12 determines that the originating third party affiliate operating the Website/Webpage O was the originator of the lead (lead originator) and second third party affiliate operating the Website/Webpage B was the product/service provider. The tracking computing system 12 alerts the originating third party affiliate operating the Website/Webpage O of the results of the lead follow-up. Optionally, the tracking computing system 12 may alert intervening third party affiliates, for example the first third party affiliate operating the Website/Webpage A of the results of the lead follow-up, particular where compensation and/or award will be provided to one or more intervening third party affiliates.
[0063] At 120 , the provider of the tracking services or other entity distributes a fee or other award to the originating third party affiliate operating Website/Webpage O, as compensation or acknowledgement for attracting consumer into the affiliated network via the Website/Webpage O. The provider of the tracking services or other entity may pay the fee or make the award from compensation provided by the second third party affiliate operating the Website/Webpage B in response to making the sale. Alternatively, the provider of the tracking services or other entity may pay the fee or make the award from compensation received form a participation fee paid by the second third party affiliate for participating in the third party affiliate network. While the provider of the tracking services has generally been discussed as a separate entity from the third party affiliates, such should not be considered limiting. In this sense, it is understood that the provider of the tracking services may also be one of the third party affiliates participating in the third party affiliation network. Additionally, the operators of intervening Websites/Webpages may also receive compensation and/or awards.
[0064] FIG. 4 is a flow diagram of an intermediate level method 200 of processing leads according to one illustrated embodiment.
[0065] At 202 , a lead is received by a lead originator and processed into a lead referral queue. A lead can be received by the system through any of the following means, but not limited to: a phone call, a form filled out on a Website/Webpage, an email, Web services transaction/event, a fax, etc. The tracking computing system 12 enters the lead into the lead referral queue.
[0066] At 204 , the tracking computing system generates a list of best matching agents, and/or next best matching agents based on various criteria. Each agent may have an administrative console to maintain an respective Agent Profile, where they can specify various criteria. A non-exhaustive list of examples may include: when the agent will accept leads, where the agent will accept leads, what kind of leads the agent will service/accept, and how the agent will accept leads. This process matches the lead with the best Agent(s) to service the Lead based on those specifics as provided by the lead. Such specifics may be generated by the affiliate providing the lead, by consumer, by the agents own company, and/or by the provider of the tracking services. In addition, the Agent selection criteria can include metrics data derived from the agent's past performance, including but not limited to: response time, follow-through, closing ratios, account status, overhead statistics, etc.
[0067] At 206 , the lead is distributed to the best matching agents with enough information for them to determine if they are interested in contacting the lead.
[0068] In one embodiment, the lead may be point cast to the agents, one by one. In such an embodiment, the agents may be ordered based on the closeness of the match to the selection criteria. Each agent is given a fixed period of time in which to respond, otherwise the lead is point cast to the next agent.
[0069] In another embodiment, the lead is broadcast to at least two agents at a time, until one agent accepts the lead. This process can and should be run multi-threaded n processes at a time in parallel, until an agent accepts the lead. The number of threads used to broadcast the lead may be dynamic based on the number of agents best matching the selected criteria. This unique broadcast methodology distinguishes itself from a linear or serial approach (i.e., point cast to one agent at a time), and advantageously requires less time to find an agent to serve the consumer. This permits the consumer to be quickly serviced by the best suited agent.
[0070] At 208 , the tracking computing system 12 saves the distribution state, for example, storing information about which best matching agents have been contacted about the lead and did not accept it, as well as, which agents the tracking computing system 12 was not able to contact, and/or which agents have not yet been contacted about the lead.
[0071] At 210 , the tracking computing system 12 or third party affiliate that is providing the lead sends the agent that accepts the lead the full details regarding the lead, including, but not limited to, the lead contact information. The tracking computing system 12 may employ a fixed time period by which the full details regarding the lead must be provided to the agent. If a third party affiliate is providing the full details to the agent, then the failure to forward the full details regarding the lead within the time period may affect the compensation or reward to be received by the third party affiliate. Alternatively, if the tracking computing system is providing the full details to the agent, then the failure to forward the full details regarding the lead within the time period may affect the compensation paid to the entity providing the tracking services or third party affiliate network. For example, the agent or agent's company may be entitled to a refund of some portion of a fee paid to participate in the third party affiliate network.
[0072] At 212 , it is determined whether the consumer to which the lead pertains agreed to a verification inquiry. At the time of inquiry the consumer is able to specify whether or not they will accept an inquiry regarding service, and may or may not be allowed to select a mode of communications for accepting such an inquiry, for example via phone call, email, and/or facsimile. The inquiry is for the purpose of confirming timely follow through of by the agent that accepts the lead, as well as the consumer's satisfaction with the service provided by the agent. This approval allows management of leads to be retained by the tracking computing system 12 and/or operator of the third party affiliated network. Therefore, if the agent has not called in the time required, or the consumer is not satisfied with the service provided, another Agent can be obtained to assist the consumer. This feature is unique, in that, the system goes beyond simply delivering a lead to an agent, by ensuring that the consumer's needs and expectations are being met using the consumer's own feedback. By tracking failures by agents to timely contact the consumer, this approach can provide a disincentive to agents accepting more leads than the agent can competently and timely handle.
[0073] At 214 , the tracking computing system 12 links or associates the originator of the lead with the with agent who is servicing the lead. For example, the tracking computing system 12 can link or associate the originator of the lead with the agent by defining or storing a relationship between entries representing the originator and the agent in the database of data storage device 24 ( FIG. 1 ).
[0074] At 216 , it is determined whether the agent contacted the consumer to which the lead pertains. The consumer is automatically contacted via the tracking computing system 12 or personally contacted by a person who is not associated with the agent who accepted the lead. The inquiry verifies that the agent succeeded in contacting and assisting the consumer to the consumer's own satisfaction. This inquiry with the consumer is made using the mode of communications selected by the consumer at the time of their original inquiry if the consumer made such a selection.
[0075] At 218 , if the agent did not contact the consumer to which the lead pertains, or if the consumer is not satisfied with the service provided by the agent, the consumer is asked whether they would like another agent to contact them.
[0076] If the consumer would like another agent to contact them, or where no contact has been made yet and the consumer still wishes to be contacted by an agent, the control returns to 204 to find the next best agent to serve the consumer represented by the lead. By selecting the next best agent, the previously selected agent is inherently removed from the process. The tracking computing system may additionally note that the agent should not be included in any new leads that correspond to the particular consumer, and/or may update selection criteria for the particular agent to reflect the dissatisfaction of the consumer.
[0077] If the consumer does not wish to be contacted by another agent, the not, then optionally an inquiry may be made if the consumer will authorize contact at a later time and the consumers desired form of communications for such contacts (e.g., email, phone call, etc.) At 220 , the tracking computing system 12 updates the status of the lead to indicate that the lead is closed and the lead was not properly serviced by any agent. Updated data may include any future contact authorization and approved methods. The absence of authorization may be treated as an implied do-not-contact request. This data may be stored for future reporting metrics.
[0078] At 220 , the tracking computing system 12 creates a report for the lead originator to notify the lead originator of the result of its originated lead. This report can be in the form of, but is not limited to, a digital transaction submitted over the Web to the lead originator's computing system 14 a - 14 e, an email, a hard copy document mailed via conventional mail, a fax, etc.
[0079] At 224 , the lead has either been distributed to an agent accepting the lead or the lead has declined further help and the distribution process of method 200 is complete.
[0080] FIG. 5 is a flow diagram of a low level method 300 of processing a lead in accordance with 202 of the method 200 ( FIG. 4 ) according to one illustrated embodiment.
[0081] At 302 , the tracking computing system 12 determines if it is time for a lead to be queued for distribution. This helps insure that a lead is always matched to the agent best able to service the lead at the time contact is requested. It must be noted that time is needed to locate a suitable and available agent to contact the consumer identified by the lead at the time requested.
[0082] If it is determined at 302 that it is not yet time for a lead to be serviced, the lead is left in the queue at 304 . Otherwise, at 306 the tracking computing system 12 gets the agent with the best matching criteria based on availability to contact the lead within the allotted time. In particular, the tracking computing system 12 determines all agents that are available to service the lead within the defined time period (e.g., 12 minutes) based on the preferences in the agents' profiles and the details provided with the lead.
[0083] At 308 , the tracking computing system 12 refines the determined best matching agent set to the service metrics of the lead. Given all agents that are available to service a lead within the defined period, the tracking computing system 12 selects those which will be a best fit for the lead based on the lead details and the information saved in the profiles of the agents.
[0084] FIGS. 6A-6C are a flow diagram of a low level method 400 of distributing the lead to the best matching agents in accordance with 206 of method 200 ( FIG. 4 ) according to one illustrated embodiment.
[0085] As illustrated the method shows a broadcast to three agents simultaneously or nearly simultaneously. The process for each of the agents is the same or similar so like acts will share a reference number and be distinguished by an alphabetic character appended to the reference number. It is to be understood that a broadcast typically may include transmission to more than three agents at once, or as few as two agents at once. The case of a point cast is illustrated by any single leg of the method 400 , and will not be further illustrated or discussed for the sake of brevity.
[0086] At 402 a - 402 c, the tracking computer system 12 or some entity not associated with the agent tries to contact the selected agent(s). Contact may be made by any communications channel, for example but is not limited to phone calls, text messages, email, facsimile, etc, and may be by multiple communications channels.
[0087] At 404 a - 404 c, it is determined whether the contact was made with the selected agent(s). A 406 a - 406 b, the tracking computing system 12 determines whether the lead is still available. This ensures that the lead has not been taken during the time that it took to contact the agent or during the time that it took to transmit the lead details to the agent after making contact.
[0088] At 408 a - 408 c, the tracking computing system 12 transmits enough information to the agent so as to allow the agent to decide whether or not the agent would like to accept the lead. This information should not include personally identifiable information about the lead, just sufficient enough to make a decision. This information may, for example, include, general geographic area, type of goods and/or services, pricing information, etc.
[0089] At 410 a - 410 b, the tracking computing system 12 determines whether agent will accept the lead and commit to servicing the lead within the defined period of time. At 412 a - 412 c, the tracking computing system 12 can again determine whether the lead is still available in response to determining that an agent will accept the lead at 410 a - 410 c.
[0090] If it is confirmed at 412 a - 412 c that the lead is still available, the tracking computing system 12 lets the agent accepting the lead know that the lead is no longer available for them to accept. Otherwise, the tracking computing system 12 updates the status of the lead at 414 a - 414 c, to indicate that the lead has been accepted by an agent. The method 400 terminates at 418 a - 418 c.
[0091] FIG. 7 is a flow diagram of a low level method 500 determining handling a lead referral and a lead queue in accordance with 202 of method 200 ( FIG. 4 ) according to one illustrated embodiment.
[0092] At 502 , the tracking computing system 12 receives a lead. At 504 , tracking computing system 12 records the identity of the lead originator for example, in the database of data storage device 24 . At 506 , the tracking computing system 12 places the lead in a backlog queue, which may for example be stored in the database of data storage device 24 ( FIG. 1 ). At 508 , the tracking computing system 12 determines whether the lead needs to be handled within the next defined period of time. If tracking computing system 12 determines that the lead does not need to be handled in the next defined period of time, the tracking computing system 12 returns or leaves the lead to the backlog queue. Otherwise, the tracking computing system 12 places the lead in a referral queue, which may, for example be stored in the database of data storage device 24 ( FIG. 1 ).
[0093] FIG. 8 is a flow diagram of a low level method 600 determining whether the agent contacted the lead and determining consumer satisfaction in accordance with 216 of method 200 ( FIG. 4 ) according to one illustrated embodiment.
[0094] At 602 , the tracking computer system 12 or some entity not associated with the agent tries to contact the consumer identified by the lead. Contact may be made by any communications channel, for example but is not limited to phone calls, text messages, email, facsimile, etc.
[0095] At 604 , the tracking computer system 12 or the entity not associated with the agent determines whether consumer identified by the lead could be contacted. If it is determined that the consumer cannot be contacted, control passes to 606 to update the status of the lead, for example by returning to 220 of method 200 ( FIG. 4 ).
[0096] If it is determined that the consumer can be contacted, it is determined at 608 whether the agent contacted the consumer. This may be done by asking the consumer during a phone call, or by emailing, text messaging or otherwise making an inquiry of the consumer.
[0097] If it is determined that the agent contacted the consumer, control passes to 610 where the lead originator is linked with the agent or agent's company, for example by returning to 214 of method 200 ( FIG. 4 ). If it is determined that the agent did not contact the consumer, it is determined whether the consumer would like to be contacted by another agent at 612 . If it is determined that the consumer does not wish to be contacted by another agent, control passes to 606 to update the status of the lead. Otherwise, control passes to 614 to select the next available agent, for example by returning to 204 of method 200 ( FIG. 4 ) and omitting the previous agent from the search criteria, or by employing a saved list of previously selected agents.
[0098] The above description of illustrated embodiments, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Although specific embodiments of and examples are described herein for illustrative purposes, various equivalent modifications can be made without departing from the spirit and scope of the invention, as will be recognized by those skilled in the relevant art. The teachings provided herein of the invention can be applied to other methods, systems and articles for attributing compensation, credit or other awards, not necessarily the exemplary referral based system generally described above.
[0099] For instance, the foregoing detailed description has set forth various embodiments of the devices and/or processes via the use of block diagrams, schematics, and examples. Insofar as such block diagrams, schematics, and examples contain one or more functions and/or operations, it will be understood by those skilled in the art that each function and/or operation within such block diagrams, flowcharts, or examples can be implemented, individually and/or collectively, by a wide range of hardware, software, firmware, or virtually any combination thereof. In one embodiment, the present subject matter may be implemented via Application Specific Integrated Circuits (ASICs). However, those skilled in the art will recognize that the embodiments disclosed herein, in whole or in part, can be equivalently implemented in standard integrated circuits, as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more controllers (e.g., microcontrollers) as one or more programs running on one or more processors (e.g., microprocessors), as firmware, or as virtually any combination thereof, and that designing the circuitry and/or writing the code for the software and or firmware would be well within the skill of one of ordinary skill in the art in light of this disclosure.
[0100] In addition, those skilled in the art will appreciate that the mechanisms of taught herein are capable of being distributed as a program product in a variety of forms, and that an illustrative embodiment applies equally regardless of the particular type of signal bearing media used to actually carry out the distribution. Examples of signal bearing media include, but are not limited to, the following: recordable type media such as floppy disks, hard disk drives, CD ROMs, digital tape, and computer memory; and transmission type media such as digital and analog communication links using TDM or IP based communication links (e.g., packet links).
[0101] The various embodiments described above can be combined to provide further embodiments. All of the U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet, including but not limited to U.S. provisional patent application Ser. No. 60/533306, filed Dec. 30, 2003 are incorporated herein by reference, in their entirety. Aspects of the invention can be modified, if necessary, to employ systems, circuits and concepts of the various patents, applications and publications to provide yet further embodiments of the invention.
[0102] These and other changes can be made to the invention in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the invention to the specific embodiments disclosed in the specification and the claims, but should be construed to include all methods, systems and articles that operate in accordance with the claims. Accordingly, the invention is not limited by the disclosure, but instead its scope is to be determined entirely by the following claims. | Tracking the origination, and/or the series of referring parties allows adequate, accurate and timely recognition of referrals or leads, fostering increased cooperation between parties. An trusted intermediary may expeditiously track or monitor the referrals or leads further enhancing cooperation between parties, allowing the successful implementation of new business models. Broadcasting the availability of a lead to multiple agents having suitable criteria increases the responsiveness to consumer inquires or leads. | 6 |
This invention relates to a method and an apparatus for injecting gasification medium into particle-loaded gasification spaces of fixed-bed, fluidized-bed or entrained-bed gasifiers by means of gasification-medium nozzles.
BACKGROUND OF THE INVENTION
Gasification medium (GM), which by means of gasification-medium nozzles (GM nozzles) is injected into particle-loaded gasification spaces of fixed-bed, fluidized-bed or entrained-bed gasifiers, frequently consists of a vapor/oxygen mixture (GM mixture). Beside pure vapor/oxygen mixtures other GM mixtures are also used, e.g. by admixing air, CO 2 and other usable gases. The GM nozzles are designed both as externally cooled and as uncooled one-component nozzles. From the multitude of gasification processes, the British Gas/Lurgi slag bath gasification process (BGL gasifier) should subsequently be selected, by means of which the fact of injection can be represented particularly clearly in its complexity.
A vapor/oxygen mixture with a mixing ratio of about 1 kg vapor/Nm 3 oxygen is injected into the BGL gasifier. The GM nozzles are inclined downwards against the horizontal. The GM jet leaving the GM nozzles is directed onto the surface of the slag bath in the bottom portion of the BGL gasifier. When operated as specified, the GM mixture reacts with coke carbon particles and other oxidizable components present in the reaction space in direct vicinity in front of the nozzle orifice and releases heat due to combustion reactions. In the developing air-blast tuyere of the BGL gasifier, temperatures up to more than 2000° C. are usually obtained. At these temperatures, the slag is present as low-viscosity liquid.
The nozzle head protruding into the reaction space of the BGL gasifier is cooled intensively to avoid slag accretions and to protect against metal oxidation. The outer contours of the GM nozzles are designed to be compact and save surface area, in order to keep working surfaces for slag and the introduction of heat into the GM nozzles as low as possible.
The GM nozzles are designed as one-component nozzles. To definitely prevent slag or carbonaceous components from entering the GM nozzle through the cylindrical nozzle orifice and from impeding or blocking the nozzle exit, the gasification medium (GM) is blown out from the nozzle orifice at rather high speed. Under nominal load of the BGL gasifier, the GM exit rate is about 60 to 180 m/s. The higher the GM exit rate, the higher the risk of particles being sucked back into the GM nozzle. The nozzle orifices are clogged and finally block the exit of gasification medium. Disturbed nozzles are detected by measuring a low flame intensity and a decrease in the amount of gasification medium reaching the nozzle. Largely clogged or even blocked, so-called “black” nozzles must be shut off for safety reasons. This leads to performance losses up to the premature shut-down of the BGL gasifier. Experience has shown that frequently a plurality of nozzles go “black” at the same time or in quick succession, must be shut off, and thus necessitate the shut-down of the BGL gasifier before long. To fortify the GM nozzles, the BGL gasifier must be cooled and drained. This leads to long downtimes with considerable losses of output and high maintenance costs. In practical operation, the BGL must repeatedly be shut off due to the ingress of slag and carbonaceous material into the GM nozzles, in particular under unstable operating conditions and during start-up processes.
An essential safety criterion for the operation of the BGL gasifier is the assurance of an undisturbed, regular outflow of the gasification medium from the GM nozzles, which can only be ensured by absolute cleanliness of the inner nozzle contour of the GM nozzle in direct vicinity of the nozzle orifice. An undisturbed jet exit generally is accompanied by the undisturbed and uniform formation of a flame in front of the nozzle. An undisturbed, free formation of a jet is the best guarantee that the oxygen discharged reacts directly in front of the nozzle, is not deflected and does not get into colder regions of the BGL gasifier or to the ceramic brick lining unreacted. So far, there are no solutions to this problem.
What turns out to be particularly critical is the increased failure frequency of the GM nozzles during the gasification of heterogeneous waste substance mixtures in the BGL gasifier, the gasification and slag flow behavior of such mixtures being characterized by particularly strong irregularities. The following causes should be mentioned: extremely quickly variable slag viscosities and rapidly changing slag bath levels due to strong variations in the ash content and quality, very high and greatly varying temperatures in front of the nozzles due to the high and varying GM/coke ratio of the generally highly volatile waste substances, strong pressure pulsations in the air-blast tuyere in front of the nozzles.
The problems of the injection of gasification medium into particle-loaded gasification spaces, which were described with reference to the example of the BGL gasifier, similarly exist also for other gasification processes, such as the HTW fluidized-bed gasification. To solve these problems, very expensive two-component nozzles are used, which restrict the operational flexibility. The susceptibility to failure can likewise not be decreased to a sufficient extent.
As a result of the disadvantages of the prior art, it is the object of the invention to ensure a stable and uninterrupted supply of gasification medium (GM) into particle-loaded gasification spaces under all operating conditions and to ensure an undisturbed, uniform and intensive formation of a flame in front of the GM nozzles, even when using extremely hetereogeneous feedstocks, to avoid the clogging of GM nozzles, the shut-down of clogged GM nozzles and thus, in the final analysis, the premature shut-down of the gasifier.
SUMMARY OF THE INVENTION
For the solution of this object it is proposed to supply the gasification medium to the gasification space such that the flow rate of the gasification medium based on isothermal and isobaric conditions (GM isorate) in the GM supply tube up to shortly before the exit of the gasification medium from the nozzle orifice (supply portion) has a minimum value, and that the gasification medium in the adjoining last nozzle portion directly up to the exit of the gasification medium from the nozzle orifice (acceleration portion) is constantly accelerated and behind the nozzle orifice is concentrated in a focus, and that in cases in which liquid slag particles or a slag bath are present in the reaction space, in the last nozzle portion as seen in flow direction against the horizontal, the deepest GM flow thread is aligned to be inclined downwards or at best horizontally.
DETAILED DESCRIPTION
Maintaining the minimum GM isorates in the supply portion shortly before the exit of the gasification medium from the nozzle orifice serves to always protect the interior of the GM nozzle against the ingress of material. Under partial load, minimum GM isorates of 15 to 20 m/s should usually be maintained.
The invention furthermore is based on the knowledge that even under rough and unsteady operating conditions the acceleration of the GM flow in the acceleration portion allows a complete and safe avoidance of the introduction of disturbing matter into the GM nozzle up to maximum GM iso exit rates. The flow rests particularly tight against the inner contour of the acceleration portion directly up to the exit of the gasification medium from the GM nozzle at the nozzle orifice, so that no material can reach the inner nozzle wall, even if the nozzle immerges into the slag bath. The GM isorate is increased in the acceleration portion by 20 to 200%, preferably by 50 to 100%, the acceleration length being 0.5 to 3 times the diameter of the supply portion. The inventive acceleration of the GM isorate effects that under all operating conditions the GM nozzles are protected against the introduction of solids and hence against clogging or blocking.
By accelerating the gasification medium in the acceleration portion directly up to the nozzle orifice, focussing the GM jet in a jet focus (focus) a few millimeters in front of the nozzle orifice and hence a small negative pressure as compared to the pressure existing at the nozzle orifice can be achieved. Therefore, the cone angle of the acceleration portion preferably is defined to lie in the range from 5 to 20°. Slag and carbonaceous components reaching the nozzle orifice from outside are moved away from the nozzle orifice into the focus and from the same along with the GM jet on into the interior of the gasification space. Thereby, the formation of external accretions at the nozzle orifice is effectively prevented. By increasing the GM exit rate, the negative pressure in front of the GM nozzle and the extension of the negative pressure region, the introduction of carbon into the GM jet and hence the carbon conversion in front of the GM nozzles is increased. In the case of the presence of liquid slag or a slag bath in the gasification space, the constriction of the GM nozzle in the acceleration portion is also limited in that, as seen in flow direction against the horizontal, the deepest GM flow thread is aligned to be inclined downwards against the horizontal by 0 to 30°, preferably 5 to 15°, or at best horizontally. In accordance with the invention, this angular limitation ensures that upon immersion of the GM nozzle into the slag bath no slag can adhere in the interior of the nozzle. Moreover, no material can deposit in the GM nozzle even during downtimes.
The invention has a fundamentally advantageous effect for the gasification of difficult gasification substances, as is represented below with reference to the example of the BGL gasifier. For the first time, the GM nozzles remain free from clogging in continuous operation. Low to high GM flow rates are mastered easily.
The operational availability in time and the performance of the BGL gasifier are no longer restricted by clogging problems of the GM nozzles. Start-up and shut-down procedures are mastered even in complicated operating situations. The increase of the GM exit rate and the focussing of the jet lead to more uniform gasification processes in the air-blast tuyere and to a higher safety with respect to the undisturbed and uniform formation of a flame in front of the GM nozzle. Dangerous jet deflections, the advance of unreacted gasification medium into colder regions up to damages of the brickwork or other uncontrolled reactions are avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the one component nozzle used in the method of the present invention, wherein the diameter at the beginning of the acceleration portion ( 7 ) is smaller than the diameter of the supply portion ( 5 ), and the deepest GM flaw thread ( 13 ) is aligned to be downwardly inclined.
FIG. 2 illustrates the one component nozzle used in the method of the present invention, wherein the diameter at the beginning of the acceleration portion ( 7 ) is equal to the diameter of the supply portion ( 5 ), and the deepest GM flow thread ( 13 ) is aligned to be horizontally inclined.
In the drawings, the following reference numerals represent the following elements:
1 gasification-medium nozzle 2 gasification-medium supply tube 3 gasification-medium mixture 4 gas space 5 supply portion 6 nozzle orifice 7 acceleration portion 9 transition 10 jet of gasification medium 11 focus 12 horizontal 13 gasification medium flow thread
EXAMPLE
The invention will subsequently be explained in detail with reference to an embodiment. It describes the supply of gasification medium into an industrial BGL gasifier for gasifying extremely heterogeneous waste substances. The GM mixture supplied to the BGL gasifier via a total of 6 GM nozzles consists of 6,000 Nm 3 /h oxygen and 5,700 g/h vapor. The GM nozzles constitute one-component nozzles of circular nozzle cross-section. FIG. 1 shows a schematic representation of the section through the front end of the GM nozzle 1 . The coaling jacket surrounding the GM supply tube 2 is not represented for simplicity. To the GM supply tube 2 GM mixture 3 is supplied with a temperature of 260° C. In the gas space of the air-blast tuyere 4 a pressure of 25 bar(a) and a mean temperature of 2,100° C. exist. In accordance with the invention, the inner nozzle contour consists of two portions, the cylindrical supply portion 5 and the acceleration portion 7 conically tapering towards the nozzle orifice 6 , which acceleration portion constitutes a welded sleeve. The place where the acceleration portion 7 begins is referred to as transition 9 . The transition 9 represents an abrupt reduction of the diameter from 25 to 24 mm. The GM mixture 3 flows through the supply portion 5 with a GM isorate of 104 m/s (300° C., 25 bar(a)). From the transition 9 up to the exit from the nozzle orifice 6 , which has a diameter of 19 mm, the GM isorate is accelerated continuously in the acceleration portion 7 . The GM jet 10 leaves the nozzle orifice 6 with a GM isorate of 179 m/s. The length of the acceleration portion is 23.8 mm, the cone angle hence is defined to be 6°. In front of the nozzle orifice 6 , the acceleration of the GM jet 10 continues for a distance of a few millimeters and in the focus 11 reaches the maximum GM isorate and the lowest static pressure.
The axis of the GM nozzle 1 is inclined 20° downwards against the horizontal 12 . The deepest GM flow thread 13 has a downward inclination against the horizontal 12 of 14°.
By realizing the above-described type of nozzle in the large-scale gasification plant, the object of the invention was solved in practice. The advantages of the invention with respect to the prior art were achieved in all stated points. | Method and apparatus for injecting gasification medium into particle-loaded gasification spaces of fixed-bed, fluidized-bed or entrained-bed gasifiers by means of gasification-medium nozzles, wherein the supply portion the isorate of the gasification medium in the gasification-medium nozzle does not fall below a minimum value, and in the adjoining acceleration portion the gasification medium is constantly accelerated and upon exit from the nozzle orifice is concentrated in a focus. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/894,144, filed Jul. 19, 2004. The disclosure of the above application is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to storage device controllers, and more particularly, to efficiently managing data flow using a WWN module.
2. Background
Conventional computer systems typically include several functional components. These components may include a central processing unit (CPU), main memory, input/output (“I/O”) devices, and streaming storage devices (for example, tape drives/disks) (referred to herein as “storage device”).
In conventional systems, the main memory is coupled to the CPU via a system bus or a local memory bus. The main memory is used to provide the CPU access to data and/or program information that is stored in main memory at execution time. Typically, the main memory is composed of random access memory (RAM) circuits. A computer system with the CPU and main memory is often referred to as a host system.
The storage device is coupled to the host system via a controller that handles complex details of interfacing the storage device to the host system. Communications between the host system and the controller is usually provided using one of a variety of standard I/O bus interfaces.
Typically, when data is read from a storage device, a host system sends a read command to the controller, which stores the read command into a buffer memory. Data is read from the device and stored in the buffer memory.
Various standard interfaces are used to move data from host systems to storage devices. Fibre channel is one such standard. Fibre channel (incorporated herein by reference in its entirety) is an American National Standard Institute (ANSI) set of standards, which provides a serial transmission protocol for storage and network protocols such as HIPPI, SCSI, IP, ATM and others. Fibre channel provides an input/output interface to meet the requirements of both channel and network users.
Host systems often communicate with storage systems using the standard “PCI” bus interface. PCI stands for Peripheral Component Interconnect, a local bus standard that was developed by Intel Corporation®. The PCI standard is incorporated herein by reference in its entirety. Most modern computing systems include a PCI bus in addition to a more general expansion bus (e.g. the ISA bus). PCI is a 64-bit bus and can run at clock speeds of 33 or 66 MHz.
PCI-X is a standard bus that is compatible with existing PCI cards using the PCI bus. PCI-X improves the data transfer rate of PCI from 132 MBps to as much as 1 GBps. The PCI-X standard (incorporated herein by reference in its entirety) was developed by IBM®, Hewlett Packard Corporation® and Compaq Corporation® to increase performance of high bandwidth devices, such as Gigabit Ethernet standard and Fibre Channel Standard, and processors that are part of a cluster.
The iSCSI standard (incorporated herein by reference in its entirety) is based on Small Computer Systems Interface (“SCSI”), which enables host computer systems to perform block data input/output (“I/O”) operations with a variety of peripheral devices including disk and tape devices, optical storage devices, as well as printers and scanners.
A traditional SCSI connection between a host system and peripheral device is through parallel cabling and is limited by distance and device support constraints. For storage applications, iSCSI was developed to take advantage of network architectures based on Fibre Channel and Gigabit Ethernet standards. iSCSI leverages the SCSI protocol over established networked infrastructures and defines the means for enabling block storage applications over TCP/IP networks. iSCSI defines mapping of the SCSI protocol with TCP/IP. The iSCSI architecture is based on a client/server model. Typically, the client is a host system such as a file server that issues a read or write command. The server may be a disk array that responds to the client request.
Serial ATA (“SATA”) is another standard, incorporated herein by reference in its entirety that has evolved from the parallel ATA interface for storage systems. SATA provides a serial link with a point-to-point connection between devices and data transfer can occur at 150 megabytes per second.
Another standard that has been developed is Serial Attached Small Computer Interface (“SAS”), incorporated herein by reference in its entirety. The SAS standard allows data transfer between a host system and a storage device. SAS provides a disk interface technology that leverages SCSI, SATA, and fibre channel interfaces for data transfer. SAS uses a serial, point-to-point topology to overcome the performance barriers associated with storage systems based on parallel bus or arbitrated loop architectures.
The SAS specification addresses all devices in its domain by using a World Wide Name (WWN) address. The WWN is a unique 64-bit field that is allocated by IEEE to storage devices manufacturers.
In a SAS domain there could be up to 256 active devices. The devices could be of Initiator type or Target type. Initiator device initiates an Input/Output process (I/O) by sending a Command frame. The Target device completes an I/O by sending a Response frame. Any Initiator device may have up to 256 active I/O commands at a given time. Before any frame is sent, a connection is established between two SAS devices. A connection consists of an “Open Address” frame with a WWN field in it. On every Open Address, the receiving device compares the Open Address WWN to open I/O commands. Also, every I/O command may have multiple connections.
Typically, storage controllers use a Micro Controller that is 8-bit wide. The foregoing process of tracking connections using the 64-bit WWN addresses is time consuming. Therefore, there is a need for a system and method for efficiently manage connections and effectively use the WWN addresses.
SUMMARY OF THE INVENTION
In one aspect of the present invention, a method for managing frames entering or leaving a storage controller is provided. The method includes, comparing frame elements of incoming frames, including a unique World Wide Name (WWN) address with a WWN module entry; and if there is a match, updating a counter value for a connection between the storage controller and a device sending frames. A WWN index value is provided to a processor of the storage controller. The counter value is increased when a command frame is received and decreased when a command is executed and a response is sent to the device.
In yet another aspect of the present invention, a storage controller for transferring data between a host and a Serial Attached Small Computer Interface (“SAS”) device is provided. The storage controller includes: a World Wide Name (“WWN”) module that includes a table having plural entries, wherein each row includes a WWN address, an initiator tag value field, and an input/output counter value that tracks plural commands for a connection. The WWN module uses the WWN index value that represents an address of a row having plural entries.
The WWN module is a part of a link module that interfaces between a transport module and a physical module for transferring information. The WWN index value is smaller than the WWN address and can be read by a micro-controller or processor of the storage controller.
In yet another aspect of the present invention, a WWN module in a storage controller is provided. The WWN module includes, a table having plural entries, wherein each row includes a WWN address, an initiator tag value field, and an input/output counter value that tracks plural commands for a connection.
This brief summary has been provided so that the nature of the invention may be understood quickly. A more complete understanding of the invention can be obtained by reference to the following detailed description of the preferred embodiments thereof concerning the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing features and other features of the present invention will now be described with reference to the drawings of a preferred embodiment. In the drawings, the same components have the same reference numerals. The illustrated embodiment is intended to illustrate, but not to limit the invention. The drawings include the following Figures:
FIG. 1A shows an example of a storage drive system used with the adaptive aspects of the present invention;
FIG. 1B shows a block diagram of a SAS module used in a controller, according to one aspect of the present invention;
FIG. 1C shows a detailed block diagram of a SAS module, according to one aspect of the present invention;
FIG. 1D shows a SAS frame that is received/transmitted using the SAS module according to one aspect of the present invention;
FIG. 2A shows a block diagram of a WWN Index module, according to one aspect of the present invention;
FIG. 2B shows yet another block diagram of a WWN Index module with plural commands, according to one aspect of the present invention;
FIGS. 3A-3G illustrate the various process steps for implementing the WWN index module, according to one aspect of the present invention; and
FIG. 4 is a process flow diagram for using the WWN index module, according to one aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Controller Overview
To facilitate an understanding of the preferred embodiment, the general architecture and operation of a controller will initially be described. The specific architecture and operation of the preferred embodiment will then be described with reference to the general architecture.
FIG. 1A shows an example of a storage drive system (with an optical disk or tape drive), included in (or coupled to) a computer system. The host computer (not shown) and the storage device 110 (also referred to as disk 110 ) communicate via a port using a disk formatter “DF” 104 . In an alternate embodiment (not shown), the storage device 110 is an external storage device, which is connected to the host computer via a data bus. The data bus, for example, is a bus in accordance with a Small Computer System Interface (SCSI) specification. Those skilled in the art will appreciate that other communication buses known in the art can be used to transfer data between the drive and the host system.
As shown in FIG. 1A , the system includes controller 101 , which is coupled to buffer memory 111 and microprocessor 100 . Interface 109 serves to couple microprocessor bus 107 to microprocessor 100 and a micro-controller 102 and facilitates transfer of data, address, timing and control information. A read only memory (“ROM”) omitted from the drawing is used to store firmware code executed by microprocessor 100 .
Controller 101 can be an integrated circuit (IC) that comprises of various functional modules, which provide for the writing and reading of data stored on storage device 110 . Buffer memory 111 is coupled to controller 101 via ports to facilitate transfer of data, timing and address information. Buffer memory 111 may be a double data rate synchronous dynamic random access memory (“DDR-SDRAM”) or synchronous dynamic random access memory (“SDRAM”), or any other type of memory.
Disk formatter 104 is connected to microprocessor bus 107 and to buffer controller 108 . A direct memory access (“DMA”) DMA interface (not shown) is connected to microprocessor bus 107 and to data and control port (not shown).
Buffer controller (also referred to as “BC”) 108 connects buffer memory 111 , channel one (CH 1 ) logic 105 , error correction code (“ECC”) module 106 to bus 107 . Buffer controller 108 regulates data movement into and out of buffer memory 111 .
CH 1 logic 105 is functionally coupled to SAS module 103 that is described below in detail. CH 1 Logic 105 interfaces between buffer memory 111 and SAS module 103 . SAS module 103 interfaces with host interface 104 A to transfer data to and from disk 110 .
Data flow between a host and disk passes through buffer memory 111 via channel 0 (CH 0 ) logic 106 A. ECC module 106 generates ECC that is saved on disk 110 during a write operation and provides correction mask to BC 108 for disk 110 read operation.
The Channels, CH 0 106 A, CH 1 105 and Channel 2 (not shown) are granted arbitration turns when they are allowed access to buffer memory 111 in high speed burst write or read operations for a certain number of clocks. The channels use first-in-first out (“FIFO”) type memories to store data that is in transit. Firmware running on processor 100 can access the channels based on bandwidth and other requirements.
To read data from device 110 , a host system sends a read command to controller 101 , which stores the read commands in buffer memory 111 . Microprocessor 100 then reads the command out of buffer memory 111 and initializes the various functional blocks of controller 101 . Data is read from device 110 and is passed to buffer controller 108 .
To write data, a host system sends a write command to disk controller 101 , which is stored in buffer 111 . Microprocessor 100 reads the command out of buffer 111 and sets up the appropriate registers. Data is transferred from the host and is first stored in buffer 111 , before being written to disk 110 . Cyclic redundancy code (“CRC”) values are calculated based on a logical block address (“LBA”) for the sector being written. Data is read out of buffer 111 , appended with ECC code and written to disk 110 .
Frame Structure:
FIG. 1D shows a SAS frame 129 that is received/transmitted using SAS module 103 . Frame 129 includes a WWN address 129 A, a start of frame (“SOF”) value 129 G, a frame header 129 B that includes a frame type field 129 E, payload/data 129 C, CRC value 129 D and end of frame (“EOF”) 129 F. WWN address 129 A is used for each open connection at a given time.
Also, a frame may be an interlock or non-interlocked, specified by field 129 E. For an interlock frame, acknowledgement from a host is required for further processing, after the frame is sent to the host. Non-interlock frames are passed through to a host without host acknowledgement (up to 256 frames per the SAS standard).
SAS Module 103 :
FIG. 1B shows a top level block diagram for SAS module 103 used in controller 101 . SAS module 103 includes a physical (“PHY”) module 112 , a link module 113 and a transport module (“TRN”) 114 described below in detail. A micro-controller 115 is used to co-ordinate operations between the various modules. A SAS interface 116 is also provided to the PHY module 112 for interfacing with a host and interface 117 is used to initialize the PHY module 112 .
FIG. 1C shows a detailed block diagram of SAS module 103 with various sub-modules. Incoming data 112 C is received from a host system, while outgoing data 112 D is sent to a host system or another device/component.
PHY Module 112 :
PHY module 112 includes a serial/deserializer (“SERDES”) 112 A that serializes encoded data for transmission ( 112 D), and de-serializes received data ( 112 C). SERDES 112 A also recovers a clock signal from incoming data stream 112 C and performs word alignment.
PHY control module 112 B controls SERDES 112 A and provides the functions required by the SATA standard.
Link Module 113 :
Link module 113 opens and closes connections, exchanges identity frames, maintains ACK/NAK (i.e. acknowledged/not acknowledged) balance and provides credit control. As shown in FIG. 1C , link module 113 has a receive path 118 that receives incoming frames 112 C and a transmit path 120 that assists in transmitting information 112 D. Addresses 121 and 122 are used for received and transmitted data, respectively. WWN index module 119 A is used for maintaining plural connections states, described below in detail.
Receive path 118 includes a converter 118 C for converting 10-bit data to 8-bit data, an elasticity buffer/primitive detect segment 118 B that transfers data from a receive clock domain to a transmit block domain and decodes primitives. Descrambler module 118 A unscrambles data and checks for cyclic redundancy check code (“CRC”).
Transmit path 120 includes a scrambler 120 A that generates CRC and scrambles (encodes) outgoing data; and primitive mixer module 120 B that generates primitives required by SAS protocol/standard and multiplexes the primitives with the outgoing data. Converter 120 C converts 8-bit data to 10-bit format.
Link module 113 uses plural state machines 119 to achieve the various functions of its sub-components. State machines 119 includes a receive state machine for processing receive frames, a transmit state machine for processing transmit frames, a connection state machine for performing various connection related functions and an initialization state machine that becomes active after an initialization request or reset.
Transport Module 114 :
Transport module 114 interfaces with CH 1 105 and link module 113 . In transmit mode, TRN module 114 receives data from CH 1 105 , loads the data (with fibre channel header (FCP) 127 ) in FIFO 125 and sends data to Link module 113 encapsulated with a header ( 129 B) and a CRC value ( 129 D). In receive mode, TRN MODULE 114 receives data from link module 113 (in FIFO 124 ), and re-packages data (extracts header 126 and 128 ) before being sent to CH 1105 . CH 1 105 then writes the data to buffer 111 . State machine 123 is used to co-ordinate data transfer in the receive and transmit paths.
WWN Index Module 119 A
WWN Index module 119 A, as shown in FIG. 2A , includes a table with “n” (where n is greater than 1) elements. WWN Index module 119 A stores information about each open connection between storage controller 101 and a device/host. WWN Index module 119 A has plural rows/layers. Each row (for example, row 206 in FIG. 2A ) is referred to by its index value (address value) 205 . For example, row 206 includes a SAS address field (64 bit WWN address) 200 , an Initiator Connection tag (16 bits) 201 , an I/O counter (10 bits) 202 , a single bit (“V”) 203 to indicate the validity of an entry and a fresh (F) field 204 that indicates the latest row that is being serviced.
When an Open Address frame is received, the WWN address 129 A (WWN address field) of the received frame is compared with the WWN address field ( 200 ) in module 119 A. A successful comparison returns a WWN index value 205 . This WWN index value 205 is provided to MC 115 . Since the WWN index value 205 is an 8-bit field, MC 115 can handle it very efficiently.
It is noteworthy that the present invention is not limited to any particular size of module 119 A or any of its entries. For example, WWN index value 205 is not limited to an 8-bit value or any other size.
If a WWN address of an Open Address frame is not recognized by module 119 A entries and the first frame is of Command type, then a new entry (or row 206 ) is created and its I/O count 202 is set to one. The new row 206 is allocated a WWN index value 205 , so that when a frame from the same source/connection arrives again, then module 119 A can return the proper WWN index value ( 205 ) after the comparison.
For each frame crossing link module 113 , the frame type is checked. If the frame is of Command type, the I/O counter of the active entry is incremented (increased) ( 202 ). If the frame is of Response type, the I/O count of the active entry is decremented (decreased). When the I/O count reaches zero, the valid bit 203 is reset and the entry becomes vacant.
FIG. 2B shows a detailed diagram of WWN module 119 A with row 206 . The various entries are loaded in rows based on receive access (path) 207 and transmit access (path) 208 . Reset command 209 is used to reset module 119 A. MC 102 , MC 115 or MP 100 may issue the reset command.
“Get Index by WWN” 213 (or signal 213 ) allows searching of module 119 A by WWN address 200 and/or Initiator Tag value 201 . MC 115 , MC 102 or MP 100 may use this function. If the “Get Index by WWN” function 213 finds an entry that matches a search term (for example, for an incoming frame), then the WWN index value 205 is returned with a “success” flag. If no match is found then a new entry is allocated and the new value is returned. If the table is full based on signal 213 , then a “fail” flag is returned. A successful allocation causes the valid bit 203 to be set. The valid bit 203 is cleared for an entry when the I/O counter value 202 reaches a certain value, for example, 0.
Signal/command “INC by Index” 212 is used to increment the index value 205 . Also, MP 100 (or MC 102 or 115 ) may load a row (for example, 206 ) by using an index value 205 (by using “Load by Index” command 211 ). Using “Clear by Index” signal/command 210 clears entries in a row ( 206 ).
FIG. 4 shows a flow diagram for using module 119 A, according to one aspect of the present invention. Turning in detail to FIG. 4 , in step S 400 , a request to open connection is made between a device (SAS peer device) 300 A ( FIG. 3A ) and controller 101 . If the request is accepted, then a connection is established in step S 401 , otherwise the process loops back to step S 400 and waits. The connection is shown as 301 A in FIG. 3A . At this stage the I/O counter value is zero (shown as 202 A).
In step S 402 , the process determines if a WWN address entry exists. If yes, the process moves to step S 404 . If an entry does not exist in step S 402 , then an entry is created in step S 403 .
In step S 404 , a WWN index value is established for the entry (WWN index value 205 ).
In step S 405 , a frame is received/transmitted by controller 101 .
In step S 406 , the process determines if a frame is of command type. If yes, then I/O counter value 202 is incremented ( 202 B, FIG. 3B ). If the frame is not of command type, then in step S 408 , the process determines if the frame is of response type. If the frame is of a response type, then the I/O counter value 202 is decremented ( 202 B, FIG. 3F ).
If the frame is not of a response type (in step S 410 ), then the connection is closed in step S 410 and in step S 411 , all the entries are de-allocated with the I/O counter value 202 cleared to zero ( 202 A, FIG. 3A ).
FIGS. 3A-3G illustrate the use of WWN module 119 A, according to one aspect of the present invention. FIG. 3A shows that a connection 301 A is established between controller 101 and device 300 A. I/O counter value is zero, shown as 202 A. FIG. 3B shows that a command 300 is received and thereafter, the I/O counter value is increased to 1 (shown as 202 B).
FIG. 3C shows that data 301 is received from device 300 A and I/O counter value remains the same (i.e. 1). FIG. 3D shows that controller 101 receives another command 302 and that device 300 A is ready for a transfer (shown as 300 B). The I/O counter value is increased to 2, shown as 202 C.
FIG. 3E shows that data 304 is received by device 300 A via controller 101 and data 303 is received from device 300 A. I/O counter value remains 2 (shown as 202 C).
FIG. 3F shows that command 300 is complete and a response 305 is received by device 300 A. I/O counter value is decreased to 1 and is shown as 202 B.
FIG. 3G shows that data 306 is received by device 300 A via controller 101 . After command 302 is complete, response 307 is sent to device 300 A. Thereafter, the I/O counter value is decreased to zero, shown as 202 A.
In one aspect of the present invention, a dynamic WWN module is provided that dynamically updates connection information. Also, the WWN module provides an easy to use index value that can be used by MC 115 , MC 102 and MP 100 .
Although the present invention has been described with reference to specific embodiments, these embodiments are illustrative only and not limiting. Many other applications and embodiments of the present invention will be apparent in light of this disclosure. | A controller including an interface module and an index module. The interface module is configured to connect devices. The index module is configured to include, in a table stored in memory, an entry for each of the devices. Each entry includes an address field. The index module is configured to: receive a frame of data including an address of one of the devices; compare the address to the address fields associated with the entries in the table; in response to the address matching one of the address fields, access an index value identifying an entry of the table when the address matches one of the address fields; and in response to the address not matching one of the address fields, generate the index value. The index value is used to connect the device associated with the matching one of the address fields with the one of the devices. | 7 |
BACKGROUND
[0001] This invention relates to authentication of users of electronic information and transaction processing systems, and more specifically to systems and methods for authenticating users of program objects in distributed computing environments based on negotiated security contexts.
[0002] Many computer and communication systems restrict access to authorized users. As typically shown in FIG. 1 , a user 110 accesses such a system 120 through a suitable interface such as a computer 130 executing a client application. The computer 130 and client application can communicate with the system 120 by either a direct connection or via the Internet using a convenient protocol such as http as illustrated by connection 140 . In accessing the system 120 , the client application recognizes that a user authentication process must be carried out as a threshold step, and thus the client application usually requests the user 110 to enter a logon ID and a password that uniquely identify the user 110 to the system 120 . The logon ID and password are conventionally forwarded to a logon component 122 via an application server component 124 included in the system 120 .
[0003] The logon component 122 compares the logon ID and password received from the user to an archive of logon IDs and passwords stored in a rules database 126 . Upon finding a match with the forwarded logon ID, the logon component 122 retrieves the corresponding password from the rules database 126 and compares the retrieved password with the password forwarded by the user 110 . If the passwords match, the logon component 122 sends an instruction or a message via the application server component 124 to the client application in computer 130 that indicates that the user 110 been properly identified and authenticated to proceed. This authentication step and/or subsequent instructions or messages may initiate a secure communication session using a convenient protocol such as https indicated by connection 150 . Subsequent communication between the system 120 and computer 130 can then proceed in private.
[0004] Where encryption is employed, a client cryptographic token such as an electronic circuit card conforming to the standards of the PC Memory Card Interface Association (a PCMCIA card or PC Card) can be used in the computer 130 . In general, a token is a portable transfer device that is used for transporting keys, or parts of keys. It will be understood that PC Cards are just one form of delivery mechanism; other kinds of tokens may also be used, such as those conforming to RSA Laboratories' software token Public-Key Cryptography Standard (PKCS) #12, floppy diskettes, and Smart Cards.
[0005] If the logon ID provided by the user 110 does not match an ID in the rules database 126 or if the password comparison fails, the logon component 122 typically sends a message or instruction through the application server component 124 to the client application to inform the user 110 that the submitted logon information was incorrect and to prompt the user to re-enter it. This process of entering and attempting to verify the logon information may be permitted to occur a few times, but in the event of repeated failure, the logon component 122 may finally reject further logon attempts by the user 110 , direct the client application to inform the user 110 that the logon process has failed, terminate the communication session, and lock out the user from any further logon attempts.
[0006] A password is one form of identification that may be presented to the logon component 122 that authenticates the user's access rights, which may range from simply viewing selected records in the system 120 to performing all transactions permitted by the system 120 . This kind of secured transaction processing is typically “state-full” in that it maintains, in the transaction session, the process state and content of the user's logon access information. Different transactions are typically implemented in modern distributed, nested, transaction processing systems by different program objects, e.g., applications or subroutines, that are substantially independent, even to the extent of executing on different processor hardware. For a user to migrate from one secured transaction to another, which is often necessary for even simple uses of today's systems, the user is generally required to logon (i.e., be authenticated) to each transaction, often with ID's and passwords unique to each transaction. This is because state-full systems impose state routing restrictions on users, and only sessions with particular restrictions can service a given user without having to close one program object and open another, with the corresponding requisite logon.
[0007] Besides the burden on system resources imposed by each logon, which requires access to and processing by a logon component and a rules database, state-full systems often compel each user to close one secured transaction (program object or application) before entering another, limiting the flexibility of the system from the user's perspective. In addition, if the path to the rules database is closed or if excessive traffic slows processing or access to any of the necessary components of the system, the user access to the desired application is compromised, even if the user's access is fully authorized. This becomes a significant problem for systems having many potential users because economics often limits the system resources that can be made available.
[0008] Another problem is that conventional enrollment systems can be viewed as “open doorways” into an otherwise protected application in that a successful logon provides a user full access to the application and a failed logon “slams the door” on access to the application. No middle ground is generally provided, whereby a properly identified user is provided partial access to an application or transaction.
[0009] Yet another problem with systems like that depicted in FIG. 1 is the vulnerability of such systems to a hacker's or a pirate's intercepting a user's logon information at any of several points and then gaining unauthorized access to a supposedly secure system, such as an online brokerage system. One countermeasure to such interception is the application of cryptography to the data being transmitted. Public-Key Cryptography (PKC), or asymmetric cryptography, is a form of data encryption that uses a pair of cryptographic keys, each pair having a public key that is used for encryption and a private (secret) key used for decryption. Exemplary PKC algorithms, which comply with contemporary government or commercial standards, are the Digital Signature Algorithm and the Rivest-Shamir-Adleman (RSA) algorithm. The alternative to PKC is a symmetric key cryptographic system that uses the same key for encryption and decryption. Exemplary symmetric systems are the Data Encryption Standard (DES) and its improvement, the Advanced Encryption Standard (AES), recently announced by the National Institute of Standards and Technology (NIST). Symmetric key cryptography is normally employed for encrypting large amounts of data since it is much faster than PKC, but PKC is still advantageously used for key distribution. Nevertheless, encrypting transmitted data may address privacy concerns in electronic commerce and communication, but encryption alone does not address the issues of integrity and authentication of the transmitted information.
[0010] In this application, “privacy” means the protection of a record from unauthorized access. “Integrity” means the ability to detect any alteration of the contents of a record or of the relative authority of a user to perform a transaction or access a record. “Authentication” means verification of the authority of a user to perform a transaction, use a system resource, or access an electronic record. It will be appreciated that “electronic record” and “record” mean information in any electronic form, regardless of type of medium or type of information. Thus, a record can be a tape cartridge, a voice transmission or recording, a video image, a multi-media object, a contract, metadata, a database of information, etc.
[0011] Integrity and authentication of information are typically handled by other cryptographic operations, in particular hashing the information to be protected and appending one or more digital signatures. In general, a one-way cryptographic function operates on the information and produces a “hash” or “message digest” in a way such that any change of the information produces a changed message digest. Since a different message digest is produced if even one bit of the information object is changed, the hash operation yields a strong integrity check. Known hashing algorithms are the Secure Hash Algorithm (SHA-1) and the Message Digest 5 (MD-5) algorithm, and new algorithms appear from time to time. Information is typically digitally signed by hashing the information, encrypting the resulting hash using the signer's private key, and appending the encrypted hash to the information. Thus, digital signatures are generated in a manner like PKC, but the keys are reversed: the encryption key is private and the decryption key is public; the digital signer signs information with the private key and a user can read the digital signature with the signer's public key. Since a digital signature is an non-forgeable data element attached or allocated to information that ties the signer to the information, the digital signature yields an authentication check. It will be appreciated that a digital signature differs from a holographic, or handwritten, signature and from a digitized holographic signature, which is a handwritten signature that has been captured electronically.
[0012] The uses of digital signatures typically involve uses of authentication certificates, which are non-forgeable, digitally signed data elements that bind the signers' identity information to the signers' public-key information. Authentication certificates have been standardized by the International Telecommunications Union (ITU) under International Standard X.509, as documented in “The Directory-Authentication Framework” (1988) and as interpreted by the Internet Engineering Task Force Public Key Infrastructure X.509 recommendations. An authentication certificate is digitally signed and issued by a Certification Authority that is responsible for ensuring the unique identification of all users. Each authentication certificate typically includes the following critical information needed in the signing and verification processes: a certificate version number, a serial number, identification of the Certification Authority that issued the certificate, identifications of the issuer's hash and digital signature algorithms, a validity period, a unique identification of the user who owns the certificate, and the user's public cryptographic signature verification key. A signer's authentication certificate may be appended to information to be protected with the user's digital signature so that it is possible for others to verify the digital signature.
[0013] Single-logon methods have been implemented in which a logon component returns a “cookie” or token to a client application that allows the client application system-wide logon in a distributed computing environment. One example of this is the SITEMINDER software product made by Netegrity, Inc., Waltham, Mass., and described at www.netegrity.com. Such single-logon methods avoid the need for repeated logons, but have severe limitations when used with state-less computing environment components.
[0014] U.S. Pat. No. 5,757,920 for “Logon Certification” and No. 5,999,711 for “Method and System for Providing Certificates Holding Authentication and Authorization Information for Users/Machines”, both to Misra et al., describe logon certificates that are provided to support disconnected operation in distributed computing systems. Each logon certificate is a secure package holding credentials information sufficient to establish the identity and rights and privileges for a user or a machine in a domain that is not the user's/machine's home domain.
[0015] U.S. Pat. No. 5,241,594 to Kung for “One-Time Logon Means and Methods for Distributed Computing Systems” describes storing password files in all networked computers in a distributed system and, after a user logs on to a computer, forwarding authentication information to a second computer using a secure transport layer protocol if the user wishes to use services at the second computer. The second computer compares the user's authentication information it receives with the user's authentication information it stores, and if the informations match, the user is logged on to the second computer.
[0016] Other logon methods and systems are described in U.S. Pat. No. 5,655,077 to Jones et al. for “Method and System for Authenticating Access to Heterogeneous Computing Services”; No. 5,689,638 to Sadovsky for “Method for Providing Access to Independent Network Resources by Establishing Connection Using an Application Programming Interface Function Call Without Prompting the User for Authentication Data”; No. 5,768,504 to Kells et al. for “Method and Apparatus for a System Wide Logan [sic] in a Distributed Computing Environment”; No. 5,774,650 to Chapman et al. for “Control of Access to a Networked System”; No. 5,884,312 to Dustan et al. for “System and Method for Securely Accessing Information from Disparate Data Sources through a Network”; and No. 6,178,511 to Cohen et al. for “Coordinating User Target Logons in a Single Sign-On (SSO) Environment”.
[0017] The problems with systems like that shown in FIG. 1 are keenly felt in many computer and communication systems, including as just one example those employed in electronic commerce. As paper documents that have traditionally recorded transactions, such as the purchase of an object, the withdrawal of bank funds, or the execution of a contract, are replaced by electronic records, serious issues of physical control of the electronic records and access to them are raised. Systems and methods for providing a verifiable chain of evidence and security for the transfer and retrieval of electronic records and other information objects in digital formats have been described in U.S. Pat. No. 5,615,268; No. 5,748,738; and No. ______; all to Bisbee et al., and U.S. patent application Ser. No. 09/452,928, filed on Dec. 2, 1999, and No. 09/737,325, filed on Dec. 14, 2000, both by Bisbee et al. These patents and applications are expressly incorporated here by reference, and describe among other things flexible business rules that enable users to have roles that are required or enabled only at particular points in a transaction or process. For example, a user may have a role of title agent only after a transaction has closed.
[0018] Such work flows and processes can be more complex than those typically associated with single-logon techniques. Moreover, many electronic records available to online inquiry are neither encrypted, nor hashed, nor digitally signed since to do so increases the processing time and resources needed for authorized users to access such information.
SUMMARY
[0019] This invention solves the above-described and other problems suffered by computer and communication systems having restricted access, providing methods and systems for providing secure access to information in an on-line, networked environment in which traditional methods of verification, integrity, and authentication are generally inapplicable or ineffective. Important features of the invention involve an encrypted data element called a security context, which is securely built and accessible only by a trusted computing environment, thereby eliminating the risk of interception, modification, or unauthorized use.
[0020] In orie aspect of the invention, a security context is built from a user's logon information and from system authorization information that define the user's access rights to protected on-line applications and electronic information. The security context is hashed and encrypted to protect the included logon and access information from theft and misuse. Following a successful logon that establishes a respective security context, the user may seek access to applications, transactions, and records without having to re-logon and without having to re-access a logon rules database. This does not preclude the user from requesting a new security context if necessitated by a change in either the user's role in a transaction or the type of transaction. A user's level of access can be controlled by a plurality of identifiers, such as the user's logon ID, the user's organization ID and sub-organization ID's, and the user's particular role or credentials within the organization. System resources protected in accordance with this invention are not limited to electronic records and computer-directed applications and transactions but also extend to secured equipment, such as facsimile machines and certified printers.
[0021] In another aspect of the invention, a method of enabling access to a resource of a processing system includes the steps of establishing a secure communication session between a user desiring access and a logon component of the processing system; verifying that logon information, provided by the user to the logon component during the secure communication session, matches stored information identifying the user to the processing system; generating a security context from the logon information and authorization information that is necessary for access to the resource; providing the security context to the user; and sending, by the user to the processing system, the security context and a request for access to the resource. The resource may be at least one of a processor, a program object, and a record of the processing system, and the logon component may provide a symmetric encryption key to the user in establishing the secure communication session. The user may digitally sign the request for access, the user's digital signature may be included with the request for access in a wrapper that is sent with the security context to the processing system, the user's digital signature may be checked by the processing system, and access to the resource may be granted only if the user's digital signature is authenticated.
[0022] The logon information may include a password and at least one of a user identifier, an organization identifier, a sub-organization identifier, a user location, a user role, and a user position. The logon information may be verified by checking for agreement between the stored information identifying the user to the processing system and the password and at least one of a user identifier, an organization identifier, a sub-organization identifier, a user location, a user role, and a user position provided by the user to the logon component.
[0023] The security context may include a plaintext header and an encrypted body, and the plaintext header may include a security context ID, a key handle, and an algorithm identifier and key size. The encrypted body may include at least one of a user identifier, an organization identifier, access information, an expiration time, public key information, symmetric key information, and a hash, and access to the resource may be denied if the expiration time differs from a selected time. The access information may specify at least one resource accessible by the user; the expiration time specifies a time after which the security context is invalid; and the hash is computed over the plaintext header and the encrypted body before encryption, and may be digitally signed by the logon component.
[0024] The method may further include the step of determining, by a stateless component of the processing system, based on the security context sent with the request for access by the user, whether access to the requested resource should be granted to the user. The request for access may be at least partially encrypted with a symmetric encryption key extracted from the security context. A hash value may be computed over the request for access and be included with the security context and the request for access sent by the user to the processing system, with the integrity of the request for access being checked based on the hash value, and access being granted only if the integrity of the hash value is verified. A request counter may be included in the request for access, and if access is granted, a response is sent to the user that includes the a request counter, enabling the user to match the response to the request for access. A response can also be an acknowledgement of an action performed (e.g., creation of a “certified” printout of a record).
[0025] In another aspect of the invention, a processing system having resources, such as processors, program objects, and records, that are selectively accessible to users includes a communication device through which a user desiring access to a resource communicates sends and receives information in a secure communication session with the processing system; an information database that stores information identifying users to the processing system and authorization information that identifies resources accessible to users and that is necessary for access to resources; and a logon component that communicates with the communication device and with the information database, wherein the logon component receives logon information provided by the user during the secure communication session, verifies the received logon information by matching against information identifying the user to the processing system that is retrieved from the information database, and generates a security context from the received logon information and authorization information. The logon component provides the security context to the user's communication device, and the user sends, to the processing system, the security context and a request for access to a resource. The processing system may further include a cryptographic accelerator, and the logon component may receive a symmetric encryption key from the cryptographic accelerator and provides the symmetric encryption key to the user's communication device.
[0026] Other aspects of the invention are described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] These and other objects and advantages of this invention will become more apparent from the following description, read in conjunction with the drawings, of which:
[0028] FIG. 1 is a block diagram of user authentication in existing processing systems;
[0029] FIG. 2 is a block diagram of user enrollment in a system in accordance with this invention;
[0030] FIG. 3 is a block diagram of user authentication in a system in accordance with this invention;
[0031] FIG. 4 a is a diagram of a security context in accordance with this invention;
[0032] FIG. 4 b is a diagram of a plaintext header of a security context;
[0033] FIG. 4 c is a diagram of a body of a security context;
[0034] FIG. 5 is a block diagram of a user interacting with a secured client application in a system in accordance with this invention;
[0035] FIG. 6 a is a diagram of a security context associated with a user request or submission;
[0036] FIG. 6 b is a diagram of a security context associated with a user request in which a time parameter and a request counter are additional authentication factors;
[0037] FIG. 7 is a diagram of the system response to a user request or submission; and
[0038] FIG. 8 illustrates methods in accordance with the invention.
DETAILED DESCRIPTION
[0039] It will be appreciated that Applicants' invention can be implemented utilizing commercially available computer systems and technology, and since the details of such are well known to those of skill in the art, they will not be described in this application.
[0040] In using secure transaction processing systems, even in a system such as that depicted in FIG. 1 , a system administrator usually must enroll a user with the system by entering identification, authorization, and attribute information that uniquely describe the user to the system. This is depicted in FIG. 2 , which shows a user's enrollment information being provided by a known authority 210 to a system administrator 220 , which enters the enrollment information into a trusted computing environment (TCE) 230 . Entered information may include such items as the user's name, user identification (ID), organization name, organization ID, and location.
[0041] The enrollment information is typically provided to an interface device such as an application server component 232 that communicates with a logon component 234 of the TCE 230 . The logon component 234 or an equivalent device generates a password for the user and securely stores the password in a protected rules database 236 . Since password generation and protection is often processing intensive, the TCE 230 may include a suitable cryptographic accelerator 238 or other special-purpose processor that implements the cryptographic algorithms used for generating and checking passwords and for other operations. The password is securely delivered to the user via the application server 232 and an approved courier 240 . The approved courier 240 may be a traditional overnight service, such as Federal Express, that delivers the password in physical form, or an e-mail server or a facsimile machine that delivers the password electronically. The user receives the password (block 250 ) and must present the password to the TCE system 230 before access is granted. The TCE is so named because it includes the elements necessary for authenticated access to the transactions offered through the application server 232 .
[0042] Many of the components for enrolling a user as depicted in FIG. 2 have additional important functions. In particular, enrollment information solicited by the system administrator and provided by a known authority to uniquely identify the user to the TCE 230 is extensive. For example, the enrollment information preferably includes organization name, organization ID, role, and optionally, location and multiple sub-organization names and IDs. The known authority may typically be associated with a sponsoring organization or other entity that endorses the user's access to secured system resources and is known to the system 230 . While the known authority or sponsoring organization generally provides the user's enrollment information to the system 230 , the user may also provide the information.
[0043] The logon component 234 examines all received enrollment information for compliance with rules and requirements maintained in the rules database 236 , which must be protected storage to ensure the integrity of the identification and authorization information it maintains. Any received enrollment information that is not in compliance preferably causes a message to be displayed or other indication to be given to the information submitter to prompt submission of correct information. In general, the rules database 236 may be initialized with user authorization and attribute information in the form of data, flags, algorithms, business rules, etc. With this information, as will be discussed more thoroughly below, the system can provide varying levels of authorized access to system resources, depending on the particular organization or sub-organization the user represents and the role the user plays in accessing particular transactions and/or records.
[0044] As with conventional systems, the enrollment information obtained by the system administrator is passed to the logon component 234 , which instead of merely storing a password in the rules database 236 , first processes the password through a suitable protective method or device such as a hashing algorithm and stores the hashed password in the rules database such that it is associated, or linked, to the particular user by the user's logon ID and optionally by the user's organization ID. The logon component 234 then forwards the unhashed (plaintext) password to the user through any of the secure communication channels discussed above. After a user has been enrolled by the system 230 and has received a password, the user can access system applications, components, transactions, and records, but only after the user is authenticated as having authority to access the secured resources.
[0045] FIG. 3 is a block diagram depicting user authentication in accordance with an aspect of this invention. After a User 310 invokes a protected Client Application 320 , whether via a direct connection to a TCE 330 or via an Internet browser, control passes automatically from the user-invoked application via an Application Server 332 to a Logon Component 334 to attempt authentication of the User 310 through the exchange of secured logon information. As indicated in FIG. 3 , the Client Application 320 may execute in a suitable computer or terminal having a Cryptographic Token as described above in connection with FIG. 1 . One function of the Logon Component 334 is generating a private/public encryption key pair at pre-selected time intervals for use in creating secret symmetric sessions between the User 310 and the Logon Component 334 . Rather than being generated by the Logon Component 334 alone, the key pairs may advantageously be generated in cooperation with an otherwise conventional Cryptographic Accelerator 338 , in which case “handles” associated with the private key and public key of a key pair are provided to the Logon Component 334 for convenience of processing.
[0046] In these secret symmetric sessions, encrypted logon information is exchanged and passwords are validated as more thoroughly discussed below. Encryption helps to secure the integrity of the information exchanged between the User 310 and the Logon Component 334 during the logon process and to minimize the possibility that any of the logon information can be intercepted and used for unauthorized access to system resources. By generating and utilizing the encryption keys internally, the system 330 precludes external, unauthorized access to the keys.
[0047] The encryption key pair that has been most recently generated can be called the “current” key pair and is preferably allocated to all logon processing until the next key pair is generated. Key pairs advantageously are usable for respective limited periods of time, so that an earlier encryption key pair persists until it expires.
[0048] As an alternative to private/public encryption key pairs, the Logon Component 334 can use a known key exchange algorithm/protocol to generate a secret symmetric session encryption key. Exemplary algorithms for creating secret symmetric keys are the Diffie-Hellman algorithm and the Key Exchange algorithm of the NIST. Even so, it is currently preferred to use application server-side authentication employing an X.509 authentication certificate that enables establishment of a secure socket layer (SSL) session. As yet another alternative, user and server authentication certificates can be used to establish a two-way authenticated SSL session. The advantage of either SSL approach is its facilitation of the use of the Cryptographic Token and the Cryptographic Accelerator 338 that relieves both the user and the Application Server 332 processors from the burden of carrying out the cryptographic operations.
[0049] After a secret symmetric key is determined by the Logon Component 334 , it is routed to the User 310 to establish a secure session, in which encrypted information can be exchanged by the User 310 and the Logon Component 334 . The Logon Component 334 then requests logon information from the User 310 . In response, the User 310 transmits its identity information and the local time (“Client Time”) to the Logon Component 334 .
[0050] The user's identity information preferably includes its logon ID, organization ID, password or shared secret (e.g., a personal identification number (PIN), a passphrase, biometric information (fingerprint, retina scan, voiceprint, etc.)), etc. The user's logon ID advantageously becomes the relative basis for accessing user-related authorization information in the Rules Database 336 . The organization ID can include a hierarchy of IDs, each representing a sub-organization within the organization, such as a subsidiary or a department, to which the user may be associated. Additionally, the identity information can include user functional data, such as the user's role, position, or credentials in the organization. The password provided by the User 310 is typically hashed at the user's side of the exchange prior to transmission to the Logon Component 334 to provide an additional level of protection against unauthorized capture of the password during transmission. Further protection against unauthorized access to the user's password may be obtained by encrypting the password, e.g., according to RSA Laboratory's PKC Standards (PKCS) #5—Password-Based Cryptography Standard, using the secret symmetric key received from the Logon Component 334 . The Client Time may also be provided during logon as an anti-spoof feature which will be described later in this description.
[0051] The Logon Component 334 decrypts the user-entered logon information if necessary, using the Application Server-side symmetric key and the Cryptographic Accelerator 338 , and compares the logon information to the authorization information in the Rules Database 336 , as linked by the entered user logon ID. The hash of the password entered by the User 310 is compared to the hashed password stored in the secured storage of the Rules Database 336 , also as linked by, or related to, the entered user logon ID to determine that the two hashes match. If any of the identification and authentication information submitted by the User 310 is in error or fails to match the data or rules in the Rules Database 336 , the User 310 is challenged by the Logon Component 334 to check and resubmit the User's information. After a predetermined number of failures, the logon session, and thus the User's access attempt, will be terminated. Such a limit helps prevent a brute force password attack. The User 310 may attempt to logon again, but several more sequential repeats of the logon failure, as determined by system security attributes in the Rules Database 336 , will lock out the User 310 and will alert a system security officer. Alternatively, the Logon Component 334 may disable the User's logon ID in the Rules Database 336 until a system security officer can review the logon failures.
[0052] After the User's identification and password information have been presented and verified, the Logon Component 334 retrieves the User's authorization information from the Rules Database 336 , as linked by the user's logon ID and conditioned on the user's organization ID(s) and role(s). Authorization information may be built at this point based on the user's organization ID(s) and role(s) as determined by any corresponding business rules in the Rules Database. The Logon Component 334 then creates a Security Context that conveys the user's identity and other relevant authorization information necessary to gain access to Application Server-based system resources, including online transactions and electronic records. This identity and authentication information is sufficient to qualify the User for the full range of activities needed to carry out those actions and accesses previously authorized for the User.
[0053] Referring now to FIGS. 4 a , 4 b , and 4 c , and initially to FIG. 4 a , a Security Context is built that comprises a Plaintext Header and a Security Context Body. The Plaintext Header, shown in more detail in FIG. 4 b , comprises a Security Context ID, a Key Handle that permits retrieval of the selected secret symmetric key, and an Algorithm Identifier, including the Key Size of the selected symmetric key. The Security Context Body, shown in more detail in FIG. 4 c , comprises at least some of user and organization identities; role and access information; Bypass Flag(s); a Time-Offset information element (the difference between the User's Current Time and the TCE's current time); an Expiration Time information element (the time later than which the Security Context is invalid); the User's Public Key Algorithm identifier, Key Size, and Public Key; the Symmetric-Session/Request Key Algorithm identifier, Key Size, and generated Symmetric Key; a known value or random number, and a hash or other suitable check value computed over the Plaintext Header and the Security Context Body content. Including the hash value in the Security Context Body ensures that the Security Context content cannot be modified without detection.
[0054] To eliminate any possibility of forgery or unauthorized alteration, the Security Context hash may be digitally signed by the Logon Component 334 . The authentication certificate of the Logon Component may be made available to all system components.
[0055] The Security Context Body is then encrypted using the Logon Component-specified symmetric or the generated private key referenced by the respective Key Handle. The Security Context and the symmetric session encryption key contained therein are then forwarded to the User and retained for the period for which the Security Context is valid. In some instances, the Time-Offset and Expiration Time values may also be returned to the User, which allows the User to renew the Security Context prior to its expiration.
[0056] At this point, Security Context building, encryption, and placement are completed and communication between the User and the Logon Component are terminated. Transaction-level communication between the User, Client Application, and TCE are re-established.
[0057] Referring to FIG. 5 , there is illustrated an embodiment of this invention in which a User 510 seeks access to protected applications (program objects) and records available from the TCE 530 via a Client Application 520 and Cryptographic Token. As can be seen from FIG. 5 , the TCE 530 includes Stateless System Components 535 that are Application Server-side program objects that are instantiated to satisfy user requests for processing or information. The term “stateless” indicates that no request history is retained and the authentication methods of the system are independent of the particular state, or application/transaction/routine, being invoked.
[0058] The Stateless Components 535 may be considered as existing at an “industry level” or at a “core level”. Core-level components are reusable program objects that are industry-independent and thus will be understood as those components that are typically at the heart of any processing system. Thus, core-level components are used by all users of the TCE. The strongest security enforcement is found at the core level where access restrictions can be enforced broadly. Industry-level components are also reusable program objects but are industry-dependent. Thus, industry-level components are used by only a subset of all users of the TCE, i.e., the subset of users that can be categorized as the respective “industry”. It will be appreciated that this description of different levels is merely for organizational convenience and that one or more levels may be employed.
[0059] It will be understood that the operation of the TCE 530 is effectively transparent to the User 510 , who simply logs onto the system and operates as the User would in an otherwise conventional distributed processing system. An important difference is that a permanent session does not have to be established between each User 510 and Application Server-side components in the TCE 530 . Application Server-side components can therefore be stateless since all the information needed to authenticate a User's request is communicated in the Security Context that is included in the User's request. After a Stateless System Component 535 finishes a task, it is free to service another User's request.
[0060] Referring again to FIG. 4 c and also to FIG. 3 , the User ID represents the User's logon ID, and the Organization ID represents the organization to which the User belongs. As discussed above, the Organization ID field can be expanded to include Sub-Organization ID's which represent subsidiary or departmental divisions under a primary organization. One advantage of this is that a single User, who may be affiliated with multiple organizations, subsidiaries, and/or departments, can have different levels of access authorized as a function of the particular organization or group that the User is representing at the time of logon. Similarly, the Roles, Credentials, and Other Authorization Information field comprises additional levels by which access can be controlled, depending on who the User is and what role or responsibility the User is fulfilling at the time of logon. These elements and rules permit customized access to protected system resources, depending, for example, on whether a User is acting as an owner, manager, agent, etc. These authorizations or access permissions are preferably established with sufficient granularity to achieve system and application security policy objectives.
[0061] A Bypass Flag(s) field indicates which, if any, security features are disabled. This reduces computation overhead when the Security Context is used among Stateless System Components 535 in an otherwise protected and trusted environment, as discussed more thoroughly below. Although illustrated as a single field, a Bypass Flag may be associated with each security feature to indicate whether or not the feature is used.
[0062] A Time-Offset field is used by the Logon Component 334 and Stateless System Components 535 to adjust for discrepancies between TCE system (current) time and Client Time, which is the time at the User's computer or browser (see FIG. 6 b ). This facilitates operation of the Security Context and TCE in environments where time synchronization among User and system components is not available. This feature can compensate when a component's internal clock is otherwise stable and within normal tolerances.
[0063] An Expiration Time field identifies the time of expiration of the Security Context, placing an upper limit on the life of the Security Context. This is enforced by the Stateless System Components 535 and can be used by Users to renew their Security Contexts. An Expiration Time is also associated with every Security Context encryption key. Exceeding the Expiration-Time value forces the Logon Component 334 to create a new Security Context encryption key. In this way, the number of Security Contexts that are protected by a given key and uses thereof can be limited. The Security Context encryption keys are deleted on the Application Server-side after the Expiration-Time value is exceeded, and thus subsequent attempts to access transactions or records using Security Contexts with outdated encryption keys fail. Either symmetric or asymmetric encryption may be employed.
[0064] The Logon Component 334 may also establish a maximum count for the number of times a particular Security Context encryption key is used. When the count in a Request Counter field (see FIG. 6 b ) exceeds this pre-established threshold, the Logon Component 334 may be asked to create a new Security Context.
[0065] The User Public Key Algorithm field may contain an algorithm ID, key, and/or Authentication Certificate. The public key pair may be generated by the Logon Component 334 or the Client Application, or created in conjunction with the issuance of a user's X.509 authentication certificate and public-key pair delivered in a Cryptographic Token. The private key is held at the User's location, possibly in a hardware Token. The public key is passed to the Logon Component 334 during symmetric session key negotiations or is passed in the user's X.509 certificate. To reduce processing overhead, the public key information may be extracted from the X.509 certificate and placed directly in the Security Context.
[0066] Referring again to FIG. 5 , with a Security Context having been established for each User 510 logging onto the system 530 with a particular logon ID, organization ID, password, and optionally, role identifier, the authority of each User 510 as verified through the Stateless System Components 535 can be determined without having to preserve any user-specific state information and without having to access a rules or authorization file. In other words, the Stateless System Components 535 need not maintain knowledge regarding any particular active User 510 or invoked Stateless System Component 535 . All such knowledge is passed in the encrypted Security Contexts. In this way, a plurality of stateless system components can be instantiated simultaneously and/or on an as-needed basis and transaction and information routing restrictions can be removed, since each Security Context/User Request is treated independently. Therefore, a plurality of secure digital components may be simultaneously accessed merely by forwarding an authenticated user's Security Context to the validation portion of each Stateless System Component.
[0067] All Stateless System Components 535 that may be asked to perform some action or to access desired information in response to a User request must be given access to the User's Security Context to determine whether the requested action or access is authorized. Since the Security Context is encrypted, the Stateless System Components 535 are provided with the right to use the cryptographic key identified in the Plaintext Header to read the contents of a particular Security Context, including the Authorization Information, in conjunction with the set of cryptographic services performed by the Cryptographic Accelerator 538 . In addition to implementing controls to limit User access to protected Components, this invention may also be applied to automatically authenticate action and access requests between Stateless System Components 535 themselves.
[0068] Following successful creation of a Security Context for a given user logon session, the Security Context can be effectively applied in several ways to control securely and efficiently user access to protected program objects and records. As illustrated by FIGS. 5 and 6 a , a User appends its User Request or Submission to the encrypted Security Context it has received in order to provide a secure access instruction/authorization to the Application Server 532 and Stateless System Components 535 to fulfill the User's Request. Referring to FIG. 6 a , a User Request, which may be directed to an action request, transaction access request, or record access request, among other things, is appended to the encrypted Security Context and forwarded through the Application Server 532 to the appropriate Stateless System Component 535 . Alternatively, the User Request may be a data submission to modify or replace an existing protected record.
[0069] It will be appreciated that the User Request or Submission depicted in FIGS. 5, 6 a , and 6 b , and for that matter substantially any of the communications described or necessitated by this description, can be enclosed in a “wrapper”, which is a kind of envelope that is used to securely hold and associate digitized handwritten and cryptographic digital signatures with part or all of one or more electronic information objects or data contained in the wrapper. Wrappers may take the form of any open standard enveloping or information object (document) formatting schemas, and generally a wrapper is a data structure containing tags that permit locating and extracting information fields contained in the wrapper. Two examples are RSA Laboratories' PKCS #7 and the World Wide Web Consortium (W3C) Extensible Markup Language (XML) Signature Syntax and Processing Draft Recommendation, although any record format supporting inclusion of digital signatures with content may be used, including, but not limited to, S/MIME, XFDL, HTML, and XHTML, which provide support for signature syntax, processing and positioning (tags). The PKCS #7 standard supports zero, one, and multiple parallel and serial digital signatures (cosign and countersign) and authenticated and unauthenticated attributes that are associated with the signatures. Information elements that may be contained in wrappers include algorithm identifiers, key size for each algorithm, content, and signatures, and wrappers can be applied recursively, which simply means that wrappers can be contained within wrappers.
[0070] Upon receipt of a Security Context/User Request, a Stateless System Component 535 directs the decryption of the Security Context. The Stateless System Component 535 first uses the Plaintext Header Key Handle and Algorithm Identifier information to identify the corresponding cached decryption key to the Cryptographic Accelerator 538 . A number of active symmetric and asymmetric encryption and decryption keys are held in protected storage by the Cryptographic Accelerator 538 , and each is referenced by a unique handle contained in a Security Context header as described above. The Stateless System Component 535 then enables the Cryptographic Accelerator 538 to decrypt the Security Context Body and User Request, which make the User's identification and access authorization information and the request contents available to the Component.
[0071] The Stateless System Component 535 verifies the integrity of the received Security Context and User Request by verifying the respective hashes and/or the digital signature, if used. The Stateless System Component 535 compares the roles, credentials, and authorization information from the decrypted Security Context Body with the User Request. If there is a mismatch between the authorization information and the Request, the access attempt fails and the User 510 is so notified, and control is passed back to the User 510 either to submit another Request or to terminate the session. Similarly, if the time of submission is outside the Expiration-Time window for the Security Context, then the access attempt fails. If insufficient information exists in the Security Context authorization information field, the Stateless System Component 535 may access the Rules Database 536 for additional information. If insufficient information still exists after accessing the Rules Database 536 , the access request fails, and the User 510 is so notified. If the access verification process has been successful, then the Stateless System Components 535 are permitted to proceed with fulfilling the user request, with a response ultimately being directed back to the User 510 .
[0072] As illustrated by FIG. 6 b , Client Time and Request Counter fields may be included in the Security Context/User Request data stream. The Client Time represents the time at the User's computer, terminal, or other system access device. The User may be given the option of comparing Client Time, as adjusted by a Time-Offset value, to the Expiration-Time limit. If the adjusted Client Time exceeds the Expiration Time, the User then knows that any authorization and access requests will fail, and the User can efficiently logoff and log back on or otherwise initiate a new session, thereby creating a new Security Context with a new Expiration Time. If the User (Client Application) is not enabled to perform this check, rejection of any and all requests, termination of the session, or a direct alert will force the User to create a new Security Context.
[0073] The Request Counter field is typically initialized at zero at the creation of the Security Context and is incremented each time a User Request with this particular Security Context is directed to the Stateless System Components 535 . In this way, use of the Security Context can be limited, with the User being denied access should the Request Counter exceed a predetermined maximum. It will be appreciated that decrementing Request Counters can also be used. Additionally, the Request Counter may be used to match Requests with System Component responses when responses are returned asynchronously (out of chronological order). Thus, a request counter is included in the request for access, and If if access is granted, a response is sent to the user that includes the arequest counter, which the user uses to match the response, which may be an acknowledgement of an action performed (e.g., creation of a “certified” printout of a record), to the request. Finally, the Request Counter can prevent “replay” attacks, in which a hacker intercepts a User Request or Component Response and falsely presents the Request for access to a protected transaction or record or replays the Response to create network and system congestion. The system 530 and client application 520 both recognize when the Request Counter in the Security Context/User Request data stream is out of synchronization with previous Requests and reject the false Request. Alternatively, Client Time ( FIG. 6 b ) can also be used to prevent replay attacks.
[0074] In another embodiment, the User Request portion of the secured Security Context/User Request stream depicted in FIGS. 6 a , 6 b may be encrypted prior to being passed to the Stateless System Components 535 , utilizing the symmetric key or the public key held by the User and disclosed in the Security Context. Encryption of all or part of the User Request additionally protects against an outsider threat or disclosure of sensitive information. Since the encryption key is internally selected within the Logon Component 334 and passed internally to the User within the Security Context or within a secure session with a login component, and because each encryption key has a limited life by application of the Expiration-Time feature, outsider access to a User Request for unauthorized use is substantially impossible. Upon receipt of the User Request, the cached decryption key is identified by the Stateless System Component 535 and used to decrypt the Request.
[0075] In another embodiment, all or part of a User Request may be hashed prior to being forwarded to the Stateless System Component 535 , with the hash value being appended to the User Request. The Stateless System Component 535 would then hash the received User Request and compare its result with the hash value appended to the User Request. If the two hash values match, the system can be reasonably assured that the User Request has not been modified. If the two hash values do not match, the User-side application can be instructed to re-send the Security Context/User Request/Hash data stream, or a message can be sent to the User advising that receipt of a corrupt Request resulted in failure prior to the request authorization process.
[0076] In yet another embodiment, a digital signature can be applied to all or part of the Security Context/User Request data, with the digital signature being verified upon receipt by the Stateless System Components 535 . Upon verification or non-verification, the Stateless System Components 535 proceed as described above in connection with Request validation. Both the hashing and digital signature features help prevent middleman and substitution attacks on the access authorization process.
[0077] In yet another embodiment of the invention, encryption and hashing of the User Request are combined to provide a secure, non-forgeable session for the authorized access of transactions and records.
[0078] FIG. 7 depicts a response to a User 510 by protected Stateless System Components 535 . The response may be transmitted to the User in plaintext, relying on the integrity of the session encryption, or the response may be encrypted using the secret encryption key embedded within the Security Context and held by the User. As discussed above, the User advantageously utilizes the Request Counter field to match the response received from the system 530 with its User Request. This is particularly important when responses are returned asynchronously (out of order), such as when the Components 535 process multiple requests and when the User submits multiple access requests across a plurality of Application Servers 532 .
[0079] It should be understood that a User does not have access either to the Security Context encryption key or to the contents of the Security Context. Only the Logon Component and Stateless System Components have such access. Use of a digital signature by the Logon Component prevents modification by any component, enabling the Security Context's content to be trusted. The User Request encryption key, Time Offset, and other relevant information needed by the User are passed to the User/Client Application during the secure Security Context setup session. It will be appreciated that both trusted and untrusted Stateless System Components can be used by layering the methods described here, increasing bit overhead as needed to achieve an appropriate level of protection.
[0080] Application of the methods described above is illustrated by FIG. 8 , although it will be understood that not all of the features described above are included.
[0081] In block 802 , a system administrator is instructed by an authorized source to enroll a user, whose identification and authorization information is entered into a system enrollment database. The user is assigned a user ID and preferably an organization ID that uniquely identify the user to the system, although it will be understood that other means of uniquely identifying users may be employed.
[0082] Block 804 indicates that three password methods may be supported: initialize (requiring the system administrator's password); check (requiring the logon component's password); and change (requiring a user's current password). During enrollment, a default password may be created and assigned to the user. The hash of the default password is associated with the user's unique identity and saved in protected storage. The plaintext password is made available to the system administrator, who arranges for its delivery to the user, preferably using an out-of-band means, such as an approved courier. The logon component facilitates the user's changing its default password to one that is more memorable. A new password can be issued if the user forgets its password or believes its password may have been compromised or from time to time.
[0083] In block 806 , a private key is used by the system's logon component to protect security contexts. A new PKC pair is generated at suitable intervals, which may vary by application or industry. The most recently generated key pair can be called the current key pair, and key pairs may conveniently be generated by any suitable hardware cryptographic accelerator. The handles of the private key and public key of the current key pair are made available to the logon component. The private key is accessible only to the logon component. Prior (non-current) key pairs persist until their respective expiration times are reached. This overlap is chosen to be sufficiently long as to minimize the need for Users to have to request new Security Contexts. The logon component uses only the current key pair.
[0084] In block 808 , the public key handle is shared with trusted stateless system components that, as trusted components, must be implemented in a protected operating environment. Access to a trusted system component is granted by the logon component's sharing the current public key handle and the address of the cryptographic accelerator with the component. Access by any other component is blocked, for example by a software or hardware firewall. Any such components require a Security Context to access system resources.
[0085] In block 810 , the first occurrence of a user's needing access to system resources (components) requires the user, through its client application, to initiate a communications session with the logon component. An SSL session is preferably invoked.
[0086] In block 812 , if an SSL encrypted session is not used, the user's client application engages in an exchange with the logon component that results in a symmetric-session encryption key existing at both the client application and the logon component. This symmetric-session encryption key is the basis of subsequent secure communications between the user and the system and authentication with all trusted stateless system components. The symmetric-session encryption key may be used to encrypt user service requests.
[0087] In block 814 , the user presents its credentials to the logon component, which asks the user to enter its unique identifying information and password. At this point, the user may be given an opportunity to change its password, either its default password generated at enrollment or its current password. System security policy typically dictates how often a user must change its password.
[0088] In the following description, the logon information is encrypted using a session-symmetric key, although as noted above an SSL session could be used. The user's client application forwards the user-entered information to the logon component using a predefined self parsing data structure such as the following, in which { } indicate an encrypted value, subscript identifies a key, and [ ] indicate plaintext:
User ID, Organization ID, {Password, Client Time} symmetric-session
[0089] To change a user's password, the client application forwards the user-entered information using a data structure such as the following:
User ID, Organization ID, {Password, New Password, New Password Confirmation, Client Time} symmetric-session
[0090] In block 816 , the logon component decrypts the Password(s) and Client Time using the symmetric-session key and computes a Delta Time value, which is the difference between the Client Time and the system time of the core server. The user's Password is then hashed according to an algorithm such as SHA-1 and compared to a hash value stored in the system database. If the hashes match, the user's Password is validated, and if a change of Password is requested, the logon component initiates the Password change procedure. If Password validation fails, the user may be given one or more chances to submit a correct Password, as specified by system security policy, before being locked out of the system.
[0091] In block 818 , after successful user/client logon, the logon component builds and returns to the user/client a Security Context (SC) that preferably includes the following elements:
SC = [ SC ID, Plain Text SC Header AlgorithmID public-current , KeySize public-current , Handle public-current ]+ { User ID, Encrypted SC body Org ID, Authorizations, Bypass Flag(s) Expiration Time, Delta Time, AlgorithmID symmetric-session , KeySize symmetric-session , Key symmetric-session , Hash} Private-current
[0092] In block 820 , the user/client application may submit requests to trusted stateless system components using the SC returned to the user/client by the logon component. The client does so by appending a request to the SC. Two examples of SC-request combinations follow:
[SC Header, {SC body} Private-current ][{Client time} symmetric-session, Request] [SC Header, {SC body} Private-current ][{Client time, Request, Hash} symmetric-session ]
[0095] In block 822 , the SC and request are verified by any trusted stateless system component by using the stored key referenced by Handle Public-current to decrypt the SC body, then extracting and using the symmetric-session key to decrypt the encrypted portion of the Request, validating the Request by at least checking that system time=Client Time±Delta Time, and further verifying the request by validating a hash and/or client digital signature if used.
[0096] In block 824 , if the SC and Request are successfully validated, then the stateless system component uses the content of the SC and Request to perform the requested actions. In this way, the stateless system component may act as a trusted proxy for the user/client. The result of the request, if fulfilled, is returned to the user/client application. If desired, the result may be encrypted using the symmetric-session key.
[0097] It will be understood that these methods and systems are effectively transparent to a user, who simply logs on to the system and operates as the user would in a conventional distributed system. An important difference is that a permanent session does not have to be established between the user/client application and server-side components, which can be stateless since all the information needed to authenticate a user's request is communicated in an non-forgeable security context. After a stateless system component finishes its task, it is free to service another user request. Additional request capacity may be obtained by simply adding application servers and/or instantiating stateless system components (program objects). These additions will also be totally transparent to client applications.
[0098] Although preferred embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principle and spirit of the invention, the scope of which is defined in the appended claims and their equivalents. | Systems and methods for providing user logon and state-less authentication are described in a distributed processing environment. Upon an attempted access by a user to an online resource, transaction, or record, a logon component asks the user to supply a logon ID and a password. The logon component verifies the provided information, and upon successful identification, a security context is constructed from information relevant to the user. The security context is sent to the user and is presented to the system each time the user attempts to invoke a new resource, such as a program object, transaction, record, or certified printer avoiding the need for repeated logon processing. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for producing an aromatic ring alkylated phenols.
2. Description of the Related Art
Aromatic ring alkylated phenols are industrially used as raw materials and intermediates of medical and agricultural medicines, resins, various additives, polymerization inhibitors, antioxidants, disinfectants, preservatives, industrial chemicals and the like. Among them, thymol having a structure in which an isopropyl group is bonded to 2-position and a methyl group is bonded to 5-position of phenol is in much demand as a vermicide. Further, 2,3,6-trimethylphenol is in much demand as a synthesis intermediate of trimethylhydroquinone which is a raw material of vitamin E. In an example for producing vitamin E from 2,3,6-trimethylphenol, in the first step, 2,3,6-trimethylphenol is oxidized to synthesis 2,3,6-trimethylbenzoquinone, and which is reduced to synthesize trimethylhydroquinone. In the second step, trimethylhydroquinone and phytol are reacted in the presence of an acid catalyst to synthesize vitamin E, according to U.S. Pat. No. 5,523,420.
Conventionally, for obtaining ortho-alkyled phenols, a gas phase reaction in which phenols and alcohol are vaporized, an passed through catalyst phase to cause a reaction thereof, a liquid phase reaction utilizing Friedel Craft's reaction, and the like, are known. For example, JP-A No. 6-25041 discloses a method in which phenols and alcohol are reacted in gas phase using manganese oxide as a catalyst to produce an aromatic ring alkylated derivative of phenols. However, this method has a problem that a reaction apparatus becomes complicated and bulky.
JP-A No. 2000-38363discloses a method in which phenols and alcohol are heated at 400° C. in a supercritical region using zirconium oxide as a catalyst, for alkylation. However, in this method, a large amount of catalyst is necessary, causing problems in cost and size of an apparatus.
SUMMARY OF THE INVENTION
The above-mentioned known method have a problem that a large and complicated reaction apparatus is necessary and a problem that a large amount of catalyst is required.
An object of the present invention is to provide a process for producing an aromatic ring alkylated phenols by using phenols and alcohol in a relatively smaller reaction vessel with a small amount of catalyst, at high reactivity.
Under these circumstances, the present inventors have intensively studied a process for producing an aromatic ring alkylated phenols from phenols, and found that an aromatic ring alkylated phenols can be easily obtained by reacting phenols with alcohols under a supercritical state in the presence of a hydroxide or alkoxide of a metal as a catalyst, and have completed the present invention.
Namely, the present invention relates to a process for producing an aromatic ring alkylated phenols, wherein said process comprises reacting phenols represented by the general formula (1):
wherein, each of R 1 , R 2 , R 3 , R 4 and R 5 independently represents a hydrogen atom, or a linear or branched alkyl group having 1 to 10 carbon atoms;
with monohydric or dihydric alcohol in the presence of a hydroxide of a metal, an alkoxide of a metal, or a hydroxide of a metal and an alkoxide of a metal under a supercritical state of the alcohol. [hereinafter, referred to as production method (I) of the present invention]
Further, the present invention relates to a process for producing an aromatic ring alkylated phenols, wherein said process comprises reacting phenols represented by the general formula (1) with monohydric or dihydric alcohol in the presence of carbon dioxide and, a hydroxide of a metal, an alkoxide of a metal or a hydroxide of a metal and an alkoxide of a metal under a supercritical state of the mixture of alcohol and carbon dioxide. [hereinafter, referred to as production method (II) of the present invention]
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be illustrated in detail below.
As the linear or branched alkyl group having 1 to 10 carbon atoms represented by R 1 , R 2 , R 3 , R 4 or R 5 in phenols represented by the general formula (1), used as a raw material in the present invention, a methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, isobutyl group, t-butyl group and the like are listed, and specific examples of the phenols of the general formula (1) include phenol, o-cresol, m-cresol, p-cresol, 2,3-xylenol, 2,4-xylenol, 2,5-xylenol, 3,4-xylenol, 3,5-xylenol, anisole, t-butylphenol and the like.
Alcohol which is another starting material in the present invention is not particularly restricted providing it is monohydric or dihydric alcohol, and preferably monohydric alcohol represented by the general formula (2):
R 6 —OH (2)
wherein, R 6 represent a linear or branched alkyl group having 1 to 10 carbon atoms. Here, as R 6 , there are listed a methyl group, ethyl group, n-propyl group, isopropyl group, n-butyl group, isobutyl group, t-butyl group and the like.
As the monohydric alcohol represented by the general formula (2), methanol, ethanol, n-propanol, isopropanol, n-butanol, isobutanol, t-butanol, pentanol, hexanol, heptanol, n-octanol, n-nonanol, n-decanol and the like are listed, and methanol, ethanol, n-propanol and n-butanol are preferable, methanol and ethanol are more preferable, and methanol is further preferable.
As the dihydric alcohol, ethylene glycol, propylene glycol and the like are listed.
In the present invention, the molar ratio of monohydric or dihydric alcohol to phenols of the general formula (1) is appropriately determined depending on compound used, and usually from 1 to 1000, and preferably from 1 to 200.
In the production method (I) of the present invention, a reaction is conducted under a condition wherein monohydric or dihydric alcohol manifests supercritical state. In the production method (II) of the present invention, a reaction is conducted under a condition wherein a mixture of monohydric or dihydric alcohol and carbon dioxide manifests supercritical state.
Here, the supercritical condition means the following condition.
A substance manifests inherent three conditions of gas, liquid and solid, and when over the critical temperature and the critical pressure, fluid phase is formed which is not condensed even if pressure is applied. This condition is referred to as supercritical condition.
Fluid under supercritical condition shows different nature from usual natures of liquid and gas. Fluid under supercritical condition is a “solvent which is not liquid”, in which the density thereof is near that of liquid, and the viscosity thereof is near that of gas, and heat conductivity and diffusion coefficient show intermediate natures between gas and liquid, and mass transfer becomes advantageous due to lower viscosity and higher diffusion property, and higher heat transferring property can be obtained because of higher conductivity.
When supercritical fluid is used as a reaction site, higher reactivity is obtained than usual gas phase and liquid phase since the reaction site is under conditions of higher density and higher diffusion property as described above.
Further, because supercritical condition has density near liquid phase, the size of a reaction apparatus thereof can be reduced as compared with gas phase.
In the present invention, the upper limit of reaction temperature is not restrictive, and preferably 450° C. or less so that phenols represented by the general formula (1) are not decomposed. The upper limit of reaction pressure is also no restrictive, and preferably 25 MPa or less since increase of pressure resistance of a reaction apparatus is expensive.
In the production method (I) of the present invention, it is necessary that a reaction is conducted under a condition wherein monohydric or dihydric alcohol manifests supercritical state. When methanol is used as the alcohol, a reaction is conducted under conditions of 240° C. or more and 8 MPa or more since methanol has a critical temperature of 240° C. and a critical pressure of 8 MPa. When ethanol is used, a reaction is conducted under conditions of 243° C. or more and 6.3 MPa or more since ethanol has a critical temperature of 243° C. and a critical pressure of 6.3 MPa. When n-propanol is used, a reaction is conducted under conditions of 264° C. or more and 5 MPa or more since n-propanol has a critical temperature of 264° C. and a critical pressure of 5 MPa. When isopropanol is used, a reaction is conducted under conditions of 235° C. or more and 4.8 MPa or more since isopropanol has a critical temperature of 235° C. and a critical pressure of 4.8 MPa. When n-butanol is used, a reaction is conducted under conditions of 287° C. or more and 4.8 MPa or more since n-butanol has a critical temperature of 287° C. and a critical pressure of 4.8 MPa.
Next, the production method (II) of the present invention will be illustrated.
In the production method (II) of the present invention, it is necessary that a reaction is conducted under a condition wherein a mixture of monohydric or dihydric alcohol and carbon dioxide manifests supercritical state, in the presence of a catalyst and carbon dioxide.
The mixing ratio of the above-mentioned alcohol and carbon dioxide is not particularly restricted, and is determined in view of solubility of phenols used in the reaction in the alcohol. The mixing ratio of the above-mentioned alcohol and carbon dioxide is preferably 10:90 to 99:1.
Cases in which methanol is used as the alcohol and phenol is used as the phenols will be illustrated specifically. For example, when the molar ratio of methanol to carbon dioxide is 75:25, this mixture has a critical temperature of 204° C. and a critical pressure of 12.75 MPa according to a literature, Journal of Chemical Thermodynamics, vol. 23, p. 970 (1991).
When an aromatic ring of phenols is methylated under temperature and pressure conditions wherein a mixture of methanol and carbon dioxide manifests supercritical condition, temperature and pressure conditions are necessary wherein the mixture manifests supercritical condition. For example, in the case of the above-mentioned mixture in which the molar ratio of methanol to carbon dioxide is 75:25, a temperature of 204° C. or more and a pressure of 12.75 MPa or more are necessary, and a temperature of 240° C. or more and a pressure of 12.75 MPa or more are more preferable.
The reaction time in the production method (I) of the present invention or the production method (II) of the present invention is appropriately determined, respectively, depending on kinds of the phenols and the alcohol, and usually in a range from 1 minute to 24 hours.
In the respective production method, the reaction has to be conducted in the presence of a catalyst, namely, a hydroxide of a metal, an alkoxide of a metal, a hydroxide of a metal and an alkoxide of a metal, and reactivity of alkylation of aromatic ring can be enhanced only by addition of a relatively small amount of the catalyst.
Typical examples of the hydroxide of a metal include, but are not limited to, lithium hydroxide, sodium hydroxide, potassium hydroxide, magnesium hydroxide, calcium hydroxide, barium hydroxide, strontium hydroxide, germanium hydroxide and the like.
The hydroxide may be combined with an alkoxide of a metal.
Examples of the alkoxide of a metal include, but are not limited to, lithium methylate, sodium methylate, potassium methylate, dimethoxymagnesium, dimethoxycalcium, dimethoxybarium, dimethoxystrontium, tetramethoxygermanium and the like.
The alkoxide may be combined with a hydroxide of a metal.
The present invention can be effected in various reaction embodiments. For example, it may be conducted by a batch system, or by a flow system, and the batch system is preferable.
An aromatic ring alkylated phenols represented by the general formula (1) is separated from reaction mixtures after completion of respective reaction of the production method (I) or the production method (II) at a purity necessary for various use. The reaction mixture may sometimes contains unreacted raw materials or other impurities in addition to the aromatic ring alkylated phenols.
The separation method is not particularly restricted, and general methods such as distillation, extraction and the like can be applied according to nature of the substituted compound.
Namely, according to the present invention, a method can be provided in which phenols represented by the general formula (1) and monohydric or dihydric alcohol are used, and an aromatic ring of the phenols is alkylated in a relatively smaller reaction vessel at higher reactivity, particularly by a batch system, with a small amount of a catalyst.
In the present invention, the addition amount of a catalyst is preferably from 0.01 to 20% by weight, more preferably from 0.05 to 2% by weight based on the phenols of the general formula (1) used in the reaction.
According to the present invention, an aromatic ring alkylated phenols can be easily obtained by reacting phenols with alcohols in a relatively smaller reaction vessel with a small amount of catalyst at high reactivity.
EXAMPLE
The following examples further illustrate the present invention in detail below, but do not limit the scope of the present invention.
Reaction materials and reaction products in examples were identified by using a gas chromatography mass analysis apparatus HP-6890 (GC: manufacture by Yokogawa Electric Corp.)-HP5973 (MS: manufacture by Yokogawa Electric Corp.) and analyzed quantitatively by using a gas chromatography apparatus GC-353B (manufactured by GL Science) equipped with FID (flame ionization detector). The conversion and selectivity in examples were calculated according to the following methods.
Conversion was calculated by the following formula:
(conversion)={1−(area of chromatograph of unreacted reaction substrates remaining in reaction solution)/(sum of areas of remaining reaction substrates and whole reaction product)}×100%.
The selectivity was calculated by the following formula:
(selectivity)={(area of gas chromatograph of reaction product to be calculated)/(sum of areas of gas chromatograph of whole reaction product)}×100%,
while hypothesizing that areas of gas chromatograph per mol of reaction products are equivalent.
Example 1
0.035 g of m-cresol (manufactured by Wako Pure Chemical Industries Ltd.), 1.358 g of methanol (manufactured by Wako Pure Chemical Industries Ltd.) and 0.33 mg of lithium hydroxide monohydrate (manufactured by Wako Pure Chemical Industries Ltd.) (0.94% by weight based on m-cresol) were charged in an autoclave (made of SUS316, inner volume: 4.5 ml) and heated up to 370° C. by a sand bath, to initiate a reaction. After 15 minutes, the autoclave was quenched, and the reaction solution was removed after the temperature of the autoclave reached room temperature. Quantification was conducted according to the above-mentioned method, as a result, the conversion of m-cresol was 64 mol %, the selectivity of 2,5-xylenol was 51 mol % and the selectivity of 2,3,6-trimethylphenol was 11 mol %. Regarding other components than these reaction products, the selectivity of 2,3-xylenol was 17 mol %, the selectivity of 3,4-xylenol was 5 mol %, the selectivity of m-methylanisole was 1 mol %, the sum of the selectivity of trimethylphenols other than 2,3,6-trimethylphenol was 4 mol %, and the selectivity of 2,3,4,6-tetramethylphenol was 1 mol %. The components were separated from the reaction solution by using liquid chromatography, and 2,5-xylenol and 2,3,6-trimethylphenyl were separated therefrom. The separated solutions were analyzed by using a gas chromatography mass analysis apparatus, to confirm that 2,5-xylenol and 2,3,6-trimethylphenol were separated from the product. Since the autoclave does not have a pressure gauge, the following experiment was conducted to estimate pressure during the reaction. Namely, a pressure gauge was installed to the same autoclave, the same amounts of m-cresol and methanol were charged and heated up to 370° C. by a sand bath, and the pressure was measured. The estimated value of the pressure during the reaction was 10 MPa.
Example 2
0.051 g of phenol (manufactured by Wako Pure Chemical Industries Ltd.), 1.358 g of methanol and 0.75 mg of lithium hydroxide monohydrate (0.15% by weight based on phenol) were charged in an autoclave (made of SUS316, inner volume: 4.5 ml, no pressure gauge) and heated up to 400° C. by a sand bath, to initiate a reaction. After 30 minutes, the autoclave was quenched, and the reaction solution was removed after the temperature of the autoclave reached room temperature. Quantification was conducted according to the above-mentioned method, as a result, the conversion of phenol was 36 mol %, the selectivity of o-cresol was 51 mol %, the selectivity of p-cresol was 10 mol %, the selectivity of 2,6-xylenol was 3 mol %, and the selectivity of 2,4-xylenol was 2 mol %. The components were separated from the reaction solution by using liquid chromatography, and o-cresol, p-cresol, 2,6-xylenol and 2,4-xylenol were separated therefrom. The separated solutions were analyzed by using a gas chromatography mass analysis apparatus, to confirm that o-cresol, p-cresol, 2,6-xylenol and 2,4-xylenol were separated from the product. Since the autoclave does not have a pressure gauge, the following experiment was conducted to estimate pressure during the reaction. Namely, a pressure gauge was installed to the same autoclave, the same amounts of phenol and methanol were charged and heated up to 400° C. by a sand bath, and the pressure was measured. The estimated value of the pressure during the reaction was 14.7 MPa.
Comparative Example 1
0.051 g of phenol, 1.352 g of methanol and 1.0 mg of zirconium oxide (manufactured by Kojundo Kagaku K.K.) (2.0% by weight based on phenol) were charged in an autoclave (made of SUS316, inner volume: 4.5 ml, no pressure gauge) and heated up to 400° C. by a sand bath, to initiate a reaction. After 30 minutes, the autoclave was quenched, and the reaction solution was removed after the temperature of the autoclave reached room temperature. Quantification was conducted according to the above-mentioned method, as a result, the conversion of phenol was 20 mol %, the selectivity of o-cresol was 50 mol %, the selectivity of p-cresol was 3 mol %, the selectivity of 2,6-xylenol was 2 mol %, and the selectivity of 2,4-xylenol was 1 mol %. Since the autoclave does not have a pressure gauge, the following experiment was conducted to estimate pressure during the reaction. Namely, a pressure gauge was installed to the same autoclave, the same amounts of phenol and methanol were charged and heated up to 400° C. by a sand bath, and the pressure was measured. The estimated value of the pressure during the reaction was 14.7 MPa.
Comparative Example 2
0.052 g of phenol, 1.358 g of methanol and 1.1 mg of zinc oxide (manufactured by Wako Pure Chemical Industries Ltd.)(2.1% by weight based on phenol) were charged in an autoclave (made of SUS316, inner volume: 4.5 ml, no pressure gauge) and heated up to 400° C. by a sand bath, to initiate a reaction. After 30 minutes, the autoclave was quenched, and the reaction solution was removed after the temperature of the autoclave reached room temperature. Quantification was conducted according to the above-mentioned method, as a result, the conversion of phenol was 11 mol %, the selectivity of o-cresol was 78 mol %, the selectivity of p-cresol was 2 mol %, the selectivity of 2,6-xylenol was 3 mol %, and 2,4-xylenol was not produced. Since the autoclave does not have a pressure gauge, the following experiment was conducted to estimate pressure during the reaction. Namely, a pressure gauge was installed to the same autoclave, the same amounts of phenol and methanol were charged and heated up to 400° C. by a sand bath, and the pressure was measured. The estimated value of the pressure during the reaction was 14.7 MPa.
Example 3
0.045 g of p-cresol (manufactured by Wako Pure Chemical Industries Ltd.), 1.485 g of methanol and 0.25 mg of lithium hydroxide monohydrate (0.56% by weight based on p-cresol) were charged in an autoclave (made of SUS316, inner volume: 4.5 ml, no pressure gauge) and heated up to 400° C. by a sand bath, to initiate a reaction. After 30 minutes, the autoclave was quenched, and the reaction solution was removed after the temperature of the autoclave reached room temperature. Quantification was conducted according to the above-mentioned method, as a result, the conversion of p-cresol was 97 mol %, and the selectivity of 2,4-xylenol was 23 mol %, and the selectivity of 2,4,6-trimethylphenol was 61 mol %. The components were separated from the reaction solution by using liquid chromatography, and 2,4-xylenol and 2,4,6-trimethylphenol were separated therefrom. The separated solutions were analyzed by using a gas chromatography mass analysis apparatus, to confirm that 2,4-xylenol and 2,4,6-trimethylphenol were separated from the product. Since the autoclave does not have a pressure gauge, the following experiment was conducted to estimate pressure during the reaction. Namely, a pressure gauge was installed to the same autoclave, the same amounts of p-cresol and methanol were charged and heated up to 400° C. by a sand bath, and the pressure was measured. The estimated value of the pressure during the reaction was 15.4 MPa.
Comparative Example 3
0.051 g of p-cresol, 1.350 g of methanol and 1.2 mg of zirconium oxide (2.4% by weight based on p-cresol) were charged in an autoclave (made of SUS316, inner volume: 4.5 ml, no pressure gauge) and heated up to 400° C. by a sand bath, to initiate a reaction. After 30 minutes, the autoclave was quenched, and the reaction solution was removed after the temperature of the autoclave reached room temperature. Quantification was conducted according to the above-mentioned method, as a result, the conversion of p-cresol was 8 mol %, the selectivity of 2,4-xylenol was 30 mol %, and 2,4,6-trimethylphenol was not produced. Since the autoclave does not have a pressure gauge, the following experiment was conducted to estimate pressure during the reaction. Namely, a pressure gauge was installed to the same autoclave, the same amounts of p-cresol and methanol were charged and heated up to 400° C. by a sand bath, and the pressure was measured. The estimated value of the pressure during the reaction was 14.7 MPa.
Comparative Example 4
0.052 g of p-cresol, 1.355 g of methanol and 1.3 mg of zinc oxide (2.3% by weight based on p-cresol) were charged in an autoclave (made of SUS316, inner volume: 4.5 ml, no pressure gauge) and heated up to 400° C. by a sand bath, to initiate a reaction. After 30 minutes, the autoclave was quenched, and the reaction solution was removed after the temperature of the autoclave reached room temperature. Quantification was conducted according to the above-mentioned method, as a result, the conversion of p-cresol was 12 mol %, the selectivity of 2,4-xylenol was 81 mol % and the selectivity of 2,4,6-trimethylphenol was 4 mol %. Since the autoclave does not have a pressure gauge, the following experiment was conducted to estimate pressure during the reaction. Namely, a pressure gauge was installed to the same autoclave, the same amounts of p-cresol and methanol were charged and heated up to 400° C. by a sand bath, and the pressure was measured. The estimated value of the pressure during the reaction was 14.7 MPa.
Example 4
0.412 g of m-cresol, 1.500 g of isopropanol and 1.9 mg of lithium hydroxide (0.46% by weight based on m-cresol) were charged in an autoclave (made of SUS316, inner volume: 4.5 ml, no pressure gauge) and heated up to 400° C. by a sand bath, to initiate a reaction. After 30 minutes, the autoclave was quenched, and the reaction solution was removed after the temperature of the autoclave reached room temperature. Quantification was conducted according to the above-mentioned method, as a result, the conversion of m-cresol was 22 mol %, and the selectivity of thymol was 62 mol %. Since the autoclave does not have a pressure gauge, the following experiment was conducted to estimate pressure during the reaction. Namely, a pressure gauge was installed to the same autoclave, the same amounts of m-cresol and isopropanol were charged and heated up to 400° C. by a sand bath, and the pressure was measured. The estimated value of the pressure during the reaction was 10 MPa. | A process for producing an aromatic ring alkylated phenols, wherein said process comprises reacting phenols represented by the general formula (1):
wherein, each of R 1 , R 2 , R 3 , R 4 and R 5 independently represents a hydrogen atom, or a linear or branched alkyl group having 1 to 10 carbon atoms;
with monohydric or dihydric alcohol in the presence of a hydroxide of a metal, an alkoxide of a metal, or a hydroxide of a metal and an alkoxide of a metal under a supercritical state of the alcohol. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a cooled screw vacuum pump comprising two rotating systems, consisting each of a screw rotor and a shaft with a floating device supporting the rotors, having, on each shaft, two mutually spaced bearings and an empty space arranged in each rotor, open on the bearing side, wherein is located an element cooling the rotor internally.
In an already proposed screw vacuum pump of this type, the bearing of the floating support on the rotor side is located within a central hollow space, open toward the bearing side, inside the rotor. Cooling is effected with the aid of a lubricating oil, which is first passed, inside a central channel in the shaft, to the bearing on the side of the rotor. In known fashion, the transported oil volume is larger than is needed for lubrication of the bearing in order to be able to carry away the maximum amount of heat possible.
With respect to the screw vacuum pump, the oil volume which, according to the state of the art, can be passed through the empty space, is limited since it is not only the bearing but also the bearing support that must be accommodated in said empty space. Therefore, there is the risk of inadequate cooling on the pressure-side region of the screw vacuum pump since it is precisely in this region that the generated heat is greatest due to the executed compression work.
Because of the existing empty space inside the rotor, the wall thickness of the rotor is also limited in the bearing region of the empty space. As a result, it is only possible at very high temperature gradients, to carry off the heat developing in the pressure-side region of the screw threads via the suction side region of the rotor, the shaft and the cooling oil. High temperature or inadequate cooling of the pressure-side region of a screw vacuum pump results in uneven rotor expansions and thus in local clearance consumption between the rotors and between each of the rotors and the housing. Run-up of rotors may, in fact, be prevented by relatively large clearances.
Relatively large clearances, however, result in deterioration of the pump operating properties. Furthermore, with respect to the prior known screw vacuum pump, there exists the danger of overheating the bearing located in the empty space, all the more so since said bearing can only be lubricated with relatively warm oil. Finally, the prior known screw vacuum pump can only be operated with vertically arranged shafts.
The present invention is based on the object of equipping a screw vacuum pump of the initially mentioned kind with improved cooling means.
According to the invention, this object is solved by making use of the fact that the bearing on the rotor side of the support is located outside the empty space in the rotor. The invention facilitates effective cooling of the rotor from the inside without being impeded by the bearing and bearing support, so that the unwelcome clearance consumption will no longer occur in this critical region.
Each rotor appropriately consists of two segments with different thread profiles, whereby the thread depth of the pressure-side segment is smaller than the thread depth of the suction side segment. A lesser thread depth in the pressure-side segment provides more space for accommodation of the empty space needed for the internal cooling.
If, in addition, the rotor and housing are stepped in such manner that the pressure-side rotor segment has a smaller diameter than the suction-side rotor segment, then this measure creates more space in the housing for the accommodation of jacket cooling.
According to another characteristic of the invention, it is appropriate to additionally provide in the wall of the pump housing, i.e at least at rotor level, channels perfused by a cooling agent.
A cooling agent of this type permits, specifically in combination with the interior cooling of the rotor according to the invention, uniform tempering of the entire pump. Consequently, the pump is able to adopt variable temperatures with variable loads, without resulting in gap reductions. It is appropriate to also include in such tempering the bearings, the bearing supports and the driving motor, in order to prevent problems due to variable temperature expansions. Lastly, a jacket cooling of the proposed type has the benefit of having the effect of excellent sound deadening.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating a preferred embodiment and are not to be construed as limiting the invention.
FIG. 1 is a section through a screw vacuum pump with cooling according to the invention; and
FIG. 2 is a partial section according to FIG. 1 with an additional design for cooling according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, a section through an exemplary embodiment of a screw vacuum pump 1 according to the invention is depicted, i.e. at the level of that of the two rotating system which is equipped with a driving motor 2 . Synchronization of the two rotating systems is effected with the aid of toothed wheels 3 .
The rotating systems, which are arranged in housing 4 , each comprise a rotor 5 and a shaft 6 . Each rotor 5 is overhung, in other words, unilaterally supported. The shaft 6 supports itself in a housing 4 via bearings 7 and 8 and also bearing supports 11 and 12 . Frontally, housing lids 13 and 14 are provided, with lid 13 on the rotor side being equipped with an inlet stub 15 . Bearing support 12 is a component of the gear-side lid 14 .
The rotor 5 consists of two positively joined rotor segments 17 and 18 having different profiles 19 and 20 . The suction-side rotor segment 17 has a large volume profile 19 in order to achieve high volume flows in a helical compression chamber. The pressure-side segment 18 of rotor 5 has both a reduced profile volume as well as a lesser diameter. This reduces the cross section of the helical compression chambers or pumping chambers 49 . Internal compression is obtained, and the work done on compression is reduced.
The inner wall of housing 4 is adapted to the rotor gradation (Gradation 21 ). A dotted line 22 indicates that the housing may be designed divisible at the level of gradation 21 . As a result, it is possible to replace the suction-side rotor segment 17 and the suction side element 4 ′ of housing 4 with rotor segments having different profiles, lengths and/or diameters as well as having housing segments 4 ′ adapted to same, in order to be able to adapt the pump to different applications.
The outlet of pump 1 which is adjacent to the pressure-side end of the thread turns is identified by the numeral 24 . It is laterally conducted outward. A housing bore 25 also issues into the outlet, joining the compression chamber with the outlet at the level at which its cross-section decreases-either by gradation or by change in the thread profile. In the housing bore 25 , there is a non-return valve 26 which opens with excessive pressure in the compression chamber and short-circuits the suction-side thread turns of the rotor segment 17 with the outlet 24 . In order to seal the helical compression chambers from the support, shaft gaskets 27 are provided which are located between bearing 7 and the rotor segment 18 .
The cooling system in the depicted exemplary embodiment comprises a rotor with interior cooling arrangement and a housing jacket to facilitate cooling.
For realization of the rotor interior cooling, the rotor 5 is equipped with a hollow space 31 , open toward its bearing-side. Said hollow space may extend through almost the entire rotor 5 .
With respect to rotor 5 , consisting of two segments 17 and 18 , the delivery or pressure-side segment 18 is appropriately designed hollow. The suction-side segment 17 closes the suction-side end of the hollow space 31 . The shaft 6 , which is appropriately designed in one single piece with rotor 5 or with the pressure-side segment 18 of rotor 5 , is likewise hollow (hollow space 32 ). In the hollow spaces 31 , 32 there is a central cooling pipe 33 , which is conducted, on the side of the bearing, out of the shaft 6 and ends, on the side of the rotor, shortly before the suction-side end of hollow space 31 . The cooling pipe 33 and the annular space formed by the cooling pipe 33 and the hollow shaft 6 are available for the supply or removal of a coolant.
In the represented exemplary embodiment of the present invention, the bearingside opening 34 of the cooling pipe 33 is in communication via line 35 with the outlet of a cooling agent pump 36 . In addition, in the region of housing lid 14 there is a coolant sump 37 in a coolant chamber 50 . Coolant sump 37 is connected via line system 38 with the inlet of cooling agent pump 36 . The sump 37 and the line system 38 are designed in such manner that the represented pump 1 can be operated in any position ranging from vertical to horizontal. Cooling agent levels which occur with horizontal and with vertical position of the pump 1 are indicated. Depending upon whether the cooling agent pump 36 is located outside (as depicted) or inside (for example on the second, not visible shaft of pump 1 at the level of the driving motor 2 ) of housing 4 , the opening 34 of the cooling pipe 33 is located either outside or inside of housing 4 .
For operation of the internal cooling of rotor 5 , the cooling agent is transported by the cooling agent pump 36 from the cooling agent sump 37 via the cooling pipe's inner surface or first channel 47 into the empty space 31 in rotor 5 . From there, it flows back into sump 37 via the annular space or second channel 48 between cooling pipe 33 and shaft 6 . The hollow space 31 is located at the level of the pressure-side region of the thread turns of pump 1 , so that this region in particular is cooled effectively. The cooling agent flowing back outside of the cooling pipe 33 along the second channel 48 tempers, among others, the hollow shaft 6 , the bearings 7 and 8 , the driving motor 2 (on the armature side), and the toothed wheels 3 , so that the thermal expansion problems are reduced.
It is advisable for the cross section of the second channel 48 between the cooling pipe 33 and the shaft 6 to decrease at the pressure end; this can be done, for example, by providing the cooling pipe 33 with a larger outside diameter in this area, As a result, a constructed pass-through opening or narrowed region 39 is formed. This constriction ensures that the spaces holding the coolant are completely filled.
It is advisable to select a material with poor thermal conductivity (such as plastic/special steel, etc.) for the cooling pipe 33 . As a result, the rotor 5 will be cooled more effectively, and the components of the pump 1 near the shaft will be tempered more uniformly.
The housing cooling system shown comprises cavities or a first and a second set of channels 41 , 42 , respectively, in the housing 4 . The first set of cooling channels provided in the area of the rotor 5 are designated 41 ; the second set of cooling channels in the area of the motor 2 are designated 42 .
One of the jobs of the cooling channels 41 in the area of the rotor 5 is to carry away the heat which develops especially on the pressure side of the rotor 5 . Another job of the channels is to temper the housing 4 as uniformly as possible in the entire area of the rotor. Finally, the channels are designed to give up the absorbed heat to the outside. The channels 41 through which the coolant flows therefore extend along the entire length of the rotor 5 . The housing lid 13 serves to seal off the channels 41 on the suction side. The housing 4 is also cooled effectively on the pressure side.
Cooling channels 42 , located at the level of the driving motor 2 , have the mentioned objects as well. They produce tempering of the driving motors (on the side of the coils) as well as tempering of the bearing support 11 . Finally, they increase, to a significant extent, the thermal discharge via the exterior surfaces of pump 1 . The pump is appropriately equipped with fins 44 , at least at the level of the cooling channels 41 and 42 .
Feeding the cooling channels 41 , 42 with cooling agent is likewise done with the aid of the cooling agent pump 36 , namely via lines 45 and 46 , if they are to be perfused parallel. Depending upon the thermal requirements, there also exists the possibility of subsequently providing same with cooling agent. One of the lines 45 or 46 could then be eliminated. The cooling agent gets from hollow spaces 41 , 42 back into the sump 37 via bores which are not represented in detail.
With vertical arrangement of shaft 6 , the cooling agent located in the sump cools the bearing support 12 , protruding into the sump 37 . With horizontal arrangement, it is appropriate to let the returning cooling agent flow back over the internal side of lid 14 , in order to cool both the bearing seat 12 as well as improve thermal discharge toward the outside.
In the depicted exemplary embodiment of the present invention according to FIG. 1, housing 4 and rotor 5 are—as already mentioned—designed partable at the level of line 22 . Consequently, there exists the possibility of replacing the suction-side segments of rotor 5 (segment 17 ) and housing 4 (segment 4 ′). Pump 1 can be adapted to various applications by installing rotor segments 17 with different profiles 19 , different length, different pitch and/or different diameter, combined in each case with an adapted housing segment. Various large profiles can be selected on the suction side in order to obtain high suction capacities, various long profiles on the suction side in order to obtain low end pressures and/or various volume gradations in order to obtain, for example, higher fluid compatibility with lower gradation or with higher gradation, high suction capacity with relatively small power consumption. Finally, there exists the possibility of providing, at the level of a reduction in the diameter of rotor 5 , a circumferential groove in order to achieve, in certain applications, a release of pressure in this region.
A cooling agent flowing through the screw vacuum pump 1 may be water, oil (mineral oil, PTFE-oil or similar) or another liquid. The utilization of oil is appropriate in order to also lubricate the bearings 7 and 8 and the toothed wheels 3 . Separate supply of cooling agent and lubricating agent, as well as corresponding gaskets, can thereby be eliminated. The only need being a controlled supply of oil to the bearings 7 and 8 .
The described solutions permit beneficial selection of raw material. For example, the rotors 5 and the housing 4 may consist of relatively inexpensive aluminum materials. The proposed cooling and, most importantly, the uniform cooling of pump 1 have the effect that, even with variable operating temperatures and relatively small gaps, play does not consume local clearance which will result in rotor to rotor contact and/or rotor to housing contact. Further gap reduction is possible if materials are employed for the internal, thermally more stressed components of pump 1 (rotors, bearings, bearing supports, toothed wheels) which have a lower thermal expansion coefficient than the material for housing 4 , which is less thermally stressed.
A moderate equilization of the expansion of all components of pump 1 is obtained as a result thereof. An exemplary selection of such material is steel, for example nickel chromium (CrNi) steel, for the interior components and aluminum for the housing. Bronze, brass or nickel silver (China or German silver) may also serve as materials for the interior components.
In an exemplary embodiment of the present invention according to FIG. 2, the interior cooling of rotor 5 comprises a cooling bushing 51 , which supports itself, on the bearing side on housing 4 and which projects into hollow space 31 . The cooling bushing 51 surrounds the shaft 6 , which is no longer designed hollow. It traverses the hollow space ( 31 ) and carries rotor 5 in the region of its suction-sided end. For supplying the cooling bushing 51 with cooling agent, one or several cooling channels 52 are provided, which are supplied by the cooling agent pump 36 in a manner not shown in more detail.
In order that the cooling bushing 51 will absorb as much heat as possible from rotor 5 , a gap 53 between cooling bushing 51 and rotor 5 is selected as small as possible. In this region, the bushing 51 is equipped with threading 54 , which has a pumping effect directed in the direction of the compression chamber. Dirt particles present there are held back.
A gap 55 between bushing 51 and shaft 6 is also relatively small in order to produce, with the aid of threading 56 , a pumping effect on the interior side of bushing 51 . Said pumping effect acts in the direction of gasket 27 /bearing 7 and keeps oil particles out of the compression chamber. | A cooled screw vacuum pump has a housing ( 4 ) two rotating systems ( 5, 6 ) consisting each of a screw rotor ( 5 ) and a shaft ( 6 ), a floating device supporting the rotors having, on each shaft, two mutually spaced bearings ( 7, 8 ) and an empty space ( 31 ) arranged in each rotor ( 5 ) open on the bearing side, wherein is respectively located an element cooling the rotor internally. In order to improve cooling it is suggested that the bearing ( 7 ) of the support located on the rotor side, is placed outside the rotor ( 5 ) empty space ( 31 ), such that in said empty space ( 31 ) there is more room available for obtaining efficient cooling. | 5 |
FIELD OF THE INVENTION
This invention relates to a novel copolymer of a polyoxyalkylene alkenyl ether and a maleic ester and an emulsifier, dispersant or cement additive comprising the same.
BACKGROUND OF THE INVENTION
Copolymers of maleic anhydride and a compound having an unsaturated group have found their application in various fields. For example, a salt of a diisobutylene-maleic anhydride copolymer is used as a dispersant in an aqueous system as described in Cement & Concrete, No. 478, p. 7 (1986), and an ethyl or butyl ester of a methyl vinyl ether-maleic anhydride copolymer is used in cosmetics as described in Nippon Hanyo Keshokin Genryoshu, p. 161, K. K. Yakuji Nipposha (1985). It has been proposed to use a copolymer of a polyoxyalkylene monoalkenyl ether and a maleic ester of a polyalkylene glycol or a monoalkyl ether thereof as a dispersant for cement as disclosed in JP-A-59-162162 (the term "JP-A3[ as used herein means an "unexamined published Japanese patent application").
However, copolymers of an olefin, e.g., diisobutylene, and maleic anhydride, while non-neutralized, are soluble only in limited kinds of solvents such as toluene. When converted to their salts, they are soluble only in water. Further, having an average molecular weight in the thousands, these copolymers are limited in application.
Esters of methyl vinyl ether-maleic anhydride copolymers are poor in lipophilic properties and therefore unsuitable for use as an emulsifier or dispersant.
Copolymers of a polyoxyalkylene monoalkenyl ether and a maleic ester of a polyalkylene glycol or a monoalkyl ether thereof, though effective as additive for cement, exhibit poor lipophilic properties. Further, similarly to the α-olefinmaleic anhydride copolymers, they are of limited application due to their average molecular weight in the thousands.
SUMMARY OF THE INVENTION
An object of this invention is to provide a novel copolymer which is of wide application as an emulsifier, a dispersant, an additive for cement, and the like.
This invention provides a copolymer of (a) a polyoxyalkylene alkenyl ether represented by formula (I): ##STR3## wherein Z is a residue of a compound having from 2 to 8 hydroxyl groups; AO is an oxyalkylene group having from 2 to 18 carbon atoms; R is an alkenyl group having from 2 to 18 carbon atoms; R 1 is a hydrocarbon group having from 1 to 40 carbon atoms; a≧0; c≧0; l≧1; m≧0; n≧0; l+m+n=2 top 8; al+bm+cn=1 to 100; and n/(l+m+n)≦1/3, and (b) a maleic ester of a compund represented by formula (II):
R.sup.2 O(A.sup.1 O).sub.d H (II)
wherein R 2 is a hydrocarbon group having from 1 to 40 carbon atoms; A 1 O is an oxyalkylene group having from 2 to 18 carbon atoms; and d is from 0 to 100; or formula (III): ##STR4## wherein Z 1 is a residue of a compound containing from 2 to 8 hydroxyl groups; A 2 O is an oxyalkylene group having from 2 to 18 carbon atoms; R 3 is a hydrocarbon group having from 1 to 40 carbon atoms; e≧0; f≧0; p≧0; q≧1; p+q=2 to 8; and ep+fq=0 to 100.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an infrared absorption spectrum of the copolymer prepared in Example 2.
FIG. 2 is an infrared absorption spectrum of the copolymer prepared in Example 3.
DETAILED DESCRIPTION OF THE INVENTION
A molar ratio of component (a) to component (b) in the copolymer of the present invention is preferably from 3:7 to 7:3, more preferably about 1:1.
In formula (I), the hydroxyl-containing compound providing a residue represented by Z includes glycols, e.g., ethylene glycol, propylene glycol, butylene glycol, hexylene glycol, styrene glycol, an alkylene glycol having from 8 to 18 carbon atoms, and neopentyl glycol; polyhydric alcohols, e.g., glycerin, diglycerin, polyglycerin, trimethyloletahen, trimethylolpropane, 1,3,5-pentanetriol, erythritol, pentaerythritol, dipentaerythritol, sorbitol, sorbitan, sorbide, a condensation product of sorbitol and glycerin, adonitrol, arabitol, xylitol, and mannitol; partial ethers or esters of the polyhydric alcohol; saccharides, e.g., xylose, arabinose, ribose, rhamnose, glucose, fructose, galactose, mannose, sorbose, cellobiose, maltose, isomaltose, trehalose, sucrose, raffinose, gentianose, and melezitose; and partial ethers or esters of the saccharide.
The oxyalkylene group as represented by AO is derived from ethylene oxide, propylene oxide, butylene oxide, tetrahydrofuran, styrene oxide, an α-olefin oxide having from 6 to 18 carbon atoms, etc. Specific examples are oxyethyelene, oxypropylene, oxybutylene, oxytetramethylene, and oxystyrene groups and an oxyalkylene group having from 6 to 18 carbon atoms. Where the oxyalkylene group comprises two or more kinds of alkylene moieties, they may be linked either in blocks or at random.
The alkenyl group having from 2 to 18 carbon atoms as represented by R preferably includes those having an unsaturated bond at the terminal thereof, e.g., vinyl, allyl, methallyl, isoprenyl, dodecenyl, octadecenyl, and allylphenyl groups.
The hydrocarbon group having from 1 to 40 carbon atoms as represented by R 1 includes methyl, ethyl, propyl, isopropyl, butyl, isobutyl, t-butyl, amyl, isoamyl, hexyl, heptyl, octyl, 2-ethylhexyl, nonyl, decyl, undecyl, dodecyl, isotridecyl, tetradecyl, hexadecyl, isocetyl, octadecyl, isostearyl, oleyl, octyldodecyl, docosyl, decyltetradecyl, benzyl, cresyl, butylphenyl, dibutylphenyl, octylphenyl, nonylphenyl, dodecylphenyl, dioctylphenyl, dinonylphenyl, and styrenated phenyl groups.
In formula (I), l, m, and n are limited for the reasons set forth below. l must be at least 1 for accomplishing copolymerization. If the number of hydroxyl groups, i.e., n, is too large, copolymerization with maleic anhydride would be attended by esterification with maleic anhydride, unfavorably resulting in formation of a three-dimensional structure. Accordingly, a relation of n/(l+m+n)≦1/3 is preferred.
In formulae (II) and (III), R 2 and R 3 have the same meaning as R 1 ; A 1 O and A 2 O have the same meaning as AO; and Z: has the same meaning as Z.
The copolymer according to the present invention can be prepared as follows. The polyoxyalkylene alkenyl ether of formula (I) and maleic anhydride are copolymerized in the presence of a radical polymerization initiator such as benzoyl peroxide. The resulting copolymer is then esterified with the compound of formula (II) or (III). Alternatively, maleic anhydride and the compound of formula (II) or (III) are subjected to esterification, and the resulting ester is then copolymerized with the polyoxyalkylene alkenyl ether of formula (I) in the presence of a radical polymerization initiator.
The maleic ester unit in the copolymer may be in the form of a monoester or a diester.
The copolymer according to the present invention is a high-molecular weight surface active agent having a weight average molecular weight of more than 1,000, sometimes far up in the ten thousands. The hydrophilic moiety of the copolymer is assigned to the oxyethylene group and hydroxyl group in AO, A 1 O or A 2 O and a carboxyl group formed on ester formation, while the lipophilic moiety is assigned to the hydrocarbon group in R 1 , R 2 or R 3 and the oxyalkylene group having 3 or more carbon atoms in AO, A 1 O or A 2 O Thus, it is possible to increase the proportion of the hydrophilic moiety for use as a water-soluble compound, for example, an additive for cement or a dispersant in an aqueous system, or to increase the proportion of the lipophilic moiety for use as an oil-soluble compound, for example, a dispersant for a non-aqueous system. For use as an oil-soluble compound, the copolymer of the present invention may further contain other lipophilic units derived from lipophilic moieties copolymerizable with the polyoxyalkylene alkenyl ether and maleic anhydride, e.g., styrene, α-olefins, acrylic esters, methacrylic esters, and vinyl acetate.
The polyoxyalkylene alkenyl ether-maleic ester copolymer having the specific structure as described above is a high-molecular weight surface active agent which can be rendered either water-soluble or oil-soluble and is of very wide application as an emulsifier, a dispersant, or an additive for cement.
The present invention is now illustrated in greater detail by way of Examples, but it should be understood that the present invention is not deemed to be limited thereto. All the percents are by weight unless otherwise indicated.
PREPARATION EXAMPLE 1
Preparation of Compound of Formula (I)
In an autoclave were charged 32 g of methanol and 1.1 g of sodium methylate as a catalyst. After purging the autoclave with nitrogen, 396 g of ethylene oxide was slowly introduced thereinto at 140° C. at a pressure of from about 0.5 to 5 kg/cm 2 G to conduct an addition reaction After completion of the reaction, the reaction mixture was cooled to room temperature, 75 g of sodium hydroxide was added thereto, followed by heating to 110° C., and the mixture was dehydrated in a nitrogen atmosphere under reduced pressure of about 20 mmHg. Nitrogen was then added thereto to raise the pressure to 1 kg/cm 2 G, and . 98 g of allyl chloride was slowly added to the mixture while stirring. The alkalinity of the reaction mixture fell and, after 4 hours from the commencement of reaction, assumed a nearly steady value, at which the reaction was stopped. The reaction mixture was neutralized with hydrochloric acid, and the by-produced salt was separated by filtration to recover an allyl ether.
PREPARATION EXAMPLE 2
Preparation of Compound of Formula (I)
In an autoclave were charged 58 g of allyl alcohol and 5.6 g of potassium hydroxide as a catalyst. After purging the autoclave with nitrogen, 2320 g of propylene oxide was slowly introduced thereinto at 100° C. at a pressure of from about 0.5 to 5 kg/cm 2 G to conduct an addition reaction. After completion of the reaction, the catalyst was neutralized with hydrochloric acid, and the by-produced potassium chloride was removed by filtration. To 1624 g of the recovered product was slowly added 21 g of metallic sodium, the mixture was heated to 110° C., and 186 g of dodecyl chloride was added thereto while stirring. The alkalinity of the reaction mixture fell and, after 4 hours from the commencement of the reaction, assumed an almost steady value, at which the reaction was ceased. The reaction mixture was neutralized with hydrochloric acid, and the by-product salt was removed to obtain an allyl ether.
PREPARATION EXAMPLE 3
Preparation of Compound of Formula (I)
In an autoclave were charged 92 g of glycerin, 5 g of boron trifluoride ethyl etherate as a catalyst, and 432 g of tetrahydrofuran. After purging the autoclave with nitrogen, 264 g of ethylene oxide was slowly introduced thereinto at 70° C. at a pressure of from about 0.5 to 5 kg/cm 2 G to conduct an addition reaction. After completion of the reaction, the catalyst was neutralized with sodium carbonate, and the by-produced salt was removed by filtration. To 630.4 g of the reasulting product was slowly added 50 g of metallic sodium, and 180 g of methallyl chloride was slowly added thereto at 100° C.with stirring. The alkalinity of the reaction mixture fell and, after 4 hours from the start of the reaction, assumed an almost steady value, at which the reaction was stopped. The reaction mixture was neutralized with hydrochloric acid, and the by-produced salt was removed by filtration to recover a methallyl ether.
PREPARATION EXAMPLES 4 TO 12
Various polyoxyalkylene alkenyl ethers of formula (I) shown in Table 1below were prepared in the same manner as in Preparation Examples 1 to 3.
TABLE 1__________________________________________________________________________ Degree of HydroxylPreparation Unsaturation ValueExample No. Compound of Formula (I) (milleq/g) (KOH-mg/g)__________________________________________________________________________1 CH.sub.2CHCH.sub.2 (OC.sub.2 H.sub.4).sub.9 OCH.sub.3 2.13 0.082 CH.sub.2CHCH.sub.2 (OC.sub.3 H.sub.6).sub.40 OC.sub.12 H.sub.25 0.39 0.18 3* ##STR5## 2.14 714 CH.sub.2CHCH.sub.2 (OC.sub.2 H.sub.4).sub.4 OCH.sub.3 3.99 0.045 CH.sub.2CHCH.sub.2 (OC.sub.2 H.sub.4).sub.33 OCH.sub.3 0.62 0.036 CH.sub.2CHCH.sub.2 (OC.sub.2 H.sub.4).sub.2 OC.sub.4 H.sub.9 4.98 0.24 ##STR6## 0.65 0.158 ##STR7## 0.73 0.229 CH.sub.2CHCH.sub.2 (OC.sub.2 H.sub.4).sub.20 OCH.sub.2 CHCH.sub.2 2.16 0.0710 CH.sub.2CHCH.sub.2 (OC.sub.2 H.sub.4).sub.20 OC.sub.18 H.sub.37 0.84 0.1311 ##STR8## 1.15 0.1612 ##STR9## 1.31 0.07__________________________________________________________________________ Note: *Additon mode in the brackets { } is at random, and C.sub.4 H.sub.8 O is an oxytetramethylene group.
PREPARATION EXAMPLE 13
Preparation of Maleic Anhydride Copolymer
______________________________________Preparation of Maleic Anhydride Copolymer______________________________________Allyl ether of Preparation Example 1 468 g (1 mol)Maleic Anhydride 98 g (1 mol)Benzoyl peroxide 6 g (1% based on monomers)Toluene 566 g (the same weight as monomers)______________________________________
The above components were charged in a four-necked flask equipped with a cooling pipe, a pipe for introducing nitrogen, a thermometer, and a stirrer. The mixture was heated to 80° C. in a nitrogen stream and stirred for 4 hours to conduct a copolymerization reaction.
Toluene was removed by distillation at 110° C. under reduced pressure of about 10 mmHg to obtain 510 g of a maleic anhydride copolymer as a clear viscous liquid.
The resulting maleic anhydride copolymer was analyzed to obtain the following results:
Elementary Analysis: Calcd. (%]: C 55.11; H 8.18; Found (%): C 55.07; H 8.1.
Degree of Saponification: 196.3 (calcd.: 198.2)
Weight Average Molecular Weight: 13300 (measured by gel-permeation chromatography, hereinafter the same)
EXAMPLE 1
A copolymerization reaction was carried out in the same manner as in Preparation Example 13, except for using the following components and changing the copolymerization temperature to 70° C.
______________________________________Alkenyl ether of Preparation Example 4 248 g (1 mol)Bis(ethylene glycol) maleate 204 g (1 mol)Azobisisobutyronitrile 5 g (1.1% based on monomers)Toluene 452 g (the same weight as monomers)______________________________________
Toluene was removed by distillation at 110° C. under reduced pressure of about 10 mmHg to obtain 420 g of a copolymer as a clear viscous liquid.
Elementary Analysis: Calcd. (%): C 52.5; H 7.5; Found (%): C 52.0; H 7.0.
Degree of Saponification: 240 (calcd.: 248)
Weight Average Molecular Weight: 2000
EXAMPLE 2
In 600 g of pyridine were dissolved 550 g of the maleic anhydride copolymer as obtained in Preparation Example 13 and 600 g of a polyoxyethylene polyoxypropylene glycol random copolymer having a structural formula of HO{C 3 H 6 O) 7 (C 2 H 4 O) 4 }H, and the solution was refluxed at 110° to 120° C. for 4 hours. Pyridine was removed by distillation under reduced pressure of 10 mmHg or less at 110° to 120° C. to obtain 1085 g of a copolymer as a clear viscous liquid.
Elementary Analysis: Calcd. (%): C 57.1; H 8.4; Found (%): C 56.4; H 8.4.
Degree of Saponification: 93.2 (calcd.: 92.3)
Weight Average Molecular Weight: 13,500
The infrared absorption spectrum of the copolymer is shown in FIG. 1.
EXAMPLE 3
The same procedure of Example 2 was repeated, except for replacing the compound as used in Example 2 with 46 g of ethanol and changing the reaction temperature to 70° to 80° C., to obtain 590 g of a copolymer as a clear viscous liquid.
Elementary Analysis: Calcd. (%): C 54.9; H 8.5; Found (%): C 54.6; H 8.2.
Degree of Saponification: 188 (calcd.: 183)
Weight Average Molecular Weight: 13,300
EXAMPLES 4 TO 12
Copolymers shown in Table 2 below were prepared in the same manner as in the foregoing Examples.
TABLE 2 Compound of Formula (1) OH-Containing Com- Solubility in Preparation Maleic Other pound (inclusive of Polymerization Average Acetone Example Example Amount Anhydride Monomer Maleic Acid Ester) Initiator Molecular Methanol No. No. (mol %) (mol %) (mol %) (mol %) (mol %) Weight Description*.sup.4 Water Ethanol 1 4 50 -- -- bis(ethylene glycol) 50 AIBN*.sup.1 1.1 2,000 liquid soluble soluble maleate 2 1 50 50 -- HO{(C.sub.3 H.sub.6 O).sub.7 (C.sub.2 H.sub.4 O).sub.4 }H 50 BPO*.sup.2 1.0 13,500 " " " (random copolymer) 3 1 50 50 -- ethanol 50 BPO*.sup.2 1.0 13,300 " " " 4 2 50 50 -- HO(C.sub.2 H.sub.4 O).sub.23 H 50 BPEH*.sup.3 1.0 20,000 " insoluble " 5 5 50 50 -- C.sub.18 H.sub.37 O(C.sub.2 H.sub.4 O).sub.20 H 50 BPO*.sup.2 1.0 18,500 solid soluble " 6 6 50 -- -- diisopropyl 50 BPO*.sup.2 1.0 3,500 liquid " " maleate 7 7 50 50 -- ##STR10## 50 BPEH*.sup.3 0.7 130,000 solid " " 8 8 50 50 -- C.sub.9 H.sub.19C.sub.6 H.sub.4O(C.sub.2 H.sub.4 O).sub.10 H 50 AIBN*.sup.1 0.9 16,300 liquid " " 9 10 40 50 styrene 50 C.sub.4 H.sub.9 O(C.sub.3 H.sub.6 O).sub.5 H 50 BPO*.sup. 2 1.2 7,400 solid " " 10 11 44 50 vinyl 2 C.sub.12 H.sub.25 OH 50 BPO*.sup.2 0.9 unmeasurable " insoluble insoluble 3 4 acetate 11 2 46 50 -- HO(C.sub.2 H.sub.4 O).sub.7 H 50 BPEH*.sup.3 1.0 unmeasurable solid insoluble insoluble 9 4 12 1 40 50 ethyl 4 HO(C.sub.3 H.sub.6 O).sub.5 H 50 BPO*.sup.2 1.0 " " " " 3 6 methacrylate 13 1 50 50 -- C.sub.4 H.sub.9 O{(C.sub.2 H.sub.4 O).sub.6 (C.sub.3 H.sub.6 O).sub.2 }H 50 BPEH*.sup.3 1.0 14,400 liquid soluble soluble (random copolymer) 14 5 50 50 -- CH.sub.3 O(C.sub.2 H.sub.4 O).sub.12 Notes: *.sup.1 Azobisisobutyronitrile *.sup.2 Benzoyl peroxide *.sup.3 tButyl peroxy2-ethylhexanoate *.sup.4 at 20° C.
EXAMPLE 15
Each of the copolymers prepared in Examples 4 to 9 was tested for performance as an emulsifier in the following composition.
______________________________________Polydimethylsiloxane (100,000 cst) 35%Emulsifier 5%Water 60%______________________________________
A mixture of polydimethylsiloxane and the copolymer was heated to 70° C., and water at 70° C. was slowly added thereto to emulsify the mixture. The resulting emulsion was allowed to stand in a thermostat at 40° C. for 1 month to examine emulsion stability.
For comparison, the same test was conducted but using the same amount of a nonionic surface active agent in place of the copolymer of the present invention.
The results of examination are shown in Table 3 below.
TABLE 3______________________________________ State of EmulsionEmulsifier of Example After Standing Remarks______________________________________Example 4 Milky white liquid InventionExample 5 " "Example 6 " "Example 7 " "Example 8 " "Example 9 " "C.sub.18 H.sub.37 O(C.sub.2 H.sub.4 O).sub.6 H separated in Comparison two layers1:1 (by weight) separated in "mixture of sorbitan two layersmonostearate andpolyoxyethylene (20mol) sorbitan monosterate______________________________________
It can be seen from Table 3 that the emulsions using the copolymer of the present invention keeps to be stable milky white liquid, proving that the copolymer is an excellent emulsifier.
EXAMPLE 16
Each the copolymers prepared in Example 1 to 9 was tested for performance as a dispersant in the following composition.
______________________________________Calcium stearate 50%Dispersant 5%Water 45%______________________________________
The dispersant was dissolved in water, and calcium stearate was slowly added and dispersed in the solution at 50° C. while stirring by means of a homogenizer to obtain a white viscous slurry. The slurry was allowed to stand in a thermostat at 40° C. for 1 month was carried out using the same amount of a nonionic surface active agent in place of the copolymer of the present invention. The results of the test are shown in Table 4 below.
TABLE 4______________________________________ State of DispersionDispersant of Example After Standing Remarks______________________________________Example 1 Fluidity was Invention maintainedExample 2 Fluidity was " maintainedExample 3 Fluidity was " maintainedExample 4 Fluidity was " maintainedExample 5 Fluidity was " maintainedExample 6 Fluidity was " maintainedExample 7 Fluidity was " maintainedExample 8 Fluidity was " maintainedExample 9 Fluidity was " maintainedC.sub.8 H.sub.17 --C.sub.6 H.sub.4 --O(C.sub.2 H.sub.4 O).sub.15 H Solidified ComparisonC.sub.18 H.sub.37 O(C.sub.2 H.sub.4 O).sub.30 H " "Polyoxyethylene " "(20 mol) sorbitanmonostearate______________________________________
It can be seen from Table 4 that the slurries using the copolymer of the present invention as a dispersant maintained a slurry state of stable fluidity, whereas those using a comparative dispersant solidified and lost fluidity.
EXAMPLE 17
Each of the copolymers prepared in Examples 1 to 14 was tested for performance as an additive for cement in the following composition.
______________________________________Water 165 kg/m.sup.3Cement 300 kg/m.sup.3Sand 758 kg/m.sup.3Gravel (max. size: 25 mm) 1067 kg/m.sup.3Air entrainng and water 0.75 kg/m.sup.3reducing agent ("PozzolithNo. 5L" produced by NissoMaster Builders Co., Ltd.)Additive 3 kg/cm.sup.3 (1% based on cement)Water/cement ratio 55.0%Sand percentage 42.0%______________________________________
In accordance with JIS R 5201, the above components were kneaded in a mortar mixer, and the slump was measured every minutes. After 60 minutes in Run Nos. 15, 16 and 17 or after 90 minutes in other runs, the mixture was cast in a mold (10×10×40 cm), released from the mold after one day, cured in water at 20° C. for 7 days from the release, and then allowed to stand at 20° C. and 65% RH (relative humidity]. The dry shrinkage of each sample was measured using a comparator method. For reference, compressive strength of each sample was measured after being allowed to stand under the above-described conditions to the age of 35 days. The results of these measurements are shown in Table 5 below.
TABLE 5__________________________________________________________________________ Slump (cm) Immediately After After After Dry Shrinkage Compressive After 30 60 90 After After After StrengthRun No. Additive Kneading Min. Min. Min. 7 Days 14 Days 28 Days (kg/cm.sup.3)__________________________________________________________________________ 1 (Invention) Copolymer of 17.2 16.9 16.5 15.6 0.020 0.035 0.044 397 Example 1 2 (Invention) Copolymer of 18.0 17.4 17.3 17.2 0.010 0.026 0.027 423 Example 2 3 (Invention) Copolymer of 17.4 17.0 16.6 16.2 0.020 0.030 0.042 398 Example 3 4 (Invention) Copolymer of 18.0 17.7 17.5 17.0 0.020 0.028 0.039 407 Example 4 5 (Invention) Copolymer of 18.0 17.8 17.4 17.1 0.018 0.021 0.029 405 Example 5 6 (Invention) Copolymer of 17.5 17.0 16.4 15.9 0.019 0.029 0.037 396 Example 6 7 (Invention) Copolymer of 17.7 17.5 17.3 17.0 0.013 0.026 0.028 411 Example 7 8 (Invention) Copolymer of 17.8 17.4 17.2 17.0 0.016 0.025 0.031 408 Example 8 9 (Invention) Copolymer of 17.6 17.0 16.5 15.8 0.014 0.022 0.033 412 Example 910 (Invention) Copolymer of 17.4 16.8 16.2 15.7 0.017 0.022 0.033 406 Example 1011 (Invention) Copolymer of 17.3 16.9 16.4 16.0 0.018 0.025 0.034 405 Example 1112 (Invention) Copolymer of 17.5 17.0 16.3 16.0 0.020 0.027 0.036 403 Example 1213 (Invention) Copolymer of 18.0 18.0 17.9 17.8 0.013 0.028 0.032 410 Example 1314 (Invention) Copolymer of 17.7 17.9 18.0 17.9 0.019 0.030 0.038 405 Example 1415 (Comparison) HO{(C.sub.3 H.sub.6 O).sub.7 (C.sub.2 H.sub.4 O).sub.3 }H*.sup.1 16.0 12.2 9.0 unmea- 0.013 0.029 0.030 420 sured16 (Comparison) sodium naphthanene- 17.3 12.5 8.8 unmea- 0.024 0.046 0.060 400 sulfonate formaldehyde sured condensate (mol. wt.: 4,000)17 (Comparison) sodium diiso- 17.4 15.8 13.8 12.9 0.025 0.044 0.060 393 butylenemaleic anhydride copolymer (mol. wt.: 5,000)18 (Comparison) none 14.0 11.2 8.3 unmea- 0.026 0.046 0.060 395 sured__________________________________________________________________________ Note: *.sup.1 The bracket { } means a random copolymer
As is shown in Table 5, the copolymers according to the present invention are excellent in prevention of slump loss and dry shrinkage without adversely affecting compressive strength.
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 thereof. | A copolymer of (a) a polyoxyalkylene alkenyl ether represented by formula (I): ##STR1## wherein Z is a residue of a compound having from 2 to 8 hydroxyl groups; AO is an oxyalkylene group having from 2 to 18 carbon atoms; R is an alkenyl group having from 2 to 18 carbon atoms; R 1 is a hydrocarbon group having from 1 to 40 carbon atoms; a≧0; b≦0; c≦0; l≦1; m≦0; z≦0; l+m+n=2 to 8; al+bm+cn=1 to 100; and n/(l+m+n)≦1/3, and (b) a maleic ester of a compound represented by formula (II):
R.sup.2 O(A.sup.1 O).sub.d H (II)
wherein R 2 is a hydrocarbon group having from 1 to 40 carbon atoms; A 1 O is an oxyalkylene group having from 2 to 18 carbon atoms; and d is from 0 to 100; or formula (III): ##STR2## wherein Z 1 is a residue of a compound containing from 2 to 8 hydroxyl groups; A 2 O is an oxyalkylene group having from 2 to 18 carbon atoms; R 3 is a hydrocarbon group having from 1 to 40 carbon atoms; e<0; f<0; p<0; q≦1; p+q=2 to 8; and ep+fq=0 to 100. The copolymer is useful as an emulsifier, a dispersant, or an additive for cement. | 2 |
FIELD OF THE INVENTION
The present invention relates to general-purpose routing resources and in particular to an implementation of a direct routing structure between complex IP cores in FPGA.
BACKGROUND OF THE INVENTION
Field Programmable Gate Array (FPGA) architecture comprises a programmable routing structure and an array of configurable logic blocks. The programmable routing matrix comprises means for connecting configurable logic blocks (hereafter referred to as logic blocks) to each other. An FPGA provides a combination of programmable logic and programmable connections to a general-purpose routing structure.
In conventional FPGAs, the Programmable Interconnect Points (PIPs) are turned on by loading appropriate values into configuration memory cells associated with the PIPs, thereby creating paths for routing and establishing the logic performed by the configurable logic blocks. The signals on the routing paths change dynamically as values are being written to and read from flip-flops. A large amount of data is exchanged between logic blocks involving complex arithmetic and logic operations. The general-purpose routing resources are used to implement the interconnects between complex logic blocks. Data between the blocks is routed through the available switch matrix structure in the FPGA.
An existing interface between complex logic blocks in FPGA is an interface between RAM and Digital Signal Processor (DSP) block. In conventional FPGAs the blocks of RAM are generated by configuring programmable parts of the FPGA. When the functionality of RAM is desired by multiple end users, it is economical to dedicate a portion of the chip to this purpose, thus allowing the particular function to be implemented at high density.
Signal processing applications require execution of complex arithmetic and logical operations within the Configurable Logic Blocks. These blocks include multiply and accumulate (MAC) units, memory blocks, multipliers, shift registers, adders.
U.S. Pat. No. 5,933,023 describing the existing structure of RAM blocks embedded in FPGAs, and is illustrated by FIG. 1A . The patent describes a structure in which blocks of RAM are integrated with Configurable Logic Blocks in FPGA. Routing lines which access configurable logic blocks also access address, data, and control lines in the RAM blocks. The logic blocks of the FPGA can use these routing lines to access portions of RAM. The routing lines allow RAM blocks and arrays of RAM blocks to be configured long, wide, or in between, and allow logic blocks to conveniently access RAM blocks in a remote part of the chip.
The drawback in the above said patent is that it cannot be used to provide an efficient routing structure between complex IP cores, where high rate of data exchange is required.
FIG. 1B is a block diagram of a configurable memory array device 200 in accordance with U.S. Pat. No. 6,104,208, which describes the function specific blocks in detail. The configurable memory array device 200 comprises configurable memory array blocks 202 ( 202 - 1 through 202 - 3 ) connected to a functional block 204 by way of a signal bus 206 . The signal bus 206 carries data and control signals, from the functional block 204 to the configurable memory array blocks ( 202 - 1 through 202 - 3 ) by using bi-directional signal lines 208 - 1 through 208 - 3 . The configurable memory array blocks 202 - 1 through 202 - 3 respectively connect to external circuitry by way of bi-directional input/output (I/O) lines; 210 - 1 through 210 - 3 .
The connectivity between the DSP block and the RAM blocks in U.S. Pat. No. 6,104,208 is not efficient and the connections have to be made using general-purpose routing resources, and Reconfigurable Interconnects are used for the purpose of routing.
FIG. 1C shows the multifunction tile by Xilinx according to U.S. Pat. No. 6,573,749. The patent describes the method and apparatus of incorporating a multiplier into an FPGA. The invention provides an alternative structure that shares routing resources with a programmable structure having variable width. The document describes a multifunction tile and in one of the embodiments, the multifunction tile includes a configurable, dual-ported RAM and a multiplier that share the Input/Output resources of the multi-function tile. The RAM block and the multiplier block share their inputs bits and therefore, whenever the multiplier block is being used, the RAM block cannot be used in 32-bit mode.
The connectivity of the multiplier block and RAM block in the above discussed patent is such that whenever the multiplier block is being used, the associated RAM block can only be used in specific modes (18 bits or less). The multiplier inputs and outputs cannot be stored in the associated RAM block.
It is therefore felt that a direct interconnect structure is required between complex IP cores (Digital Signal Processors, Memory, High speed microprocessors) in FPGA, to avoid inefficient performance of general-purpose routing resources and for providing an integral connectivity between the complex IP cores and FPGA.
SUMMARY OF THE INVENTION
To address the above-discussed deficiencies of the prior art, it is an object of the present invention to provide a direct interconnect structure between complex IP cores in FPGA.
It is another object of the present invention to provide configurable bus width connectivity between the IP cores.
It is further an object of the present invention to provide simultaneous routing of data among the IP cores and the logic blocks in FPGA.
To achieve said objectives the present invention provides an improved FPGA having a direct routing structure, comprising:
a direct interconnect structure for providing selective data routing without stressing the general-purpose routing resources and enabling high rate of data exchange within the FPGA,
at least two IP cores connected to each other through said direct interconnect structure for enabling simultaneous data interaction among the ports of said IP cores, and providing configurable bus width routing between said IP cores, and
a plurality of logic blocks connected to said IP cores through said direct interconnect structure for enabling simultaneous data routing among said IP cores and said plurality of logic blocks.
Further, the present invention provides a method for implementing direct routing in FPGA, the method comprising steps of:
enabling simultaneous data interaction among ports of said IP cores through said direct interconnect structure,
providing configurable bus width routing between said IP cores through the selectors of the direct interconnect structure, and
simultaneously routing data among said IP cores and said plurality of logic blocks through the direct interconnect structure.
Thus, the present invention provides a direct an efficient routing structure between complex IP cores as signal processors and memory incorporated in FPGA.
Before undertaking the DETAILED DESCRIPTION OF THE INVENTION below, it may be advantageous to set forth definitions of certain words and phrases used throughout this patent document: the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or,” is inclusive, meaning and/or; and the phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like. It should be noted that the functionality associated with any particular apparatus or controller may be centralized or distributed. Definitions for certain words and phrases are provided throughout this patent document, those of ordinary skill in the art should understand that in many, if not most instances, such definitions apply to prior, as well as future uses of such defined words and phrases.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described with reference to and as illustrated by the accompanying drawings, in which like reference numerals represent like parts, and in which:
FIG. 1A illustrates an existing PRIOR ART structure of FPGA with embedded Random Access Memory according to U.S. Pat. No. 5,933,023.
FIG. 1B illustrates the block diagram of an existing PRIOR ART configurable memory array according to U.S. Pat. No. 6,104,208.
FIG. 1C illustrates the PRIOR ART multifunction tile in accordance with U.S. Pat. No. 6,573,749;
FIG. 2 illustrates the improved FPGA in accordance with the present invention;
FIG. 3 illustrates the distribution of signals in the sub blocks of the memory block in accordance with the instant invention;
FIG. 4 illustrates the distribution of signals in the sub blocks of the signal-processing block in accordance with the instant invention;
FIGS. 5 and 6 illustrate the input matrices of the direct interconnect structure according to the instant invention;
FIG. 7A illustrates the input port of the signal-processing block being driven by the memory block;
FIG. 7B illustrates the simultaneous routing between the memory block and the signal-processing block;
FIG. 7C illustrates the configurable bus width routing between the signal processing block and the memory block;
FIG. 8A illustrates the data routing from the output port of the signal-processing block to the first input port of the memory block;
FIG. 8B illustrates the data routing from the output port of the signal-processing block to the second input port of the memory block;
FIG. 9 illustrates the bi-directional data interaction between the memory and signal-processing block; and
FIG. 10 illustrates the multi port connectivity among the memory, signal processing block and logic block.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 2 through 10 , discussed below, and the various embodiments used to describe the principles of the present invention in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the invention. Those skilled in the art will understand that the principles of the present invention may be implemented in any suitably arranged FPGA or like circuitry.
FIG. 1 has been described under the heading ‘Background of the Invention’.
The complex IP cores (hereafter referred to as memory block and DSP block) that are connected through the Direct Interconnect structure are implemented in the FPGA are shown in FIG. 2 . FIG. 2 shows that the size of the memory block (RAM block) is 18 K bits, which comprises 16K data bits and 2K parity bits. The parity bits are available only in cross modes greater than or equal to eight (8). In the center of the FPGA is a plurality of Reconfigurable Logic Blocks (RLBs), separated periodically by columns of RAM blocks followed by the DSP blocks for providing routing between the Configurable Logic Blocks in FPGA. FIG. 2 also illustrates one column each of the RAM block and the DSP block. The RAM and DSP blocks span the height of eight (8) Reconfigurable Logic Blocks. Signals are exchanged between RAM blocks and the DSP blocks by using the Direct Interconnect structure as shown in the FIG. 2 . The Direct Interconnect structure comprises a configurable routing structure and hardwired interconnect structure for providing direct routing with minimized delay. Hardwired interconnects in the direct routing structure obviate the routing delay that would have been caused by routing the IP cores through the conventional switch matrix structure. The configurable routing structure is elaborated with reference to FIGS. 5 and 6 in this document. RAM Block is configured to operate in multiple modes as a 512×32 array or as a 1028×16 array.
The RAM blocks illustrated in FIG. 2 are dual port RAM blocks with each of the ports individually configurable in multiple modes. Since, said RAM block can be used as 16K×1 array, the total number of address bits required to address the RAM block is 14. Thus, there are 28 address bits for the two ports of the memory and they operate as a single array for the two ports. Further, the total number of data bits for each port is 32.
The RAM block comprises sub blocks ( 301 to 308 ) are shown in FIG. 3 . These sub blocks interact with the multiple switch boxes of the general-purpose routing structure besides being connected to the DSP block through the Direct Interconnect structure. The I/O port structure of the RAM block comprises two input ports (Ports A and B) and an output port. The Conventional signals in said RAM block have not been illustrated for the sake of simplicity. The address bits are designated by variables ADD_A and ADD_B for port A and port B respectively, wherein the number following the variables specifies the order of address bits. The data input bits are designated by variables DI_A and DI_B respectively and the data output bits are designated by DO_A and DO_B for signals A and B respectively.
The DSP block comprises a plurality of sub blocks ( 401 to 408 ) and an I/O port structure comprising three input ports and an output port as shown in FIG. 4 . Signals A and B are 18 bit wide, whereas signal C is 36 bit wide and the output bus is also 36 bits wide. Conventional signals in said DSP block have not been shown for the sake of simplicity. The Data Input bits are designated as DI and the number following them specifies the order of the data bits. The data output bits are designated as DO.
The configurable routing structure is herein ( FIG. 5 ) described with reference to one sub block of the memory (RAM) block. The configurable routing structure comprises a selector (multiplexer) structure, wherein the selector structure comprises a plurality of logic selectors thus embodying a discrete selector structure. The selector structure in FIG. 5 comprises four logic selectors of size n×3, wherein n equals the number of inputs to the logic selectors in the selector structure. The select lines function for the multiplexers are provided by the configuration bits in the FPGA. The distribution of signals in the logic selectors is such that the address inputs for port A and B of the memory are distributed in the four logic selectors. It is therefore observed that all these signals can be routed simultaneously with the help of Direct Interconnects. These addresses can be generated in the reconfigurable logic blocks adjacent to the RAM block and can be routed through the Direct Interconnects.
The RAM block described here can be configured in any of the following modes: n×1, n×2, n×4, n×8, n×16, n×32, where n designates the number of bits in the array. It is further observed that in all these cases the lower data bits ( 0 to 15 ) are used in all the cases while the upper data ( 16 to 31 ) bits are used only in the n×32 mode.
Above said configurable bus width is achieved by using a discrete multiplexing logic (plurality of multiplexers) in the configurable routing structure. The upper data bits of port B and the lower data bits of port A are multiplexed to form one combination. Similarly, the upper data bits of port A and the lower data bits of port B are multiplexed together for providing a multi-port bi-directional data interaction among the IP cores and the configurable logic blocks in the FPGA.
The stated distribution of signals implies that the lower data bits of both the ports can be routed simultaneously into the RAM block using the Direct Interconnects without stressing the general purpose routing resources. Further, the 32 data bits of any one port (A or B) can be routed simultaneously using the Direct Interconnect Structure. The data bits may be generated in the logic blocks adjacent to the RAM blocks or may be computed in the DSP block also adjacent to the RAM block.
FIG. 6 shows the configurable routing structure interacting with a sub block of the DSP block. The routing structure herein described is similar to the routing structure of the RAM block and comprises four logic selectors of size n×2 and n×3. The routing structure receives inputs from the memory block and the DSP block. The DSP block takes three inputs namely, A, B and C of width 18 , 18 and 36 respectively and operates on these signals and gives the following combination of output signals.
Out=(sigma) A*B Or Out= A*B+C
FIGS. 7A , 7 B and 7 C illustrate the method in which both A and B port outputs of RAM block can drive the A and B port inputs of the DSP block. The port names herein prefixed by DIs indicate the data input ports and those prefixed by DOs indicate data output ports. FIG. 7A shows the connectivity between the two bits each of ports A and B of the signal processor and memory. FIG. 7B shows that the B and C inputs of the DSP block are fed simultaneously. FIG. 7C shows that the 32 data bits of input C of the DSP block can be fed by the RAM block using the Direct Interconnect structure described in FIG. 6 .
FIGS. 8A and 8B show the routing combinations by which the DSP block outputs can feed the memory block address and data inputs. The flexible address bus accessibility in the figure further illustrating the configurable bus width routing. The port names (A, B) in above said figures that are prefixed by ADD signify the address inputs of the memory block, whereas the port names prefixed by DIs signify the data inputs of the memory block. The bi-directional connectivity between the DSP block and the memory block ensures a faster and efficient routing structure, which is essential for effective implementation of digital signal processing applications.
Above said routing combinations are explained explicitly as follows:
1) All the data bits of A, and all the data bits of B of the DSP block can be simultaneously routed from the memory block to the DSP block via Direct Interconnects. 2) All the data bits of A and the lower data bits of C of the DSP block can be routed form the RAM block to the DSP block. 3) All the data bits of C (except the last four bits i.e. parity bits) can be routed to the DSP block from the RAM block. 4) All the address bits of port A and port B of the RAM block can be simultaneously routed from the adjacent logic block. 5) All the data input bits of port A and port B of the RAM block can be simultaneously routed from the adjacent logic blocks. 6) All the outputs of DSP block (except for the last four bits) may drive the port A data input bits of RAM block. 7) All the outputs of DSP block (except for the last four bits) may drive the port B data input bits of RAM block. 8) All these signals may also be routed form the adjacent logic block via the Direct Interconnect structure.
The bi-directional data routing between the memory and the signal-processing block is further explained using FIG. 9 . The plurality of logic selectors in the Direct Interconnect structure enable the bi-directional routing between complex IP cores.
The discrete structure of the logic selectors is significant in providing configurable bus width connectivity between the IP cores.
The DIs that signify the data inputs in the signal processing block are routed through the direct interconnect structure to the DOs of the memory block and are further routed to the logic block ( FIG. 10 ), the logic block thus facilitating the minimal delay multiport data interaction among the IP cores (memory and signal processor) and the plurality of the logic blocks.
It is therefore observed that implementation of the network of Direct Interconnects between the RAM blocks, DSP blocks and the Reconfigurable Logic Blocks not only offer fast and efficient data exchange between them but also integrates these blocks to the core. This structure is significant in complex Digital Signal Processing Applications where the data computed in the DSP block needs to be stored in memory or the coefficients of filters are stored in memory and are required in the DSP block for computation. It is intended that the present invention encompass such changes and modifications as fall within the scope of the appended claims. | An improved FPGA having a direct interconnect structure to provide selective data routing without stressing the general-purpose routing resources and to enable high rate of data exchange within the FPGA. At least two IP cores are connected to each other through the direct interconnect structure to enable simultaneous data interaction among the ports of the IP cores and to provide configurable bus width routing between the IP cores, and a plurality of logic blocks connected to the IP cores through the direct interconnect structure to enable simultaneous data routing among the IP cores and the plurality of logic blocks. | 7 |
FIELD OF THE INVENTION
[0001] This invention relates to an apparatus for a rotating device including rotation for children's swings.
BACKGROUND OF THE INVENTION
[0002] Rotating devices are used in industry and are seen in playground equipment.
[0003] The patents referred to herein are provided herewith in an Information Disclosure Statement in accordance with 37 CFR 1.97.
SUMMARY OF THE INVENTION
[0004] The Device ( 1 ) provides a rotating shaft ( 1000 ) with upper and lower sleeves ( 1100 , 1170 ) supported by upper and lower bearing assemblies ( 1130 , 1160 ) within a nipple/coupling frame ( 1050 ) which is anchored in a concrete base. The rotating shaft ( 1000 ) will support a swing set for children in addition to having other uses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The foregoing and other features and advantages of the present invention will become more readily appreciated as the same become better understood by reference to the following detailed description of the preferred embodiment of the invention when taken in conjunction with the accompanying drawings, wherein:
[0006] FIG. 1 illustrates a vertical section of the Rotating Device ( 1 ) showing the rotating shaft ( 1000 ), rotating shaft cover ( 1020 ), rotating shaft cover inside diameter ( 1022 ), rotating shaft cover weld ( 1025 ), swing arm assembly ( 1030 ), swing arm right ( 1032 ) and swing arm left ( 1033 ). Also seen is the nipple/coupling frame ( 1050 ), upper sleeve ( 1100 ), upper sleeve indentation ( 1102 ), upper sleeve weld ( 1105 ), sleeve inside diameter ( 1107 ), upper nipple ( 1110 ), nipple inside diameter ( 1112 ), upper coupling ( 1120 ) and coupling inside diameter ( 1122 ). Also illustrated is the upper bearing assembly ( 1130 ), upper bearing ( 1133 ), upper bearing race ( 1137 ), the intermediate nipple ( 1140 ), the lower coupling ( 1150 ), lower bearing assembly ( 1160 ), lower bearing ( 1163 ), lower bearing race ( 1167 ), lower sleeve ( 1170 ), lower sleeve indentation ( 1172 ), lower sleeve weld ( 1175 ), lower nipple ( 1180 ), swing seat assembly ( 1190 ), swing seat suspension ( 1192 ), swing seat suspension connector ( 1194 ), swing seat ( 1196 ), swing cable ( 1198 ) and swing cable connector ( 1199 ).
[0007] FIGS. 1A , 1 B and 1 C show swing arm assembly mount assembly ( 1029 ), the swing arm assembly mount assembly aperture ( 1028 ), swing arm assembly ( 1030 ), swing arm right ( 1032 ) and swing arm left ( 1033 ).
[0008] FIGS. 2 , 3 and 4 illustrate a detail of the swing arm assembly ( 1030 ) showing the swing arm right ( 1032 ) and swing arm left ( 1033 ) most distal to the rotating shaft ( 1000 ); seen is the swing arm swing seat connection system ( 1034 ) with a swing arm swing seat connection carabiner ( 1035 ), a swing arm swing seat loop ferrule ( 1036 ), a flattened swing arm swing seat connection section ( 1037 ) and a swing arm swing seat connection aperture ( 1039 ).
DETAILED DESCRIPTION
[0009] FIG. 1 illustrates a Rotating Device ( 1 ). A cylindrical rotating shaft ( 1000 ), in the preferred embodiment, rotates relative to a nipple/coupling frame ( 1050 ). It will be appreciated by those of ordinary skill in mechanical arts that a rigid structure, fulfilling the structure formed by the interconnection of nipples and couplings, as is seen hereafter, can be formed and used in place of the combination of nipples and couplings as seen here. Here the preferred embodiment is a nipple/coupling frame ( 1050 ) formed of nipples and couplings. An upper sleeve ( 1100 ) is slidably received by the rotating shaft ( 1000 ) and a lower sleeve ( 1170 ) is slidably received by the rotating shaft ( 1000 ). The upper sleeve ( 1100 ) and the lower sleeve ( 1170 ) are rigidly and immovably affixed to the rotating shaft ( 1000 ) generally by welding.
[0010] An upper bearing assembly ( 1130 ) is slidably received by the rotating shaft ( 1000 ) and is intermediate the upper sleeve ( 1100 ) and the lower sleeve ( 1170 ) and is proximal to the upper sleeve ( 1100 ) and is distal to the lower sleeve ( 1170 ). A lower bearing assembly ( 1160 ) is slidably received by the rotating shaft ( 1000 ), is intermediate the upper sleeve ( 1100 ) and the lower sleeve ( 1170 ) and is proximal to the lower sleeve ( 1170 ) and is distal to the upper sleeve ( 1100 ).
[0011] The nipple/coupling frame ( 1050 ) rotatably supports the upper bearing assembly ( 1130 ) and the lower bearing assembly ( 1160 ) allowing the rotating shaft ( 1000 ) to rotate relative to the nipple/coupling frame ( 1050 ). The nipple/coupling frame ( 1050 ) extending downwardly for vertical anchoring of the Rotating Device ( 1 ) in a generally concrete foundation.
[0012] The cylindrical rotating shaft ( 1000 ) is rigid, generally composed of metal pipe. The upper sleeve ( 1100 ) and the lower sleeve ( 1170 ) are rigid and generally formed of metal pipe.
[0013] The upper bearing assembly ( 1130 ) is comprised of an upper bearing ( 1133 ) and an upper bearing race ( 1137 ) and the upper sleeve ( 1100 ) bears on the upper bearing ( 1133 ). The upper bearing race ( 1137 ) is distal to the upper sleeve ( 1100 ) and proximal to the lower sleeve ( 1170 ).
[0014] The lower bearing assembly ( 1160 ) is comprised of a lower bearing ( 1163 ) and a lower bearing race ( 1167 ). The lower sleeve ( 1170 ) bears on the lower bearing ( 1163 ) and the lower bearing race ( 1167 ) is distal to the lower sleeve ( 1170 ) and proximal to the upper sleeve ( 1100 ).
[0015] The nipple/coupling frame ( 1050 ) is comprised of an upper nipple ( 1110 ) which is sized to be loosely received by the upper sleeve ( 1100 ). Extending downwardly the upper nipple ( 1110 ) has male threads which mate with female threads of an upper coupling ( 1120 ). Extending downwardly the upper coupling ( 1120 ) has female threads which mate with male threads of an intermediate nipple ( 1140 ). Extending downwardly the intermediate nipple ( 1140 ) has male threads which mate with female threads of a lower coupling ( 1150 ). Extending downwardly the lower coupling ( 1150 ) has female threads which mate with male threads of a lower nipple ( 1180 ). The lower nipple ( 1180 ) is sized to be loosely received by the lower sleeve ( 1170 ).
[0016] The upper bearing race ( 1137 ) bears on or is supported by the intermediate nipple ( 1140 ) proximal to the upper coupling ( 1120 ) and is permanently affixed thereto by an intermediate nipple weld ( 1145 ). The lower bearing race ( 1167 ) bears on or is supported by the intermediate nipple ( 1140 ) proximal to the lower coupling ( 1150 ) and is permanently affixed thereto by an intermediate nipple weld ( 1145 ). The upper bearing race ( 1137 ) is contained by the upper coupling ( 1120 ) and the lower bearing race ( 1167 ) is contained by the lower coupling ( 1150 ).
[0017] A rotating shaft cover ( 1020 ) is upward from the upper nipple ( 1110 ) and is immovably affixed by pipe affixing means, generally welding, to the rotating shaft ( 1000 ) by a rotating shaft cover weld ( 1025 ). In the preferred embodiment, the rotating shaft cover ( 1020 ) is outwardly extending from the rotating shaft ( 1000 ) and, most distal to the rotating shaft ( 1000 ) turns downwardly to receive and contain the upper nipple ( 1110 ) distal to the upper coupling ( 1120 ). The rotating shaft cover ( 1020 ) provides protection for the upper sleeve ( 1100 ) and rotating shaft ( 1000 ) from the rain and dust.
[0018] A swing arm assembly ( 1030 ) is comprised of an outwardly extending swing arm right ( 1032 ) and an outwardly extending swing arm left ( 1033 ). The swing arm right ( 1032 ) and swing arm left ( 1033 ) are aligned, are generally orthogonal to the rotating shaft ( 1000 ) and are formed from rigid materials generally metal pipe. The swing arm assembly ( 1030 ) is immovably affixed by pipe affixing means to the rotating shaft ( 1000 ) by the rotating shaft cover weld ( 1025 ). Pipe affixing means to immovably affix the swing arm assembly ( 1030 ) at the rotating shaft cover ( 1020 ) includes a variety of pipe affixing means commonly recognized by those of ordinary skill in the pipe affixing arts. Pipe affixing means to immovably affix the swing arm assembly ( 1030 ) at the rotating shaft cover ( 1020 ) includes welding of the swing arm assembly ( 1030 ) to the rotating shaft cover ( 1020 ). Alternatively pipe affixing means to immovably affix the swing arm assembly ( 1030 ) at the rotating shaft cover ( 1020 ) may comprise a swing arm assembly mount assembly ( 1029 ) where the swing arm assembly mount assembly ( 1029 ) has at least one swing arm assembly mount assembly aperture ( 1028 ) sized to receive the swing arm right ( 1032 ) and the swing arm left ( 1033 ). The swing arm right ( 1032 ) and the swing arm left ( 1033 ) may comprise a single length of metal pipe which is inserted into the at least one swing arm assembly mount assembly aperture ( 1028 ) and is welded thereto. Alternatively, and as the preferred embodiment, the pipe affixing means to immovably affix the swing arm assembly ( 1030 ) at the rotating shaft cover ( 1020 ) comprising a swing arm assembly mount assembly ( 1029 ) where the swing arm assembly mount assembly ( 1029 ) has at least one swing arm assembly mount assembly aperture ( 1028 ) sized to receive the swing arm right ( 1032 ) and the swing arm left ( 1033 ) and additionally is threaded. The respective swing arm right ( 1032 ) and the swing arm left ( 1033 ) are threaded and are threadedly received by the at least one swing arm assembly mount assembly aperture ( 1028 ) and are welded to the swing arm assembly mount assembly ( 1029 ).
[0019] An upper sleeve indentation ( 1102 ) is formed in the upper sleeve ( 1100 ) to temporarily fix the upper sleeve ( 1100 ) in place pending immovably welding the upper sleeve ( 1100 ) to the rotating shaft ( 1000 ) with the upper sleeve weld ( 1105 ). A lower sleeve indentation ( 1182 ) is formed in the lower sleeve ( 1170 ) to temporarily fix the lower sleeve ( 1170 ) in place pending immovably welding the lower sleeve ( 1170 ) to the rotating shaft ( 1000 ) with the lower sleeve weld ( 1185 ). The upper sleeve indentation ( 1102 ) and the lower sleeve indentation ( 1182 ) are formed by a hammer strike. In the preferred embodiment the rotating shaft ( 1000 ) is threaded, with shaft threads ( 1171 ) proximal the threaded lower sleeve ( 1170 ) to allow tightening of the lower sleeve ( 1170 ) against the lower bearing ( 1163 ). In an alternative embodiment the rotating shaft ( 1000 ) may be threaded with the threads yielding to the deformation of the upper sleeve ( 1100 ) and the lower sleeve ( 1170 ) when struck by a hammer strike.
[0020] At least one swing seat assembly ( 1190 ), comprised of a swing seat suspension ( 1192 ), which is generally a rope, cable or chain, is connected to the swing arm assembly ( 1030 ), distal to the rotating shaft ( 1000 ), at the swing arm right ( 1032 ) or the swing arm left ( 1033 ). The swing seat suspension ( 1192 ) is connected by swing seat suspension affixing means comprising generally eye-bolts. At least one swing seat ( 1196 ) is affixed by swing seat affixing means to the at least one swing seat suspension ( 1192 ) distal to the swing arm right ( 1032 ) or the swing arm left ( 1033 ). In the preferred embodiment the at least one swing seat ( 1196 ) is generally disk shaped and composed of semi rigid materials including plastic. It will be appreciated that the swing seat ( 1196 ) can be any platform upon which a child can sit, e.g., a plank, a tube or a bar. The rotating device ( 1 ) may be rotated, in the preferred embodiment, by at least one swing cable ( 1198 ) connected to the swing arm right ( 1032 ) or the swing arm left ( 1033 ) by a swing cable connector ( 1199 ) comprised of swing cable connector connection means including an eye-bolt or a chain link welded to the swing arm right ( 1032 ) or the swing arm left ( 1033 ), proximal the rotating shaft ( 1000 ). The operator will stand next to the rotating shaft ( 1000 ) and pull the at least one swing cable ( 1198 ) thereby rotating the rotating device ( 1 ).
[0021] At least one swing seat suspension ( 1192 ) is connected to the swing arm right ( 1032 ) and/or the swing arm left ( 1033 ) by a swing arm swing seat connection system ( 1034 ); the swing seat connection system ( 1034 ) is comprised of a swing arm swing seat connection section ( 1037 ) of the swing arm right ( 1032 ) and separately of the swing arm left ( 1033 ) most distal from the rotating shaft ( 1000 ); the swing arm swing seat connection section ( 1037 ) is flattened with a swing arm swing seat connection aperture ( 1039 ) therein; a swing arm swing seat connection carabiner ( 1035 ) clip is fastened through the swing arm swing seat connection aperture ( 1039 ); a loop is formed in the swing seat suspension ( 1192 ) proximal the swing arm right ( 1032 ) and also at the swing arm left ( 1033 ). The loop is received by the respective swing arm swing seat connection carabiner ( 1035 ) clip and is secured by a swing arm swing seat loop ferrule ( 1036 ). It will be appreciated that the swing cable ( 1198 ) can be comprised of more than one cable, rope or chain. In the preferred embodiment the swing seat ( 1196 ) is suspended by a single swing seat suspension ( 1192 ). | The Rotating Device ( 1 ) comprises a rotating shaft ( 1000 ) being bearing interrelated to a nipple/coupling frame. The rotating shaft ( 1000 ) supports swing arms right and left from which are suspended swing seats. The nipple/coupling frame extends into and is supported by a generally concrete foundation. | 0 |
TECHNICAL FIELD
The present invention relates to radical-polymerizable resins (free-radically polymerizable resins or radically polymerizable resins), radical-polymerizable resin compositions, and cured materials (cured products) obtained therefrom. They are useful in the fields of stress-relaxation adhesives, waveguides (e.g., optical waveguides and hybrid substrates), optical fibers, sealants, underfill materials, ink-jet inks, color filters, nanoimprinting materials, and flexible substrates (flexible boards) and are particularly useful as stress-relaxation adhesives.
BACKGROUND ART
When an adhesive is applied to an adherend, and the adhesive includes a material having a coefficient of thermal expansion different from that of a material constituting the adherend, the two materials constituting the adhesive and the adherend thermally expand (or contract) in different degrees upon heating or cooling to cause a stress. The stress may disadvantageously cause peeling (separation) at the adhesive interface between the adhesive and the adherend. For example, such an adhesive is adopted to a recently studied technique of stacking two or more plies of a semiconductor device or wafer in a direction perpendicular to the substrate plane. According to this technique, two or more plies of a semiconductor device or a wafer are stacked and bonded with the adhesive to give a stack, and a through hole penetrating the stack is provided to form a through-silicon via. Thus, electrodes vertically connected to each other are provided with a higher degree of vertical integration. However, when a material constituting the adhesive has a coefficient of thermal expansion different from that of a material constituting the adherend semiconductor device, wafer, or through-silicon via, the two materials thermally expand (or contract) in different degrees upon heating or cooling to cause a stress. The stress may cause peeling (separation) at the adhesive interface between the adhesive and the adherend. In addition, the semiconductor device, wafer, and through-silicon via are thin-walled, fragile, and thereby liable to break when receiving external force applied as a result of heating or cooling.
According to a customary technique, an adhesive having a small difference in coefficient of thermal expansion from that of a material constituting the adherend has been employed to suppress peeling at the adhesive interface, which peeling is caused by the difference in coefficient of thermal expansion. This technique, however, should employ different adhesives from one adherend material to another and should thereby require adhesives of various types.
In contrast to this, an adhesive having sufficient flexibility, if developed, may avoid the need of employing different adhesives from one adherend material to another, because this adhesive can relax the stress which occurs between the adhesive and the adherend upon heating or cooling and which is caused by difference in thermal expansion. Patent Literature (PTL) 1 discloses a polymerizable resin composition including a polymerizable resin and a radically polymerizable monomer, in which the polymerizable resin is obtained by polymerization of monomer components containing an unsaturated monomer having an alicyclic epoxy group and/or an oxetane group in the molecule. The polymerizable resin composition, however, gives a cured material which is not sufficiently flexible and does not sufficiently relax the stress caused by difference in coefficient of thermal expansion between materials constituting the adhesive and the adherend.
CITATION LIST
Patent Literature
PTL 1: Japanese Unexamined Patent Application Publication (JP-A) No. 2001-81182
SUMMARY OF INVENTION
Technical Problem
An object of the present invention is to provide a radical-polymerizable resin, a radical-polymerizable resin composition, and a cured material thereof, in which the resin and the resin composition are capable of giving a cured material which is satisfactorily flexible, can relax stress upon usage as an adhesive, and does not cause disadvantages such as separation at the adhesive interface and breakage of the adherend, which stress occurs between the adhesive and the adherend upon heating or cooling and is caused by difference in coefficient of thermal expansion between them.
Another object of the present invention is to provide a radical-polymerizable resin, a radical-polymerizable resin composition, and a cured material thereof, in which the resin and the resin composition are capable of giving a cured material which is satisfactorily flexible and thermally stable and has excellent adhesiveness.
Solution to Problem
After intensive investigations to achieve the objects, the present inventors have found a resin which is obtained through cationic polymerization of a compound in combination with a (meth)acrylic ester, which is liquid at 0° C., and which has a weight-average molecular weight of 500 or more, in which the compound has an epoxy group or oxetanyl group with a specific structure, and the (meth)acrylic ester has an epoxy group or oxetanyl group having a specific structure. The present inventors have also found that this radical-polymerizable resin, when cured, gives a cured material which is satisfactorily flexible and can relax stress upon usage as an adhesive to remarkably less cause disadvantages such as separation at the adhesive interface and breakage of the adherend, in which the stress occurs between the adhesive and the adherend upon heating or cooling and is caused by difference in coefficient of thermal expansion between them. The present invention has been made based on these findings.
Specifically, the present invention provides a radical-polymerizable resin obtained through cationic polymerization of a first compound in combination with a second compound, the first compound being at least one compound selected from compounds each represented by one of following Formulae (1a) and (1b):
wherein R a , R b , R c , R d , R e , and R f are the same as or different from one another and each represent hydrogen atom or a hydrocarbon group having 1 to 20 carbon atoms and optionally containing an oxygen atom, where at least one of R a , R b , R c , and R d , and at least one of R e and R f are each independently a hydrocarbon group having 4 to 20 carbon atoms and optionally containing an oxygen atom, where at least two of R a , R b , R c , and R d , together with the adjacent one or two carbon atoms, may be linked to form a ring, and where R e and R f , together with the adjacent carbon atom, may be linked to form a ring, and
the second compound being at least one compound selected from compounds each represented by one of following Formulae (2a) to (2f):
wherein R x represents hydrogen atom or methyl group; R 1 , R 2 , R 3 , and R 4 each independently represent hydrogen atom or a hydrocarbon group having 1 to 5 carbon atoms; A 1 represents single bond, an alkylene group having 1 to 5 carbon atoms, an alkyleneoxyalkylene group having 1 to 5 carbon atoms, or an alkyleneoxy group having 1 to 5 carbon atoms, where the oxygen atom of the alkyleneoxy group is bound to the ring in the formula; and A 2 represents an alkylene group having 1 to 3 carbon atoms. The radical-polymerizable resin is liquid at 0° C. and has a weight-average molecular weight of 500 or more.
The present invention also provides a radical-polymerizable resin composition including the radical-polymerizable resin.
The radical-polymerizable resin composition may further include an initiator for thermally-induced or energy-ray-induced radical polymerization. The initiator for thermally-induced radical polymerization is preferably an organic peroxide.
The radical-polymerizable resin composition may further include a silane coupling agent represented by following Formula (3):
wherein R x represents hydrogen atom or methyl group; A 3 represents a hydrocarbon group having 1 to 20 carbon atoms; and R g , R h , and R i are the same as or different from one another and each represent an alkoxy group having 1 to 3 carbon atoms or an alkyl group having 1 to 3 carbon atoms, where at least one of R g , R h , and R i is an alkoxy group having 1 to 3 carbon atoms. The presence of the silane coupling agent may help the resin composition, upon usage as an adhesive, to have a significantly higher adhesive strength to an inorganic material as an adherend.
The radical-polymerizable resin composition may further include a radically polymerizable monomer having two to six radically polymerizable functional groups. The presence of such a multifunctional radically polymerizable monomer may help the resin composition, upon usage as an adhesive, to have a further higher adhesive strength.
The present invention further provides a cured material obtained through radical polymerization of the radical-polymerizable resin composition.
The cured material may be in the form of a film or fiber.
Advantageous Effects of Invention
The radical-polymerizable resin according to the present invention is a resin obtained through cationic polymerization of a compound having an epoxy group or oxetanyl group with a specific structure in combination with a (meth)acrylic ester having an epoxy group or oxetanyl group with a specific structure, is liquid at 0° C., and has a weight-average molecular weight of 500 or more. The radical-polymerizable resin, when subjected to radical polymerization, gives a cured material with suitably controlled intervals between crosslinking points. The cured material is therefore satisfactorily flexible even after curing. Upon usage typically as an adhesive, the cured material can relax stress and remarkably less causes disadvantages such as separation at the adhesive interface and breakage of the adherend, in which the stress occurs between the adhesive and the adherend upon heating or cooling and is caused by difference in coefficient of thermal expansion between them. The radical-polymerizable resin is cured through radical polymerization, and this eliminates the need of an acid generator to be used as a polymerization initiator and avoids disadvantages such as corrosion of circuits and substrates of electronic components, which corrosion is caused by an acid if remains. A radical-polymerizable resin composition including the radical-polymerizable resin according to the present invention gives a cured material which is satisfactorily thermally stable and flexible, and has excellent adhesiveness.
DESCRIPTION OF EMBODIMENTS
A radical-polymerizable resin according to an embodiment of the present invention is a resin obtained through cationic polymerization of at least one compound (A) and at least one (meth)acrylic ester (B), in which the at least one compound (A) is selected from compounds each represented by one of Formulae (1a) and (1b) and has an epoxy group or oxetanyl group, and the at least one (meth)acrylic ester (B) is selected from compounds each represented by one of Formulae (2a), (2b), (2c), (2d), (2e), and (2f) and has an epoxy group or oxetanyl group. The radical-polymerizable resin is liquid at 0° C. and has a weight-average molecular weight of 500 or more.
[Compound (A) Having Epoxy Group or Oxetanyl Group]
Compounds (A) having an epoxy group or oxetanyl group are each represented by one of Formulae (1a) and (1b). In Formulae (1a) and (1b), R a , R b , R c , R d , R e , and R f are the same as or different from one another and each represent hydrogen atom or a hydrocarbon group having 1 to 20 carbon atoms and optionally containing an oxygen atom, where at least one of R a , R b , R c , and R d , and at least one of R e and R f are each independently a hydrocarbon group having 4 to 20 carbon atoms and optionally containing an oxygen atom. The hydrocarbon group having 1 to 20 carbon atoms is typified by aliphatic hydrocarbon groups (e.g., alkyl groups), such as methyl, ethyl, propyl, isopropyl, butyl, isobutyl, s-butyl, t-butyl, pentyl, hexyl, octyl, 2-ethylhexyl, decyl, dodecyl, tetradecyl, hexadecyl, and octadecyl groups; alicyclic hydrocarbon groups such as cyclopentyl, cyclohexyl, cyclooctyl, and cyclododecyl groups; aromatic hydrocarbon groups such as phenyl and naphthyl groups; and groups each including two or more of them bonded to each other. These hydrocarbon groups may contain oxygen atom (—O—) between carbon atoms.
At least two of R a , R b , R c , and R d , together with the adjacent one or two carbon atoms, may be linked to form a ring. Independently, R e and R f , together with the adjacent carbon atom, may be linked to form a ring. Examples of such rings include monocyclic or polycyclic carbon rings having 4 to 20 carbon atoms and optionally containing an oxygen atom, such as cyclopentane ring, cyclohexane ring, cyclooctane ring, decalin ring, norbornane ring (i.e., bicyclo[2.2.1]heptane ring), 7-oxabicyclo[2.2.1]heptane ring, tricyclo[5.2.1.0 2,6 ]decane ring, and tricyclo[6.2.1.0 2,7 ]undecane ring.
The substituents R a , R b , R c and R e are each independently preferably hydrogen atom or an alkyl group having 1 to 4 carbon atoms. The substituents R d and R f are each independently preferably a hydrocarbon group having 4 to 20 carbon atoms and optionally containing an oxygen atom.
Of the compounds represented by Formula (1a) and having an epoxy group, preferred are compounds of Formula (1a) in which R a , R b , and R c are all hydrogen atoms, and R d is a hydrocarbon group having 4 to 20 carbon atoms and optionally containing an oxygen atom; and compounds of Formula (1a) in which R a and R d are each independently hydrogen atom or methyl group, and R b and R c , together with the adjacent two carbon atoms, form a ring having 4 to 20 carbon atoms.
Typical examples of the compounds represented by Formula (1a) and having an epoxy group include 1,2-epoxyhexane, 1,2-epoxyheptane, 1,2-epoxyoctane, 1,2-epoxydecane, 1,2-epoxydodecane, 1,2-epoxytetradecane, 1,2-epoxytetradecane, 1,2-epoxyhexadecane, 1,2-epoxyoctadecane, 2,3-epoxyhexane, 2,3-epoxyheptane, 2,3-epoxydecane, and cyclohexene oxide.
Of the compounds represented by Formula (1b) and having an oxetanyl group, preferred are compounds of Formula (1) in which R e is hydrogen atom or an alkyl group having 1 to 4 carbon atoms (e.g., ethyl group), and R f is a hydrocarbon group having 4 to 20 carbon atoms and optionally containing an oxygen atom (e.g., oxymethyl group substituted with a hydrocarbon group having 3 to 19 carbon atoms).
Typical examples of the compounds represented by Formula (1b) and having an oxetanyl group include 3-ethyl-3-(propoxymethyl)oxetane, 3-ethyl-3-(butoxymethyl)oxetane, 3-ethyl-3-(hexyloxymethyl)oxetane, 3-ethyl-3-(2-ethylhexyloxymethyl)oxetane, 3-ethyl-3-[(phenoxy)methyl]oxetane, 3-ethyl-3-(benzyloxymethyl)oxetane, and 3-ethyl-3-(cyclohexyloxymethyl)oxetane.
[(Meth)acrylic Ester (B) having Epoxy Group or Oxetanyl Group]
(Meth)acrylic esters (B) having an epoxy group or oxetanyl group are each represented by one of Formulae (2a), (2b), (2c), (2d), (2e), and (2f). In Formulae (2a) to (2f), R x represents hydrogen atom or methyl group; R 1 , R 2 , R 3 , and R 4 each independently represent hydrogen atom or a hydrocarbon group having 1 to 5 carbon atoms; A 1 represents single bond, an alkylene group having 1 to 5 carbon atoms, an alkyleneoxyalkylene group having 1 to 5 carbon atoms, or an alkyleneoxy group having 1 to 5 carbon atoms, where the oxygen atom of the alkyleneoxy group is bonded to the ring in the formula; and A 2 represents an alkylene group having 1 to 3 carbon atoms.
Exemplary hydrocarbon groups having 1 to 5 carbon atoms as R 1 to R 4 include aliphatic hydrocarbon groups (e.g., alkyl groups), such as methyl, ethyl, propyl, isopropyl, butyl, isobutyl, and pentyl groups; and cycloalkyl groups such as cyclopropyl, cyclobutyl, and cyclopentyl groups. Each of R 1 to R 4 is independently preferably hydrogen atom or an alkyl group having 1 to 3 carbon atoms.
As A 1 , the alkylene group having 1 to 5 carbon atoms is typified by linear or branched chain alkylene groups having 1 to 5 carbon atoms, such as methylene, ethylene, propylene, trimethylene, tetramethylene, and pentamethylene groups. The alkyleneoxyalkylene group having 1 to 5 carbon atoms is exemplified by ethyleneoxymethylene, ethyleneoxyethylene, ethyleneoxypropylene, propyleneoxymethylene, and propyleneoxyethylene groups. The alkyleneoxy group having 1 to 5 carbon atoms, where the oxygen atom of the alkyleneoxy group is bonded to the ring in the formula, is typified by ethyleneoxy, propyleneoxy, trimethyleneoxy, tetramethyleneoxy, and pentamethyleneoxy groups.
The alkylene group having 1 to 3 carbon atoms as A 2 is exemplified by methylene, ethylene, propylene, and trimethylene groups.
The (meth)acrylic esters represented by Formula (2a) and having an epoxy group are typified by glycidyl (meth)acrylate. The (meth)acrylic esters represented by Formula (2b) and having an epoxy group are typified by 3,4-epoxycyclohexylmethyl (meth)acrylate. The (meth)acrylic esters represented by Formula (2c) and having an epoxy group are exemplified by 2,3-epoxycyclopentyl (meth)acrylate. The (meth)acrylic esters represented by Formula (2d) and having an epoxy group are exemplified by 3,4-epoxytricyclo[5.2.1.0 2,6 ]dec-8-yl (or 9-yl) (meth)acrylate and 5-[3,4-epoxytricyclo[5.2.1.0 2,6 ]dec-8-yl (or 9-yl)oxy]pentyl (meth)acrylate.
Exemplary (meth)acrylic esters represented by Formula (2e) and having an oxetanyl group include 3-ethyl-3-oxetanylmethyl (meth)acrylate [i.e., 3-ethyl-3-(meth) acryloyloxymethyloxetane]. Exemplary (meth)acrylic esters represented by Formula (2f) and having an oxetanyl group include 3-ethyl-3-[2-(meth)acryloyloxyethyloxymethyl]oxetane.
The radical-polymerizable resin according to the present invention is obtained through cationic polymerization of at least one compound (A) represented by one of Formulae (1a) and (1b) and having an epoxy group or oxetanyl group in combination with at least one (meth)acrylic ester (B) represented by one of Formulae (2a), (2b), (2c), (2d), (2e), and (2f) and having an epoxy group or oxetanyl group.
The ratio of the total amount of compounds (A) having an epoxy group or oxetanyl group to the total amount of (meth)acrylic esters (B) having an epoxy group or oxetanyl group is, in terms of weight ratio [(the former):(the latter)] of from 1:99 to 99:1, preferably from 20:80 to 97:3, more preferably from 40:60 to 95:5, and particularly preferably from 50:50 to 95:5. If the ratio is excessively small, the resulting resin composition may often give an insufficiently flexible cured material through radical polymerization; and, if the ratio is excessively large, the resin composition may often fail to give a cured material through radical polymerization.
The cationic polymerization reaction may be performed in the presence of a solvent. The solvent is not limited, as long as being inert to the reaction, and is typified by benzene, toluene, and xylenes.
The cationic polymerization reaction may employ a polymerization initiator. The polymerization initiator is not limited, as long as capable of inducing cationic polymerization, and can be any of known or customary cationic polymerization initiators and acid generators. These are typified by protonic acids such as perchloric acid, sulfuric acid, phosphoric acid, p-toluenesulfonic acid, trichloroacetic acid, and trifluoroacetic acid; Lewis acids such as boron trifluoride, aluminum bromide, aluminum chloride, antimony pentachloride, ferric chloride, tin tetrachloride, titanium tetrachloride, mercury chloride, and zinc chloride; as well as iodine and triphenylchloromethane. Each of them may be used alone or in combination.
The polymerization initiator may be used in the cationic polymerization reaction in an amount of typically from about 0.01 to about 50 percent by weight, and preferably from about 0.1 to about 20 percent by weight, relative to the total amount of cationically polymerizable compounds [total amount of the compounds (A) having an epoxy group or oxetanyl group and the (meth)acrylic esters (B) having an epoxy group or oxetanyl group].
The cationic polymerization reaction may be performed in the presence of a radical polymerization inhibitor. The radical polymerization inhibitor is typified by quinone/phenol inhibitors such as 4-methoxyphenol, hydroquinone, methylhydroquinone, dimethylhydroquinone, trimethylhydroquinone, hydroquinone monomethyl ether, 2,5-di-tert-butylhydroquinone, p-tert-butylcatechol, mono-t-butylhydroquinone, p-benzoquinone, naphthoquinone, 2,5-di-tert-butyl-p-cresol, α-naphthol, and nitrophenol; thioether inhibitors; and phosphite inhibitors.
During the reaction, a polymerization reaction with ring-opening proceeds between the epoxy or oxetanyl moiety of the epoxy- or oxetanyl-containing compound (A) and the epoxy or oxetanyl moiety of the epoxy- or oxetanyl-containing (meth)acrylic ester (B) to form a radical-polymerizable resin having an ethyleneoxy unit and/or a trimethyleneoxy unit in the principal chain and having a terminal (meth)acryloyloxy group.
The radical-polymerizable resin according to the present invention is liquid at 0° C. Namely, the radical-polymerizable resin is a liquid substance having fluidity at 0° C. A resin being solid at 0° C. may disadvantageously give an insufficiently flexible cured material through radical polymerization. The radical-polymerizable resin according to the present invention has a weight-average molecular weight of 500 or more (e.g., from 500 to about 500000), preferably from 550 to 200000, and more preferably from 600 to 100000. A radical-polymerizable resin having a weight-average molecular weight of less than 500 may not be cured through radical polymerization.
[Radical-polymerizable Resin Composition]
A radical-polymerizable resin composition according to an embodiment of the present invention includes the radical-polymerizable resin as a radically polymerizable compound.
The radical-polymerizable resin composition includes the radical-polymerizable resin in a content of typically 5 percent by weight or more and may substantially include the radical-polymerizable resin alone. For the formation of a more flexible cured material, the radical-polymerizable resin composition includes the radical-polymerizable resin in a content of preferably 10 percent by weight or more, more preferably 30 percent by weight or more (e.g., from 30 to 99.9 percent by weight), and particularly preferably 60 percent by weight or more (e.g., from 60 to 95 percent by weight). The radical-polymerizable resin composition, if including the radical-polymerizable resin in a content of less than 5 percent by weight, may give an insufficiently flexible cured material by curing through radical polymerization.
The radical-polymerizable resin composition according to the present invention may include, as a radically polymerizable compound, the radical-polymerizable resin alone or in combination with another radically polymerizable compound than the radical-polymerizable resin. Typically, the radical-polymerizable resin composition may contain another radically polymerizable compound (hereinafter also referred to as “other radically polymerizable compound”) than the radical-polymerizable resin and the compounds represented by Formulae (2a), (2b), (2c), (2d), (2e), and (2f).
The radical-polymerizable resin accounts for typically 20 percent by weight or more, preferably 40 percent by weight or more, and more preferably 60 percent by weight or more (e.g., from 60 to 95 percent by weight) of the total amount of radically polymerizable compounds in the radical-polymerizable resin composition.
The other radically polymerizable compound is exemplified by compounds having one or more radically polymerizable groups such as (meth)acryloyl groups, (meth)acryloyloxy groups, (meth)acryloylamino groups, vinylaryl groups, vinyl ether groups, and vinyloxycarbonyl groups, per molecule.
Exemplary compounds having one or more (meth)acryloyloxy groups per molecule include methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl (meth)acrylate, isobutyl (meth)acrylate, t-butyl methacrylate, 2-ethylhexyl (meth)acrylate, isodecyl (meth)acrylate, n-lauryl (meth)acrylate, n-stearyl (meth)acrylate, n-butoxyethyl (meth)acrylate, butoxydiethylene glycol (meth)acrylate, methoxytriethylene glycol (meth)acrylate, methoxypolyethylene glycol (meth)acrylates, cyclohexyl (meth)acrylate, n-hexyl (meth)acrylate, tetrahydrofurfuryl (meth)acrylate, benzyl (meth)acrylate, phenoxyethyl (meth)acrylate, isobonyl (meth)acrylate, 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl (meth)acrylate, 2-hydroxybutyl (meth)acrylate, dimethylaminoethyl (meth)acrylate, diethylaminoethyl (meth)acrylate, methacrylic acid, 2-methacryloyloxyethyl succinate, 2-methacryloyloxyethyl hexahydrophthalate, 2-methacryloyloxyethyl-2-hydroxypropyl phthalate, 2-methacryloyloxyethyl acid phosphate (2-hydroxyethyl methacrylate phosphate), ethylene glycol di(meth)acrylate, diethylene glycol di(meth)acrylate, triethylene glycol di(meth)acrylate, 1,4-butanediol di(meth)acrylate, neopentyl glycol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, 1,9-nonanediol di(meth)acrylate, 1,10-decanediol di(meth)acrylate, glycerol di(meth)acrylate, 2-hydroxy-3-acryloyloxypropyl (meth)acrylate, dimethyloltricyclodecane di(meth)acrylate, trifluoroethyl (meth)acrylate, perfluorooctylethyl (meth)acrylate, isoamyl (meth)acrylate, isomyristyl (meth)acrylate, 2-(meth)acryloyloxyethyl isocyanate, 1,1-bis(acryloyloxy)ethyl isocyanate, and 2-(2-methacryloyloxyethyloxy)ethyl isocyanate; as well as derivatives of them.
The compounds having one or more (meth)acryloyloxy groups per molecule include the silane coupling agent represented by Formula (3). In Formula (3), R x represents hydrogen atom or methyl group; A 3 represents a hydrocarbon group having 1 to 20 carbon atoms; and R g , R h , and R i are the same as or different from one another and each represent an alkoxy group having 1 to 3 carbon atoms or an alkyl group having 1 to 3 carbon atoms, where at least one of R g , R h , and R i is an alkoxy group having 1 to 3 carbon atoms.
The hydrocarbon group having 1 to 20 carbon atoms as A 3 is typified by linear or branched chain alkylene groups such as methylene, ethylene, propylene, trimethylene, tetramethylene, pentamethylene, hexamethylene, octamethylene, decamethylene, tetradecamethylene, and hexadecamethylene groups; cycloalkylene groups such as cyclopentylene and cyclohexylene groups; arylene groups such as phenylene group; and divalent hydrocarbon groups each including two or more of these bonded to each other. As R g , R h , and R i , the alkoxy group having 1 to 3 carbon atoms is exemplified by methoxy, ethoxy, propoxy, and isopropoxy groups; and the alkyl group having 1 to 3 carbon atoms is exemplified by methyl, ethyl, propyl, and isopropyl groups.
Typical examples of the silane coupling agent represented by Formula (3) include 3-(meth)acryloyloxypropyltrimethoxysilane, 3-(meth)acryloyloxypropyltriethoxysilane, 3-(meth)acryloyloxypropyldimethoxymethylsilane, and 3-(meth)acryloyloxypropylmethoxydimethylsilane.
Exemplary compounds having one or more (meth)acryloylamino groups per molecule include (meth) acryloylmorpholine, N,N-dimethylacrylamide, N,N-diethylacrylamide, N-methylacrylamide, N-ethylacrylamide, N-propylacrylamide, N-isopropylacrylamide, N-butylacrylamide, N-n-butoxymethylacrylamide, N-hexylacrylamide, and N-octylacrylamide; as well as derivatives of them.
Exemplary compounds having one or more vinylaryl groups per molecule include styrene, divinylbenzene, methoxystyrene, ethoxystyrene, hydroxystyrene, vinylnaphthalene, vinylanthracene, 4-vinylphenyl acetate, (4-vinylphenyl)dihydroxyborane, (4-vinylphenyl)boranic acid, (4-vinylphenyl)boronic acid, 4-ethenyiphenylboronic acid, 4-vinylphenylboranic acid, 4-vinylphenylboronic acid, p-vinylphenylboric acid, p-vinylphenylboronic acid, N-(4-vinylphenyl)maleimide, N-(p-vinylphenyl)maleimide, and N-(p-vinylphenyl)maleimide; as well as derivatives of them.
Exemplary compounds having one or more vinyl ether groups per molecule include 2-hydroxyethyl vinyl ether, 3-hydroxypropyl vinyl ether, 2-hydroxypropyl vinyl ether, 2-hydroxyisopropyl vinyl ether, 4-hydroxybutyl vinyl ether, 3-hydroxybutyl vinyl ether, 2-hydroxybutyl vinyl ether, 3-hydroxyisobutyl vinyl ether, 2-hydroxyisobutyl vinyl ether, 1-methyl-3-hydroxypropyl vinyl ether, 1-methyl-2-hydroxypropyl vinyl ether, 1-hydroxymethylpropyl vinyl ether, 4-hydroxycyclohexyl vinyl ether, 1,6-hexanediol monovinyl ether, 1,4-cyclohexanedimethanol monovinyl ether, 1,3-cyclohexanedimethanol monovinyl ether, 1,2-cyclohexanedimethanol monovinyl ether, p-xylene glycol monovinyl ether, m-xylene glycol monovinyl ether, o-xylene glycol monovinyl ether, diethylene glycol monovinyl ether, triethylene glycol monovinyl ether, tetraethylene glycol monovinyl ether, pentaethylene glycol monovinyl ether, oligoethylene glycol monovinyl ethers, polyethylene glycol monovinyl ethers, dipropylene glycol monovinyl ether, tripropylene glycol monovinyl ether, tetrapropylene glycol monovinyl ether, pentapropylene glycol monovinyl ether, oligopropylene glycol monovinyl ethers, and polypropylene glycol monovinyl ethers; as well as derivatives of them.
Exemplary compounds having one or more vinyloxycarbonyl groups per molecule include isopropenyl formate, isopropenyl acetate, isopropenyl propionate, isopropenyl butyrate, isopropenyl isobutyrate, isopropenyl caproate, isopropenyl valerate, isopropenyl isovalerate, isopropenyl lactate, vinyl acetate, vinyl propionate, vinyl butyrate, vinyl caproate, vinyl caprylate, vinyl laurate, vinyl myristate, vinyl palmitate, vinyl stearate, vinyl cyclohexanecarboxylate, vinyl pivalate, vinyl octanoate, vinyl monochloroacetate, divinyl adipate, vinyl methacrylate, vinyl crotonate, vinyl sorbate, vinyl benzoate, and vinyl cinnamate; as well as derivatives of them.
Of other radically polymerizable compounds for use herein, preferred are radically polymerizable monomers each having two or more (e.g., two to six) radically polymerizable functional groups, such as ethylene glycol di(meth)acrylate, diethylene glycol di(meth)acrylate, triethylene glycol di(meth)acrylate, 1,4-butanediol di(meth)acrylate, neopentyl glycol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, 1,9-nonanediol di(meth)acrylate, 1,10-decanediol di(meth)acrylate, and glycerol di(meth)acrylate; of which multifunctional acrylic monomers are more preferred. These compounds are preferred for the formation of a cured material having a higher adhesive strength. Each of them may be used alone or in combination.
The radical-polymerizable resin composition may contain the radically polymerizable monomer having two or more (e.g., two to six) radically polymerizable functional groups in an amount of typically from 1 to 50 percent by weight, preferably from 5 to 40 percent by weight, and more preferably from 8 to 30 percent by weight, based on the total amount of radically polymerizable compounds in the composition.
The radical-polymerizable resin composition herein may contain a silane coupling agent represented by Formula (3) as the other radically polymerizable compound. The silane coupling agent, when added, helps the resin composition to give a cured material having a further higher adhesive strength to an inorganic material.
The radical-polymerizable resin composition may contain the silane coupling agent represented by Formula (3) in an amount of typically from 0.01 to 10 percent by weight, preferably from 0.1 to 5 percent by weight, and more preferably from 0.3 to 3 percent by weight, based on the total amount of radically polymerizable compounds in the resin composition.
The radical-polymerizable resin composition according to the present invention may include, but not exclusively, a polymerization initiator. The polymerization initiator can be any one, as long as capable of inducing radical polymerization, and is typified by known or customary initiators for thermally-induced polymerization (thermal polymerization initiators) and initiators for energy-ray-induced polymerization (energy-ray-induced polymerization initiators).
Exemplary thermal polymerization initiators include organic peroxides and azo compounds (azo radical-polymerization initiators). The organic peroxides are exemplified by ketone peroxides, diacyl peroxides (e.g., benzoyl peroxide), hydroperoxides, dialkyl peroxides, peroxy ketals, alkyl peresters, and percarbonates. The azo compounds are typified by azobisisobutyronitrile (AIBN), azobis-2,4-dimethylvaleronitrile, and dimethyl 2,2′-azobis(isobutyrate).
Among them, preferred are peroxide radical-polymerization initiators including organic peroxides, of which diacyl peroxides (e.g., benzoyl peroxide) are more preferred. A peroxide radical-polymerization initiator, when used, helps the radical-polymerizable resin composition to be cured without occurrence of bubbles and thus enables fine and firm adhesion of an adherend. An azo radical-polymerization initiator, if employed, may cause the radical-polymerizable resin composition to be cured with occurrence of bubbles.
The energy-ray-induced polymerization initiators are typified by benzophenone, acetophenone benzil, benzil dimethyl ketone, benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, dimethoxyacetophenone, dimethoxyphenylacetophenone, diethoxyacetophenone, and diphenyl disulfite. Each of them may be used alone or in combination.
The polymerization initiator may be used in combination with a synergistic agent to enhance the conversion of photo-adsorbed energy to polymerization-initiating free radicals. The synergistic agent is typified by amines such as triethylamine, diethylamine, diethanolamine, ethanolamine, dimethylaminobenzoic acid, and methyl dimethylaminobenzoate; and ketones such as thioxanthone, 2-isopropylthioxanthone, 2,4-diethylthioxanthone, and acetylacetone.
The radical-polymerizable resin composition contains, if any, a polymerization initiator in an amount of from about 0.01 to about 50 percent by weight, and preferably from about 0.1 to about 20 percent by weight, relative to the total amount of radically polymerizable compounds (total weight of the radical-polymerizable resin and the other radically polymerizable compounds) in the radical-polymerizable resin composition.
The radical-polymerizable resin composition according to the present invention may further contain other additives according to necessity, within ranges not adversely affecting advantageous effects of the present invention. Exemplary other additives include known or customary additives such as setting-expandable monomers, photosensitizers (e.g., anthracene sensitizers), resins, adhesion promoters, reinforcers, softeners, plasticizers, viscosity modifiers, solvents, inorganic or organic particles (e.g., nano-scale particles), and fluorosilanes.
The radical-polymerizable resin composition according to the present invention can form a cured material when subjected to a heating treatment and/or irradiation with an energy ray to promote the radical polymerization reaction. The heating treatment, when employed, may be performed at a temperature of typically from about 20° C. to about 200° C., preferably from about 50° C. to about 150° C., and more preferably from about 70° C. to about 120° C. The temperature, however, may be suitably controlled according to the types of components to be reacted and of a catalyst. The irradiation with an energy ray, when employed, may use any of light sources such as mercury lamps, xenon lamps, carbon arc lamps, metal halide lamps, sunlight, electron beams, laser beams, radiation, and X-rays. The irradiation with an energy ray may be followed by a heating treatment at a temperature of typically from about 50° C. to about 180° C. to allow curing to proceed.
The radical polymerization reaction may be performed under normal atmospheric pressure, under reduced pressure, or under a pressure (under a load). The reaction may be performed in any atmosphere, such as air atmosphere, nitrogen atmosphere, or argon atmosphere, as long as not adversely affecting the reaction.
The cured material obtained through radical polymerization of the radical-polymerizable resin composition according to the present invention is not limited in shape or form and may for example be in the form of a film or fiber. A cured material in the form of a film (film-like cured material) can be produced typically by applying the radical-polymerizable resin composition to a substrate (base material) using an applicator so as to have a uniform thickness, and applying heat and/or an energy ray to promote the radical polymerization reaction. A cured material in the form of a fiber (fibrous cured material) can be produced typically by quantitatively extruding the radical-polymerizable resin composition using a syringe, and applying heat and/or an energy ray to the extruded radical-polymerizable resin composition to promote the radical polymerization reaction.
The resulting cured material has excellent adhesiveness and is satisfactorily flexible. The radical-polymerizable resin composition according to the present invention is therefore useful particularly as a stress-relaxation adhesive. For satisfactory flexibility and excellent thermal stability of the cured material, the radical-polymerizable resin composition is also useful in the fields typically of waveguides (e.g., optical waveguides and hybrid substrates), optical fibers, sealants, underfill materials, ink-jet inks, color filters, nanoimprinting materials, and flexible substrates and is particularly useful in the fields of flexible optical waveguides, flexible adhesives, and underfill materials.
EXAMPLES
The present invention will be illustrated in further detail with reference to several working examples below. It should be noted, however, that these examples are never construed to limit the scope of the present invention.
Example 1
Production of Radical-polymerizable Resin
A mixture (monomer mixture) of 9.28 g of toluene, 4.41 g (34.4 mmol) of glycidyl acrylate (GA), 17.2 g (172 mmol) of 1,2-epoxyhexane, and 0.0385 g of p-methoxyphenol was placed in a three-necked flask equipped with an initiator-dropping line, a N 2 line, and a thermometer, followed by temperature adjustment to 25° C. Next, a mixture of 5.60 g of toluene and 0.95 g (6.60 mmol) of boron trifluoride diethyl etherate (BF 3 OEt 2 ) was quantitatively added dropwise over 2 hours using a delivery pump. The resulting mixture after the completion of dropwise addition was held for 4 hours to yield a resin composition. This was purified by precipitation from five times the amount of methanol (containing 0.1% of p-methoxyphenol), held in a vacuum dryer (40° C., full vacuum) for 20 hours, and yielded a colorless, transparent liquid resin (C1).
The resin (C1) had a number-average molecular weight (Mn) of 600 and a weight-average molecular weight (Mw) of 900 as molecular weights measured through gel permeation chromatography (GPC). The resin remained liquid even at 0° C.
Example 2
Production of Radical-polymerizable Resin
A mixture (monomer mixture) of 10.3 g of toluene, 6.76 g (34.4 mmol) of 3,4-epoxycyclohexylmethyl methacrylate (trade name “CYCLOMER M-100,” supplied by Daicel Chemical Industries, Ltd. (now Daicel Corporation)), 17.2 g (172 mmol) of 1,2-epoxyhexane, and 0.0385 g of p-methoxyphenol was placed in a three-necked flask equipped with an initiator-dropping line, a N 2 line, and a thermometer, followed by temperature adjustment to 25° C. Next, a mixture of 5.60 g of toluene and 0.95 g (6.60 mmol) of BE 3 OEt 2 was quantitatively added dropwise over 2 hours using a delivery pump. The resulting mixture after the completion of dropwise addition was held for 4 hours to yield a resin composition. This was purified by precipitation from five times the amount of methanol (containing 0.1% of p-methoxyphenol), held in a vacuum dryer (40° C., full vacuum) for 20 hours, and yielded a colorless, transparent liquid resin (C2).
The resin (C2) had an Mn of 500 and an Mw of 800 as molecular weights measured by GPC. The resin remained liquid even at 0° C.
Example 3
Production of Radical-polymerizable Resin
A mixture (monomer mixture) of 9.90 g of toluene, 5.86 g (34.4 mmol) of 3-ethyl-3-oxetanylmethyl acrylate (trade name “OXE-10,” supplied by Osaka Organic Chemical Industry Ltd.), 17.2 g (172 mmol) of 1,2-epoxyhexane, 0.0385 g of p-methoxyphenol was placed in a three-necked flask equipped with an initiator-dropping line, a N 2 line, and a thermometer, followed by temperature adjustment to 25° C. Next, a mixture of 5.60 g of toluene and 0.95 g (6.60 mmol) of BF 3 OEt 2 was quantitatively added dropwise over 2 hours using a delivery pump. The resulting mixture after the completion of dropwise addition was held for 4 hours to yield a resin composition. This was purified by precipitation from five times the amount of methanol (containing 0.1% of p-methoxyphenol), held in a vacuum dryer (40° C., full vacuum) for 20 hours, and yielded a colorless, transparent liquid resin (C3).
The resin (C3) had an Mn of 5000 and an Mw of 8500 as molecular weights measured by GPC. The resin remained liquid even at 0° C.
Example 4
Production of Radical-polymerizable Resin
A mixture (monomer mixture) of 10.5 g of toluene, 7.37 g (34.4 mmol) of 3-ethyl-3-(2-acryloyloxyethyloxymethyl)oxetane (“OXT-C2”) synthetically prepared according to a known procedure, 17.2 g (172 mmol) of 1,2-epoxyhexane, and 0.0385 g of p-methoxyphenol was placed in a three-necked flask equipped with an initiator-dropping line, a N 2 line, and a thermometer, followed by temperature adjustment to 25° C. Next, a mixture of 5.60 g of toluene and 0.95 g (6.60 mmol) of BF 3 OEt 2 was quantitatively added dropwise over 2 hours using a delivery pump. The resulting mixture after the completion of dropwise addition was held for 4 hours to yield a resin composition. This was purified by precipitation from five times the amount of methanol (containing 0.1% of p-methoxyphenol), held in a vacuum dryer (40° C., full vacuum) for 20 hours, and yielded a colorless, transparent liquid resin (C4).
The resin (C4) had an Mn of 5600 and an Mw of 9200 as molecular weights measured by GPC. The resin remained liquid even at 0° C.
Example 5
Production of Radical-polymerizable Resin
A mixture (monomer mixture) of 18.7 g of toluene, 4.41 g (34.4 mmol) of GA, 39.3 g (172 mmol) of 3-ethyl-3-(2-ethylhexyloxymethyl)oxetane (trade name “OXT-212,” supplied by Toagosei Co., Ltd.), and 0.0385 g of p-methoxyphenol was placed in a three-necked flask equipped with an initiator-dropping line, a N 2 line, and a thermometer, followed by temperature adjustment to 25° C. Next, a mixture of 5.60 g of toluene and 0.95 g (6.60 mmol) of BF 3 OEt 2 was quantitatively added dropwise over 2 hours using a delivery pump. The resulting mixture after the completion of dropwise addition was held for 4 hours to yield a resin composition. This was purified by precipitation from five times the amount of methanol (containing 0.1% of p-methoxyphenol), held in a vacuum dryer (40° C., full vacuum) for 20 hours, and yielded a colorless, transparent liquid resin (C5).
The resin (C5) had an Mn of 4400 and an Mw of 8500 as molecular weights measured by GPC. The resin remained liquid even at 0° C.
Example 6
Production of Radical-polymerizable Resin
A mixture (monomer mixture) of 19.7 g of toluene, 6.76 g (34.4 mmol) of “CYCLOMER M-100,” 39.3 g (172 mmol) of “OXT-212,” and 0.0385 g of p-methoxyphenol was placed in a three-necked flask equipped with an initiator-dropping line, a N 2 line, and a thermometer, followed by temperature adjustment to 25° C. Next, a mixture of 5.60 g of toluene and 0.95 g (6.60 mmol) of BF 3 OEt 2 was quantitatively added dropwise over 2 hours using a delivery pump. The resulting mixture after the completion of dropwise addition was held for 4 hours to yield a resin composition. This was purified by precipitation from five times the amount of methanol (containing 0.1% of p-methoxyphenol), held in a vacuum dryer (40° C., full vacuum) for 20 hours, and yielded a colorless, transparent liquid resin (C6).
The resin (C6) had an Mn of 3800 and an Mw of 8300 as molecular weights measured by GPC. The resin remained liquid even at 0° C.
Example 7
Production of Radical-polymerizable Resin
A mixture (monomer mixture) of 19.3 g of toluene, 5.86 g (34.4 mmol) of “OXE-10,” 39.3 g (172 mmol) of “OXT-212,” and 0.0385 g of p-methoxyphenol was placed in a three-necked flask equipped with an initiator-dropping line, a N 2 line, and a thermometer, followed by temperature adjustment to 25° C. Next, a mixture of 5.60 g of toluene and 0.95 g (6.60 mmol) of BF 3 OEt 2 was quantitatively added dropwise over 2 hours using a delivery pump. The resulting mixture after the completion of dropwise addition was held for 4 hours to yield a resin composition. This was purified by precipitation from five times the amount of methanol (containing 0.1% of p-methoxyphenol), held in a vacuum dryer (40° C., full vacuum) for 20 hours, and yielded a colorless, transparent liquid resin (C7).
The resin (C7) had an Mn of 4500 and an Mw of 7000 as molecular weights measured by GPC. The resin remained liquid even at 0° C.
Example 8
Production of Radical-polymerizable Resin
A mixture (monomer mixture) of 19.3 g of toluene, 6.34 g (34.4 mmol) of 3-ethyl-3-oxetanylmethyl methacrylate (trade name “OXE-30,” supplied by Osaka Organic Chemical Industry Ltd.), 39.2 g (172 mmol) of “OXT-212,” and 0.0385 g of p-methoxyphenol was placed in a three-necked flask equipped with an initiator-dropping line, a N 2 line, and a thermometer, followed by temperature adjustment to 25° C. Next, a mixture of 5.60 g of toluene and 0.95 g (6.60 mmol) of BF 3 OEt 2 was quantitatively added dropwise over 2 hours using a delivery pump. The resulting mixture after the completion of dropwise addition was held for 4 hours to yield a resin composition. This was purified by precipitation from five times the amount of methanol (containing 0.1% of p-methoxyphenol), held in a vacuum dryer (40° C., full vacuum) for 20 hours, and yielded a colorless, transparent liquid resin (C8).
The resin (C8) had an Mn of 3600 and an Mw of 5100 as molecular weights measured by GPC. The resin remained liquid even at 0° C.
Example 9
Production of Radical-polymerizable Resin
A mixture (monomer mixture) of 20.0 g of toluene, 7.37 g (34.4 mmol) of “OXT-C2,” 39.3 g (172 mmol) of “OXT-212,” and 0.0385 g of p-methoxyphenol was placed in a three-necked flask equipped with an initiator-dropping line, a N 2 line, and a thermometer, followed by temperature adjustment to 25° C. Next, a mixture of 5.60 g of toluene and 0.95 g (6.60 mmol) of BF 3 OEt 2 was quantitatively added dropwise over 2 hours using a delivery pump. The resulting mixture after the completion of dropwise addition was held for 4 hours to yield a resin composition. This was purified by precipitation from five times the amount of methanol (containing 0.1% of p-methoxyphenol), held in a vacuum dryer (40° C., full vacuum) for 20 hours, and yielded a colorless, transparent liquid resin (C9).
The resin (C9) had an Mn of 23300 and an Mw of 40900 as molecular weights measured by GPC. The resin remained liquid even at 0° C.
Comparative Example 1
Production of Radical-polymerizable Resin
A mixture (monomer mixture) of 1.89 g of toluene, 4.41 g (34.4 mmol) of GA, and 0.0385 g of p-methoxyphenol was placed in a three-necked flask equipped with an initiator-dropping line, a N 2 line, and a thermometer, followed by temperature adjustment to 25° C. Next, a mixture of 5.60 g of toluene and 0.95 g (6.60 mmol) of BF 3 OEt 2 was quantitatively added dropwise over 2 hours using a delivery pump. The resulting mixture after the completion of dropwise addition was held for 4 hours to yield a resin composition. This was purified by precipitation from five times the amount of methanol (containing 0.1% of p-methoxyphenol), held in a vacuum dryer (40° C., full vacuum) for 20 hours, and yielded a colorless, transparent liquid resin (C10).
The resin (C10) had an Mn of 450 and an Mw of 700 as molecular weights measured by GPC.
Comparative Example 2
Production of Radical-polymerizable Resin
A mixture (monomer mixture) of 2.90 g of toluene, 6.76 g (34.4 mmol) of “CYCLOMER M-100,” and 0.0385 g of p-methoxyphenol was placed in a three-necked flask equipped with an initiator-dropping line, a N 2 line, and a thermometer, followed by temperature adjustment to 25° C. Next, a mixture of 5.60 g of toluene and 0.95 g (6.60 mmol) of BF 3 OEt 2 was quantitatively added dropwise over 2 hours using a delivery pump. The resulting mixture after the completion of dropwise addition was held for 4 hours to yield a resin composition. This was purified by precipitation from five times the amount of methanol (containing 0.1% of p-methoxyphenol), held in a vacuum dryer (40° C., full vacuum) for 20 hours, and yielded a colorless, transparent liquid resin (C11).
The resin (C11) had an Mn of 550 and an Mw of 850 as molecular weights measured by GPC.
Comparative Example 3
Production of Radical-polymerizable Resin
A mixture (monomer mixture) of 2.51 g of toluene, 5.86 g (34.4 mmol) of “OXE-10,” and 0.0385 g of p-methoxyphenol was placed in a three-necked flask equipped with an initiator-dropping line, a N 2 line, and a thermometer, followed by temperature adjustment to 25° C. Next, a mixture of 5.60 g of toluene and 0.95 g (6.60 mmol) of BF 3 OEt 2 was quantitatively added dropwise over 2 hours using a delivery pump. The resulting mixture after the completion of dropwise addition was held for 4 hours to yield a resin composition. This was purified by precipitation from five times the amount of methanol (containing 0.1% of p-methoxyphenol), held in a vacuum dryer (40° C., full vacuum) for 20 hours, and yielded a colorless, transparent liquid resin (C12).
The resin (C12) had an Mn of 4000 and an Mw of 7500 as molecular weights measured by GPC.
Comparative Example 4
Production of Radical-polymerizable Resin
A mixture (monomer mixture) of 2.72 g of toluene, 6.34 g (34.4 mmol) of “OXE-30,” and 0.0385 g of p-methoxyphenol was placed in a three-necked flask equipped with an initiator-dropping line, a N 2 line, and a thermometer, followed by temperature adjustment to 25° C. Next, a mixture of 5.60 g of toluene and 0.95 g (6.60 mmol) of BF 3 OEt 2 was quantitatively added dropwise over 2 hours using a delivery pump. The resulting mixture after the completion of dropwise addition was held for 4 hours to yield a resin composition. This was purified by precipitation from five times the amount of methanol (containing 0.1% of p-methoxyphenol), held in a vacuum dryer (40° C., full vacuum) for 20 hours, and yielded a colorless, transparent liquid resin (C13).
The resin (C13) had an Mn of 3600 and an Mw of 4000 as molecular weights measured by GPC.
Comparative Example 5
Production of Radical-polymerizable Resin
A mixture (monomer mixture) of 3.16 g of toluene, 7.37 g (34.4 mmol) of “OXT-C2,” and 0.0385 g of p-methoxyphenol was placed in a three-necked flask equipped with an initiator-dropping line, a N 2 line, and a thermometer, followed by temperature adjustment to 25° C. Next, a mixture of 5.60 g of toluene and 0.95 g (6.60 mmol) of BF 3 OEt 2 was quantitatively added dropwise over 2 hours using a delivery pump. The resulting mixture after the completion of dropwise addition was held for 4 hours to yield a resin composition. This was purified by precipitation from five times the amount of methanol (containing 0.1% of p-methoxyphenol), held in a vacuum dryer (40° C., full vacuum) for 20 hours, and yielded a colorless, transparent liquid resin (C14):
The resin (C14) had an Mn of 19000 and an Mw of 39000 as molecular weights measured by GPC.
Examples 10 to 45 and Comparative Examples 6 to 15
Preparation of Thermally-induced Radical-polymerizable Resin Compositions
Thermally-induced radical-polymerizable resin compositions were prepared by mixing and dissolving respective components in formulations and blending ratios as given in Tables 1 to 3 below. In Tables 1 to 3, numerical values are indicated by part by weight; the abbreviations C1 to C14 represent the radical-polymerizable resins obtained in Examples 1 to 9 and Comparative Examples 1 to 5, respectively; “decane diacrylate” refers to 1,10-decanediol diacrylate (bifunctional acrylate; supplied by Wako Pure Chemical Industries, Ltd.); “silane coupling agent” represents 3-acryloyloxypropyltrimethoxysilane (i.e., 3-trimethoxysilylpropyl acrylate); and “BPO” represents benzoyl peroxide (radical-polymerization initiator).
Example 46
Preparation of Photo-induced Radical-polymerizable Resin Composition
A photo-induced radical-polymerizable resin composition was prepared by mixing with and dissolving in 16 g of the radical-polymerizable resin (C7) obtained in Example 7, 2 g of 1,10-decanediol diacrylate (bifunctional acrylate; supplied by Wako Pure Chemical Industries, Ltd.) and 0.2 g of benzophenone (photo-induced radical-polymerization initiator).
Example 47
Production of Film-like Cured Materials
Each of the thermally-induced radical-polymerizable resin compositions obtained in Examples 10 to 45 was poured into a Teflon (registered trademark) mold (20 mm by 50 mm by 1 mm), dried in a vacuum dryer (at 40° C. for 10 minutes, full vacuum), cured by heating (at 140° C. for 10 minutes) in a N 2 atmosphere, and thereby yielded film-like cured materials.
Example 48
Production of Film-like Cured Material
The photo-induced radical-polymerizable resin composition obtained in Example 46 was poured into a Teflon (registered trademark) mold (20 mm by 50 mm by 1 mm), dried in a vacuum dryer (at 40° C. for 10 minutes, full vacuum), irradiated with an ultraviolet ray using a belt-conveyer type ultraviolet irradiator (UVC-02516SAA02, supplied by Ushio Inc.), and yielded a film-like cured material. The irradiation was performed at an irradiation energy of about 2 J and at a wavelength of 320 to 390 nm. The cured material after the irradiation with the ultraviolet ray was subjected to a heating treatment at 100° C. in an air atmosphere for one hour.
Example 49
Production of Fibrous Cured Material
The photo-induced radical-polymerizable resin composition (20 g) obtained in Example 46 was extruded from a syringe, the extruded composition was irradiated with an ultraviolet ray (at a wavelength of 365 nm), and yielded a fibrous cured material having diameters of from 50 to 2000 μm.
[Evaluation Tests]
(1) Adhesion Process of Silicon Wafer
Each of the thermally-induced radical-polymerizable resin compositions obtained in Examples 10 to 45 and Comparative Examples 6 to 15 was applied to each of substrates (a silicon wafer, a TEMPAX glass, an aluminum plate, and a PET film) using a spin coater so as to have a thickness of about 1 to 5 μm. The resulting coatings were dried in a vacuum dryer (at 40° C. for 10 minutes, full vacuum), followed by lamination and bonding (at 140° C. for 10 minutes) to give samples. The samples (bonded samples) were subjected to the following evaluations. The results are indicated in Tables 1 to 3, in which Specimens 1 to 5 represent the following samples.
Specimen 1: Sample including two plies of the silicon wafer bonded to each other
Specimen 2: Sample including two plies of the TEMPAX glass bonded to each other
Specimen 3: Samples including the silicon wafer and the TEMPAX glass bonded to each other
Specimen 4: Sample including the aluminum plate and the TEMPAX glass bonded to each other
Specimen 5: Sample including two plies of the PET film bonded to each other.
(2) Evaluation of how Bonding is
Each of the bonded samples (Specimens 3) including the silicon wafer and the TEMPAX glass bonded to each other was observed under a microscope, whether or not bubbles and/or separation occurred was examined, and how bonding is was evaluated according to the following criteria:
Criteria: A sample showing neither bubbles nor separation was evaluated as “good”; and a sample showing bubbles and/or separation was evaluated as “poor.”
(3) Adhesive Strength
Each of the bonded samples (Specimens 1) including two plies of the silicon wafer bonded to each other was subjected to a peel test (delamination test). A sample which was bonded but could be delaminated by hand was evaluated as “Fair”; a sample which was not delaminated by hand but was delaminated at a bending stress of 7 J/m 2 or less in a four-point bending test was evaluated as “Good”; and a sample which was resistant to delamination at a bending stress of 7 J/m 2 or more in the four-point bending test was evaluated as “Very good (VG).”
(4) Heat Shock Test
Each of the bonded samples was subjected to a test of heating at 150° C. for 30 minutes and, immediately after the heating, immersing in liquid nitrogen, where the test was repeated a total of five times. The bonded samples after the tests were examined visually and under a microscope on whether or not separation, cracking (cracks), and any change in comparison to the samples before the tests occurred, followed by evaluation according to the following criteria.
Criteria: A sample showing neither separation nor cracking (cracks) was evaluated as “Good”; and a sample showing separation and/or cracking (cracks) was evaluated as “Poor.” For Specimens 1, a sample without separation and cracking was evaluated as “Good.” For Specimens 5, the heating was performed up to 140° C. in consideration of the thermal stability of the PET film.
TABLE 1
Examples
10
11
12
13
14
15
16
17
18
Radical-
C1
100
polymerizable
C2
100
resin
C3
100
composition
C4
100
C5
100
C6
100
C7
100
C8
100
C9
100
Decane diacrylate
Silane coupling agent
BPO
1
1
1
1
1
1
1
1
1
Evaluation on how bonding is
Good
Good
Good
Good
Good
Good
Good
Good
Good
Adhesive strength
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Heat shock
Specimen 1
Good
Good
Good
Good
Good
Good
Good
Good
Good
test
Specimen 2
Good
Good
Good
Good
Good
Good
Good
Good
Good
Specimen 3
Good
Good
Good
Good
Good
Good
Good
Good
Good
Specimen 4
Good
Good
Good
Good
Good
Good
Good
Good
Good
Specimen 5
Good
Good
Good
Good
Good
Good
Good
Good
Good
Examples
19
20
21
22
23
24
25
26
27
Radical-
C1
80
polymerizable
C2
80
resin
C3
80
composition
C4
80
C5
80
C6
80
C7
80
C8
80
C9
80
Decane diacrylate
20
20
20
20
20
20
20
20
20
Silane coupling agent
BPO
1
1
1
1
1
1
1
1
1
Evaluation on how bonding is
Good
Good
Good
Good
Good
Good
Good
Good
Good
Adhesive strength
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Fair
Heat shock
Specimen 1
Good
Good
Good
Good
Good
Good
Good
Good
Good
test
Specimen 2
Good
Good
Good
Good
Good
Good
Good
Good
Good
Specimen 3
Good
Good
Good
Good
Good
Good
Good
Good
Good
Specimen 4
Good
Good
Good
Good
Good
Good
Good
Good
Good
Specimen 5
Good
Good
Good
Good
Good
Good
Good
Good
Good
TABLE 2
Examples
28
29
30
31
32
33
34
35
36
Radical-
C1
100
polymerizable
C2
100
resin
C3
100
composition
C4
100
C5
100
C6
100
C7
100
C8
100
C9
100
Decane diacrylate
Silane coupling agent
1
1
1
1
1
1
1
1
1
BPO
1
1
1
1
1
1
1
1
1
Evaluation on how bonding is
Good
Good
Good
Good
Good
Good
Good
Good
Good
Adhesive strength
Good
Good
Good
Good
Good
Good
Good
Good
Good
Heat shock
Specimen 1
Good
Good
Good
Good
Good
Good
Good
Good
Good
test
Specimen 2
Good
Good
Good
Good
Good
Good
Good
Good
Good
Specimen 3
Good
Good
Good
Good
Good
Good
Good
Good
Good
Specimen 4
Good
Good
Good
Good
Good
Good
Good
Good
Good
Specimen 5
Good
Good
Good
Good
Good
Good
Good
Good
Good
Examples
37
38
39
40
41
42
43
44
45
Radical-
C1
80
polymerizable
C2
80
resin
C3
80
composition
C4
80
C5
80
C6
80
C7
80
C8
80
C9
80
Decane diacrylate
20
20
20
20
20
20
20
20
20
Silane coupling agent
1
1
1
1
1
1
1
1
1
BPO
1
1
1
1
1
1
1
1
1
Evaluation on how bonding is
Good
Good
Good
Good
Good
Good
Good
Good
Good
Adhesive strength
VG
VG
VG
VG
VG
VG
VG
VG
VG
Heat shock
Specimen 1
Good
Good
Good
Good
Good
Good
Good
Good
Good
test
Specimen 2
Good
Good
Good
Good
Good
Good
Good
Good
Good
Specimen 3
Good
Good
Good
Good
Good
Good
Good
Good
Good
Specimen 4
Good
Good
Good
Good
Good
Good
Good
Good
Good
Specimen 5
Good
Good
Good
Good
Good
Good
Good
Good
Good
TABLE 3
Comparative Examples
6
7
8
9
10
11
12
13
14
15
Radical-
C10
100
80
polymerizable
C11
100
80
resin
C12
100
80
composition
C13
100
80
C14
100
80
Decane diacrylate
20
20
20
20
20
Silane coupling agent
1
1
1
1
1
1
1
1
1
1
BPO
1
1
1
1
1
1
1
1
1
1
Evaluation on how bonding is
Good
Good
Good
Good
Good
Good
Good
Good
Good
Good
Adhesive strength
Good
Good
Good
Good
Good
Good
Good
Good
Good
Good
Heat shock
Specimen 1
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
test
Specimen 2
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Specimen 3
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Specimen 4
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Specimen 5
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
Poor
INDUSTRIAL APPLICABILITY
Radical-polymerizable resins according to embodiments of the present invention have the aforementioned advantageous effects and are advantageous in various uses represented by stress-relaxation adhesives. | Provided is a radical-polymerizable resin capable of giving a cured material which is satisfactorily flexible, can relax stress upon usage as an adhesive, and does not cause disadvantages such as separation at the adhesive interface or breakage of an adherend, which stress occurs between the adhesive and the adherend upon heating or cooling and is caused by difference in coefficient of thermal expansion between them.
The radical-polymerizable resin is obtained through cationic polymerization of a compound represented by any of following Formulae (1a) and (1b) and a compound represented by any of following Formulae (2a), (2b), (2c), (2d), (2e), and (2f). The radical-polymerizable resin is liquid at 0 ° C. and has a weight-average molecular weight of 500 or more. Symbols in the formulae are as defined in the description. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 14/683,317 titled “Padlock Retaining Device,” filed Apr. 10, 2015, now U.S. Pat. No. 9,551,167 issued on Jan. 24, 2017, which claims the benefit of U.S. Provisional Patent Application No. 62/052,134 titled “Padlock Retaining Device,” filed Sep. 18, 2014, the contents of which are incorporated herein by reference in their entirety.
BACKGROUND
Roll-up doors are used for a wide variety of applications. For example, roll-up doors are frequently used to secure the interiors of enclosed storage areas, such as the areas within storage units in a commercial self-storage rental facility.
When used to secure the interior of enclosed storage areas, the roll-up doors are typically made from steel and the doors are provided with a locking apparatus. In the most common applications, such locking apparatuses comprise at least one slidable bolt attached to the door or a strong slide rail. FIG. 1 illustrates such a locking apparatus. The slidable bolt can be alternatively (1) slid in one direction along the slide rail to a “latched position,” wherein the bolt is caused to protrude into a strike plate mounted on the door frame (to prevent the door from traveling upward) and (2) slid in the opposite direction along the slide rail to an “unlatched position,” wherein the bolt is retracted out of the strike plate (to allow the door to again freely travel upward).
Typically, the slide rail and the slidable bolt each have a padlock retainer portion defining a locking through-hole which is sized and dimensioned to accept a padlock shackle (curved portion). The holes in the padlock retainer portions are located so that, when the bolt is slid to the latched position, the holes are aligned with one another such that a padlock shackle can be placed and secured within both holes to lock the bolt within the latched position (as illustrated in FIG. 2 ).
It is also common that both the slide rail and the bolt have an auxiliary hole—termed a manager's overlock hole—which can be used by the manager of a facility employing the roll-up door to lock the door in the latched position (for example, if rent is overdue). The manager's overlock hole can also be used to retain the padlock on the roll-up door when the bolt is in the unlatched position. This design seems to provide the user with a convenient place to store the padlock when it is not being used, such as immediately after the user unlocks the padlock and slides the bolt to the unlatched position in preparation for opening the roll-up door. The problem with this design, however, is that, if the user forgets to remove the padlock from the manager's overlock hole before the roll-up door is opened, the padlock will be carried upwards as the roll-up door is opened and strike the upper horizontal portion of the door frame. This is illustrated in FIG. 3 . Because roll-up doors are typically heavy and carry considerable momentum, such striking of the door frame can cause significant damage to the door frame, to the latch assembly and/or to the roll-up door. If the door frame is made of steel or other heavy material, the striking of the door frame with the padlock can rip the latch assembly off of the roll-up door.
Accordingly, there is a need for a padlock retaining device that addresses the problem often encountered with the use of roll-up doors.
SUMMARY OF THE INVENTION
The invention satisfies this need. The invention is a unique padlock retaining device. The padlock retaining device comprises: a) a stand-alone body, separate from any locking device or latching device, the body having one or more body attachment facilitators and b) a lock containment section attached to and extending away from the body for accepting and retaining an open padlock.
The invention is also a method of employing the padlock retaining device to prevent damage caused by inadvertently opening a roll-up door with a padlock still attached to the roll-up door.
DRAWINGS
These and other features, aspects and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings where:
FIG. 1 is a sketch illustrating a slide lock of the prior art;
FIG. 2 is a sketch illustrating a slide lock attached to a roll up door disposed within a door frame, wherein a padlock has been operably placed on the slide lock to secure the slide lock in a latched position;
FIG. 3 is a sketch illustrating the roll up door of FIG. 2 wherein the padlock has been opened and hung loosely on the slide lock and wherein the roll up door has been rolled up to inadvertently cause the padlock to strike the top of the door frame;
FIG. 4 is a perspective view of a padlock retaining device having features of the invention;
FIG. 5 is a front view of the padlock retaining device illustrated in FIG. 4 ;
FIG. 6 is a side view of the padlock retaining device illustrated in FIG. 4 ;
FIG. 7 is a top view of the padlock retaining device illustrated in FIG. 4 ; and
FIG. 8 is a sketch illustrating a slide lock attached to a roll up door disposed within a door frame, and a padlock opened and hung loosely on a padlock retaining device having features of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The following discussion describes in detail one embodiment of the invention and several variations of that embodiment. This discussion should not be construed, however, as limiting the invention to those particular embodiments. Practitioners skilled in the art will recognize numerous other embodiments as well.
Definitions
As used herein, the following terms and variations thereof have the meanings given below, unless a different meaning is clearly intended by the context in which such term is used.
The terms “a,” “an,” and “the” and similar referents used herein are to be construed to cover both the singular and the plural unless their usage in context indicates otherwise.
As used in this disclosure, the term “comprise” and variations of the term, such as “comprising” and “comprises,” are not intended to exclude other additives, components, integers, ingredients or steps.
The Invention
In one aspect, the invention is a padlock retaining device 10 built specifically to hold a padlock 12 in a convenient location adjacent to a roll-up door 14 , not on the roll-up door 14 itself. FIGS. 4-7 illustrate one embodiment of the invention.
The padlock retaining device 10 comprises a body 16 , one or more body attachment facilitators 18 , and a lock containment section 20 . The padlock retaining device 10 can be any size and dimension, and made from any material, including plastic, wood or metal. In the embodiment illustrated in FIGS. 4-7 , the padlock retaining device 10 can be 2 and ¾ inches tall, 1 and ⅞ inches wide and preferably can be made from a single plate of steel.
The body 16 can be any shape and dimension, but preferably the body 16 is planar. In the embodiment illustrated in FIGS. 4-7 , the body 16 is in the shape of a padlock. In the embodiment illustrated in FIGS. 4-7 , the padlock retaining device 10 has two body attachment facilitators 18 which be used to attach the padlock retaining device 10 to a wall surface 36 adjacent a roll-up door 14 . Optionally, the two body attachment facilitators 18 can be fastener holes, and the padlock retaining device 10 can be attached to the wall surface 36 using any type of fastener, for example, stainless steel fasteners, screws or rivets depending on the application.
The lock containment section 20 is configured to accept and retain a padlock shackle 22 . The lock containment section 20 is coupled to the body 16 at a sufficient angle to accept and retain a padlock shackle 22 . The lock containment section 20 can be made from any material, including plastic, wood or metal, but preferably it is made from steel. The lock containment section 20 can be any size and dimension, but preferably it is about ⅞ inches long.
Optionally, the padlock retaining device 10 can be made from a single plate of steel, as shown in the embodiment illustrated in FIGS. 4-7 . Because the padlock retaining device 10 can be made from a single plate of steel, the lock containment section 20 is a portion of the padlock retaining device 10 that is bent away from the body 16 . Preferably the lock containment section 20 is bent away from the body 16 at a 90 degree angle with respect to the body 16 .
The lock containment section 20 can also have a padlock shackle retaining hole 26 defined therein. The padlock shackle retaining hole 26 is sized and dimensioned to accept and retain a padlock shackle 22 . The padlock shackle 22 is inserted through the padlock shackle retaining hole 26 such that the padlock 12 is now retained by the padlock retaining device 10 .
In another aspect, the invention is a method of employing the padlock retaining device 10 to prevent damage caused by inadvertently opening a roll-up door 14 with a padlock 12 still attached to the roll-up door 14 .
The padlock retaining device 10 is especially useful for a roll-up door 14 comprising a locking apparatus 32 having:
a slidable bolt 34 attached to the door on a slide rail, wherein the bolt 34 can be alternatively (1) slid in one direction along the slide rail to a “latched position,” wherein the bolt 34 is caused to protrude into a strike plate mounted on the door frame (to prevent the roll-up door 14 from travelling upward) and (2) slid in the opposite direction along the slide rail to an “unlatched position,” wherein the bolt 34 is retracted out of the strike plate (to allow the roll-up door 14 to again freely travel upward);
padlock retainer portions defined within both the slide rail and the bolt 34 to provide a locking through-hole which is sized and dimensioned to accept a padlock shackle 22 , the holes in the padlock retainer portions being located so that, when the bolt 34 is slid to the latched position, the holes are aligned with one another such that a padlock shackle 22 can be placed and secured within both holes to lock the bolt 34 within the latched position; and
a manager's overlock hole defined in both the slide rail and the bolt 34 which is operatively configured to retain the padlock 12 on the roll-up door when the bolt 34 is in the unlatched position.
As discussed above, many users secure the padlock 12 to the manager's overlock hole (not shown) after they have removed the padlock 12 from the roll-up door 14 , but prior to actually opening the roll-up door 14 . Then the roll-up door 14 is moved upward to an open position, which causes the locking apparatus 32 to strike the upper portion of the door frame 38 .
In the method, the padlock retaining device 10 is attached to a wall surface 36 —typically a vertical wall surface—separate from the roll-up door 14 for which a padlock 12 is used to secure the roll-up door 14 in the latched position. Then the padlock 12 is retained on the padlock retaining device 10 when the padlock 12 is not in use by disposing the padlock shackle 22 into the padlock shackle retaining hole 26 —as illustrated in FIG. 8 .
The method of employing the padlock retaining device 10 comprises the steps of providing the padlock retaining device 10 , attaching the padlock retaining device 10 to a wall surface 36 separate from the roll-up door 14 by the one or more body attachment facilitators 18 , disposing the padlock shackle 22 into the lock containment section 20 , and retaining the padlock 12 on the padlock retaining device 10 when the padlock 12 is not in use.
The method effectively prevents damage to the roll-up door 14 , the locking apparatus 32 and/or the door frame 38 by inadvertently rolling the roll-up door 14 upwards while the padlock 12 is attached in the auxiliary manager's overlock hole of the locking apparatus 32 —thereby causing the locking apparatus 32 to strike the upper portion of the door frame 38 .
Although the present invention has been discussed in considerable detail with reference to certain preferred embodiments, other embodiments are possible. Therefore, the scope of the appended claims should not be limited to the description of preferred embodiments contained in this disclosure. | A padlock retaining device having: a) a stand-alone body, separate from any locking device or latching device, the body having one or more body attachment facilitators and b) a lock containment section attached to and extending away from the body for accepting and retaining an open padlock. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
None.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to child safety restraint systems in transportation, and in particular, to child restraint systems for use on aircraft. More specifically, the present invention relates to a removable, portable strap assembly for securing automotive child safety seats to aircraft seats and frames in compliance with federal aviation safety regulations.
2. Description of Related Art
The safe transportation of children is an issue of national interest. Every state in the nation has enacted laws pertaining to the use of child safety seats in vehicles for the transportation of infants and toddlers under 2 years of age. Substantial progress has been made in the design of these seats and education of the public in the necessity of their use. Airline transportation has provided safety engineers with different problems to address than automobiles. Additionally, since travel by infants and toddlers on aircraft is less frequent than by automobile, design improvements have lagged. Since parents traveling with infants and toddlers are required to have child car safety seats at their final destinations, the safety seats normally travel with the parents, but often are stored as luggage, with the children being held by the parents or secured into an aircraft seat with a standard lap belt. The small bodies of children are not well protected by a lap belt, and are at extreme risk when being held by a parent or guardian. Infants held by a parent or guardian also pose a serious risk to other passengers and crewmembers, since the adult is unable to hold onto the child in severe turbulence, high energy stops, and crashes. The result is that infants and toddlers on aircraft are currently at much higher risk of injury or death than adults.
Presently, a number of child car seat designs are commercially available. These include, but are not limited to:
1. Rear-facing Infant Seats with and without removable bases (birth to 20 lbs.)
2. Convertible Seats, Rearward Facing Position (birth to 20 lbs.)
3. Convertible Seats, Forward Facing Position (20 to 40 lbs.)
4. Forward Facing Only Seats (20 to 60 lbs.)
5. High-Back Booster Seats with Built-in Harness (30 to 40 lbs. when used with harness).
6. Belt Positioning Booster Seats (40 to 80 lbs.)
The weight descriptions are used for general identification purposes only. The foregoing description is not intended to be instructive as to the use or safety of any car seat. Weight recommendations are usually combined with height recommendations and these numbers vary substantially from model to model. The manufacturers' recommendations for the individual car seat design should be consulted and followed. Forward facing child safety seats (not including booster seats) now include a top tether strap to provide additional protection to the child's head. This is part of the “Lower Anchors and Tethers for Children (LATCH) System,” which is also intended to make installation of child safety seats easier by requiring child safety seats to be installed without using the vehicle's seat belt system. This adjustable tether strap is attached to the back of a child safety seat, and has a hook for securing the seat to a tether anchor located on the rear shelf area, the rear floor, or on the back of the rear seat of the vehicle.
Aircraft operators currently permit the use of existing aircraft restraint belts in combination with (#1) Rear-facing Infant Seats and (#2) Convertible Seats, Rearward Facing Position. However, the use of existing aircraft restraint belts in combination with (#3) Convertible Seats, Forward Facing Position, (#4) Forward Facing Only Seats, and (#5) High-Back Booster Seats with Built-in Harness, fails to provide adequate safety for children in a survivable crash situation. The use of (#6) Belt Positioning Booster Seats is prohibited.
The Federal Aviation Administration (FAA) currently accepts the use of automobile safety seats that meet the specific requirements of Federal Motor Vehicle Safety Standard (FMVSS) §213 as required by Federal Aviation Regulation (FAR) §121.311.
Public and governmental awareness of the continuing safety issues related to children traveling by plane has increased dramatically in recent years. On May 16, 1995, the National Transportation Safety Board issued Safety Recommendation A-95-51 recommending revision of 14 Code of Federal Regulation (CFR) Parts 91, 135, and 121 to require that all occupants be restrained during take-off, landing, and turbulent conditions, and that all infants and small children be restrained in a manner appropriate to their size.
On Feb. 11, 1998, the FAA issued an Advanced Notice of Proposed Rulemaking (ANPRM) seeking comments, data, and analysis regarding the use of existing child restraint systems during all phases of flight. The FAA is now developing a Notice of Proposed Rulemaking (NPRM) to require that all occupants (including infants and children) be properly restrained during take-off, landing, and turbulent conditions, when the seatbelt sign is illuminated and when instructed by a crewmember. Pending revisions to FAR §121.311 and new regulations under development, are intended to provide infants and toddlers an “equivalent level of safety” to that of the adult passengers by utilization of child safety seats secured to aircraft seats in a manner that meets the dynamic test requirements of FAR §25.562.
The use of existing forward facing child safety seats, secured by an aircraft lap belt, will not achieve the requirements of the new and revised Federal Aviation Regulations. The inventors have recognized that one reason for this failure is that when tension is applied to existing seat belts, they pull downward on the child safety seat. This allows a forward facing child seat to pitch, or rotate forward in the event of a crash. When this occurs, infants experience excessive head acceleration and possible collision with the seat backs of the seats in the adjacent row. The problem results from the relatively low and forwardly located position of the attach shackle of aircraft lap belts. The present invention corrects this problem with a simple, inexpensive, removable system that can be retrofitted to the great majority of the hundreds of thousands of commercial aircraft seats currently in use.
The concept of designing “aircraft only” child seats has a number of disadvantages. One disadvantage is that it would increase travel cost. Another disadvantage is that use of aircraft only safety seats becomes substantially inconvenient for travelers and airlines. Families would have to bring two child safety seats with them for every child. Alternatively, airlines would be forced to inventory numerous heavy, expensive, and bulky “aircraft only” safety seats. Another disadvantage is that this would increase the weight of the cargo of the aircraft, since parents would be traveling with the automotive safety seat anyway.
The option of dedicating a limited number of selected seats with integral safety seats to children has similar problems. One disadvantage is that such designs are not easily removable or portable, and would thus limit the seating arrangements between parents and children, since the number and spatial arrangement cannot accommodate the variable number of family members. Another disadvantage of these devices is that they are higher in weight. Another disadvantage of these devices is that they are expensive. Another disadvantage of these devices is that they pose additional sanitation issues.
It can thus be seen that there is a need to develop a design for securing automotive safety seats securely into aircraft seats in a manner that provides infants and toddlers at least an equivalent degree of safety as is provided to adults. There is also a need to design a system that meets or exceeds the requirements of the Federal Aviation Regulations. There is also a need to design a system that is removable, portable, and light-weight, and not bulky to store. There is also a need to design a system that can accommodate the various aircraft seat designs. There is also a need to design a system that is inexpensive and convenient to use. There is also a need to design a system that can utilize car safety seats in securing infants and toddlers safely in aircraft seats.
BRIEF SUMMARY OF THE INVENTION
A primary advantage of the present invention is that it provides infants and toddlers a degree of safety that is at least equivalent to that currently provided to adult passengers. Another advantage of the present invention is that it exceeds all current and pending Federal Aviation Regulations. Another advantage of the present invention is that it is removable, portable, and light-weight, and not bulky to store. Another advantage of the present invention is that it can accommodate the various aircraft seat designs. Another advantage of the present invention is that it can accommodate both forward and aft facing orientations of children. Another advantage of the present invention is that it is simple and inexpensive to manufacture. Another advantage of the present invention is that it is easy to install. Another advantage of the present invention is that it can utilize FMVSS §213 approved car safety seats to secure infants and toddlers safely to aircraft seats. Another advantage of the present invention is that it does not interfere with evacuations, passenger comfort, tray table use, seat back pocket and safety information card access, or carry-on luggage storage. Other advantages of the present invention will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.
In the preferred embodiment of the present invention, an aircraft child restraint system is disclosed comprising a pair of anchors having a beam connector on one end and a belt connector on the opposite end. The beam connectors are connectable to the forward seat beam of an aircraft seat. A first belt assembly has a latch plate on one end, and a clip on the opposite end. The clip removably attaches the first belt assembly to the belt connector of one of the anchors. A second belt assembly has a releasable buckle on one end, and a clip on the opposite end. In the preferred embodiment, the second belt assembly includes a second belt adjustment assembly located between the ends of the assembly. The clip removably attaches the second belt assembly to the belt connector of the other anchor. The latch plate is quick-connectable to the buckle.
In another embodiment, zip-ties are used to secure the anchors to the rear seat beam of an aircraft seat. In another embodiment, a first belt adjuster movably connects the latch plate to the belt. In another embodiment, the first and second belt assemblies are constructed of polyester webbing. In another embodiment, a webbing guard is located on at least one belt assembly. In another embodiment, the webbing guard is imprinted to identify the preferred position of the belt assembly as “window-side” or “aisle-side.” In another embodiment, an adjuster pad is located on the second belt assembly. In another embodiment, the anchors are made of wire rope. In another embodiment, the wire rope is 7×19⅛″ stainless steel cable. In another embodiment, the beam connector is a loop formed at the end of the wire rope and a rope grip for securing the loop. In another embodiment, a protective shrink-wrap is applied to at least a portion of the wire rope. In another embodiment, the shrink-wrap is color-coded to assist in location of the anchor. In another embodiment, the belt connector comprises a thimble located at the end of the wire rope, with a loop formed by the wire rope around the thimble, and a loop sleeve securing the loop around the thimble. In another embodiment, the clip is a snap hook attached to the belt assembly.
In an alternative embodiment, an aircraft child restraint system comprises a first belt assembly having a latch plate on one end and a beam connector on the opposite end. A second belt assembly has a releasable buckle on one end, a beam connector on the opposite end, and a second belt adjuster located between the buckle and clip. Each beam connector is removably connectable to the forward seat beam of an aircraft seat. The latch plate is quick-connectable to the buckle.
In an alternative embodiment, an aircraft child restraint system comprises a first belt assembly having a latch plate on one end and a beam connector on the opposite end. A second belt assembly has a releasable buckle on one end, a beam connector on the opposite end, and a second belt adjuster located between the buckle and clip. Each beam connector is removably connectable to the aft seat beam of an aircraft seat. The latch plate is quick-connectable to the buckle.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
FIG. 1 is a front view of an embodiment of the present disclosures of a commercially available child safety seat secured in an aircraft seat by the present disclosure and a child secured safely within the automotive safety seat.
FIG. 2 is a side view of a typical child safety seat.
FIG. 3 is a side view of a typical commercial aircraft seat.
FIG. 4 is a side view of an embodiment of the anchor of the present disclosure.
FIG. 5 is a front view of a zip-tie element of an embodiment of the present disclosure.
FIG. 6 is an isometric view of an embodiment of the present disclosure, showing the anchor of FIG. 4, and zip-ties of FIG. 5, attached to the lower framework of the commercial aircraft seat of FIG. 3 .
FIG. 7 is a front view of an embodiment of the first belt assembly of the present disclosure.
FIG. 8 is a front view of an embodiment of the second belt assembly of the present disclosure.
FIG. 9 is a front view of an embodiment of the padding element of the present disclosure.
FIG. 10 is a top view of an embodiment of the anchor of the present disclosure, showing the assembled relationship between the anchors and belt assemblies.
FIG. 11 is a side view of an embodiment of the present disclosure, showing the lower framework of a commercial aircraft seat, showing an anchor attached to the framework as also shown in FIG. 6, and showing the first belt assembly connected to the anchor.
FIG. 12 is a side view of an embodiment of the present disclosure showing a child safety seat restrained in a commercial aircraft seat with the child restraint system of the present disclosure.
FIG. 13 is a top view of an embodiment of the present disclosure showing a child safety seat restrained in a commercial aircraft seat with child restraint system of the present disclosure.
FIG. 14 is a rear view of an embodiment of the present disclosure showing a child safety seat restrained in a commercial aircraft seat with child restraint system of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
FIG. 1 is a front view of a typical child safety seat 10 , having a harness assembly 12 . Safety seat 10 is in a forward facing position, and secured in a commercial aircraft seat 20 by a child restraint system 50 (not visible in this view). A child is secured safely within child safety seat 10 .
FIG. 2 is a side view of child safety seat 10 . A frame 14 includes a channel 16 for placement of an automotive seat belt (not shown). A cushion 18 covers frame 14 for the comfort and safety of the child. For purposes of use with the disclosed invention, only child safety seats 10 used in a forward facing position and including a harness 12 (not shown) are applicable.
FIG. 3 is a side view of a typical commercial aircraft seat 20 . Aircraft seat 20 has a seat back 22 . A tray table 24 extends from, and retracts into, the rear of seat back 22 . A pair of armrests 26 are located generally perpendicular to seat back 22 . A seat base 28 rests on a diaphragm 30 . Diaphragm 30 is mounted on a front beam 32 and a rear beam 34 . Front beam 32 and rear beam 34 are connected by spreader bars 36 . Front beam 32 is also attached to a pair of front legs 38 . Front beam 32 and rear beam 34 are also attached to a pair of rear legs 39 . Front legs 38 and rear legs 39 are attached to seat track fitting 40 , which attaches aircraft seat 20 to the floor structure of the fuselage of the airplane. Standard lap belts (not shown) are attached to aircraft seat 20 at an attach shackle 42 . It will be understood by a person of ordinary skill in the art that commercial aircraft seats known in the industry comprise numerous variations and additional complications to the above description, but that the above description will suffice for the purpose of understanding the present invention, its application, and its equivalents.
FIG. 4 is a side view of an anchor 52 of child restraint system 50 . In the preferred embodiment of child restraint system 50 , a pair of anchors 52 is used. In a preferred embodiment, anchor 52 is made generally of wire rope. In another preferred embodiment, the wire rope is 7×19⅛″ stainless steel cable, which is well known in the industry. Anchor 52 has a beam connector 54 at one end. In a preferred embodiment, beam connector 54 is comprised of a loop 56 formed at the end of anchor 52 , and a rope grip 58 securing loop 56 to anchor 52 . In a preferred embodiment, rope grip 58 is of the commercial available type, such as the Gripple® Model available from Cooper Tools, 1000 Lufkin Rd., Apex, N.C. 27502. In another preferred embodiment, the end of anchor 52 is capped with a stop sleeve 60 . Capping anchor 52 with stop sleeve 60 prevents injury to passengers and crewmembers, and damage to anchor 52 and carry-on luggage. In another preferred embodiment, protective shrink-wrap tubing 62 is shrink wrapped on at least a portion of anchor 52 . Tubing 62 also prevents injury to passengers and crewmembers, and damage to anchor 52 and carry-on luggage. In a more preferred embodiment, tubing 62 is color-coded in a distinctly visible color, such as red. Color-coding tubing 62 improves visibility for crewmembers looking for an aircraft seat 20 fitted with anchors 52 . A belt connector 64 is located on anchor 52 on the end opposite beam connector 54 . In a preferred embodiment, belt connector 64 is comprised of a loop 66 formed by anchor 52 around a thimble 68 . A loop sleeve 70 secures loop 66 around thimble 68 .
FIG. 5 is a front view of a zip-tie 72 of child restraint system 50 . In this embodiment, one or more zip-ties 72 are used to secure anchor 52 to rear beam 34 of aircraft seat 20 . This can best be seen in FIG. 6 . In FIG. 6, beam connector 54 attaches one end of anchor 52 to front beam 32 of aircraft seat 20 . Zip-ties 72 secure anchor 52 to rear beam 34 of aircraft seat 20 . On the opposite end of anchor 52 , belt connector 64 extends past rear beam 34 .
FIG. 7 is a front view of an embodiment of a first belt assembly 74 of child restraint system 50 . In a preferred embodiment, first belt assembly 74 has a first belt 76 made of polyester webbing, such as the type well known to one skilled in the art. A latch plate 78 is attached to one end of first belt 76 . A clip 80 is attached to the opposite end of first belt 76 . Clip 80 is removably connectable to belt connector 64 of anchor 52 . In a preferred embodiment, clip 80 is a snap hook, such as that commercially available and well known to one skilled in the art. In another embodiment, a first belt adjuster 82 adjustably connects latch plate 78 to first belt 76 . In another embodiment, a webbing guard 84 is located on first belt 76 , between latch plate 78 and clip 80 . In another embodiment, a guard mark 85 identifies first belt assembly 74 as being preferably positioned on the “outboard” or “window-side” of an aircraft seat 20 . In another embodiment, a guard mark 97 identifies second belt assembly 96 as being preferably positioned on the “inboard” or “aisle-side” of an aircraft seat 20 .
FIG. 8 is a front view of an embodiment of a second belt assembly 86 of child restraint system 50 . In a preferred embodiment, second belt assembly 86 has a second belt 88 made of polyester webbing, such as the type well known to one skilled in the art. A releasable buckle 90 is attached to one end of second belt 88 . Buckle 90 is releaseably connectable to latch plate 78 of first belt assembly 74 . A clip 92 is attached to the opposite end of second belt 88 . Clip 92 is removably connectable to belt connector 64 of anchor 52 . In a preferred embodiment, clip 92 is a snap hook, such as the type commercially available and well known to one skilled in the art. A second belt adjuster 94 adjustably connects buckle 90 to second belt 88 . In another embodiment, a webbing guard 96 is located on second belt 88 , between buckle 90 and clip 92 . In another embodiment, a pad 98 is positioned on second belt 88 , and located over second belt adjuster 94 . This is best seen in FIG. 9 .
FIG. 10 is a top view of an embodiment of child restraint system 50 . In this view, the assembled relationship anchors 52 , first belt assembly 74 and second belt assembly 86 are shown. As seen in this figure, connection between clip 80 and belt connector 64 removably attaches first belt assembly 74 to an anchor 52 . Likewise, connection between clip 92 and belt connector 64 removably attaches second belt assembly 86 to a second anchor 52 . Also shown in this figure, connection between buckle 90 and latch plate 78 , releasably connects second belt assembly 86 to first belt assembly 74 .
In an alternative not shown, but easily understood from the foregoing figures and description, a simple anchor 52 is attached to rear beam 34 . In this embodiment, anchor 52 is essentially belt connector 54 . This embodiment requires that space permits attachment of anchor 52 on rear beam 34 of the particular aircraft seat 20 . This embodiment eliminates the need for any attachment to front beam 32 .
Operation of the Invention
In the preferred embodiment of the present invention, anchors 52 are made of wire rope or other suitable material, and have a beam connector 54 at one end. As can best be seen in FIG. 11 and also in FIG. 6, beam connectors 54 are attached to front beam 32 of commercial aircraft seat 20 , which has been designated and configured by the air carrier as a seat desirable for children to travel in. Belt connector 64 is located on the opposite end of anchors 52 . In a preferred embodiment, anchors 52 are secured to rear beam 34 of seat 20 by zip-ties 72 or other suitable means. In this position, belt connectors 64 of anchors 52 extend past rear beam 34 , and are readily locatable and accessible to crewmembers and passengers. Also in this position, anchors 52 will not interfere with evacuations, passenger comfort, tray table use, seat back pocket and safety information card access, or the placement and removal of carry-on luggage under seat 20 . These relationships are best seen in FIG. 14 . In another embodiment, anchors 52 are color-coded for visibility.
In a preferred embodiment, crewmembers will refer to guard mark 85 of webbing guard 84 to locate first belt assembly 74 on the window-side of aircraft seat 20 . Alternatively, or coincident with that identification, crewmembers may refer to guard mark 97 of webbing guard 96 to locate second belt assembly 86 on the aisle-side of aircraft seat 20 .
As best seen in FIG. 12, a child safety seat 10 is positioned against seat base 28 and seat back 22 of aircraft seat 20 . Clip 80 of first belt assembly 74 is attached to belt connector 64 of one anchor 52 . Clip 92 of second belt assembly 86 is attached to belt connector 64 of the other anchor 52 . Second belt adjuster 94 permits extension of the length of second belt 88 between buckle 90 and clip 92 . Likewise, in another embodiment, first belt adjuster 82 permits extension of the length of first belt 76 between latch plate 78 and clip 80 .
The length of first belt assembly 74 is adjusted so that latch plate 78 is slightly forward of the front of seat back 22 . With the length of second belt assembly 86 fully extended, buckle 90 is passed through channel 16 of frame 14 of child safety seat 10 . As seen in FIG. 13, latch plate 78 is then connected to buckle 90 outside of child safety seat 10 , preferably on the outboard, or window side. This leaves buckle 90 accessible for easy release of latch plate 78 for removal of car safety seat 10 . In FIG. 13, the broken line represents frame 14 of car safety seat 10 , showing the clearance to buckle 90 in the assembled position. Referring back to FIG. 12, it can be seen when child restraint system 50 is assembled and connected, first belt assembly 74 and second belt assembly 86 are secured together at one end, and to anchors 52 at the opposite end. Each anchor 52 is attached to either first belt assembly 74 or second belt assembly 86 on one end, and to front beam 32 of seat 20 at the opposite end. When latch plate 78 is connected to buckle 90 , the combined length of first belt assembly 74 and second belt assembly 86 can be tensioned by adjustment of second belt adjuster 94 . In another embodiment, buckle 90 can always be positioned outside of channel 16 for easy access by coincident adjustment of first belt adjuster 82 . The tensioning of the combined length of first belt assembly 74 and second belt assembly 86 secures car seat 10 in place in aircraft seat 20 . The child can then be placed into car seat 10 and secured by harness assembly 12 . In this configuration, the resultant force acting on connected first belt assembly 74 and second belt assembly 86 during a crash is above the connection of armrest 26 to seat 20 , and therefore at an angle closer to the horizon than can be achieved by using standard aircraft seat lap belts attached to attach shackle 42 of aircraft seat 20 . This change results in a substantial improvement in the safety of the child traveling by air.
During use, protective shrink-wrap tubing 62 prevents injury to passengers and crewmembers, and damage to anchor 52 and carry-on luggage. In another embodiment, tubing 62 is color-coded in a distinctly visible color, such as red, which improves visibility for crewmembers looking for an aircraft seat 22 fitted with anchors 52 . In another embodiment, webbing guard 84 protects first belt 76 and webbing guard 96 protects second belt 88 from damage by contact during installation and use with the various mechanical features of commercial aircraft seat 20 , such as seat back pivots, reclining arms, armrest support structures, seat back pocket springs, and the like. Similarly, pad 98 protects buckle 90 . Webbing guard 96 may be imprinted to identify the preferred window-side and aisle-side use of first belt assembly 74 and second belt assembly 86 .
Upon landing and deplaning, the guardian of the child passenger can release the connection of buckle 90 to latch plate 78 and remove child seat 10 . First belt assembly 74 can then be detached from anchor 52 by crewmembers by releasing clip 80 . Likewise, second belt assembly 86 can be detached from anchor 52 by crewmembers by releasing clip 92 . The pair of anchors 52 can be left in place for convenient use during another flight. First belt assembly 74 and second belt assembly 86 are small, light, and flexible, which permit easy storage onboard the aircraft.
Tests on child restraint system 50 were conducted on Feb. 13, 2001, at the Federal Aviation Administration Civil Aeromedical Institute (CAMI) Biodynamics Research Laboratory in Oklahoma City, Okla. CAMI sled tests were performed with multiple channel acceleration measurements as shown in Table 1 below. Six measured, and two calculated data fields were collected. The acceleration pulse measured in these tests meets the requirements for testing transport category airplane passenger seats as specified in 14 CFR 25.562.
Channel 3 measures Chest X Acceleration. This is the acceleration measured in the X (fore-aft) direction at the center of gravity of the test dummy's chest. This acceleration can be correlated to the potential for internal injuries. The current limit established by the Federal Motor Vehicle Safety Standard in FMVSS §213, is 60 g's.
Calculated Channel 2 is the Head Injury Criteria (HIC). The HIC is calculated from the resultant head acceleration (the vector sum of all three accelerations). The HIC can be correlated to the potential for scull fracture and brain injury. The current limit established in FMVSS §213 is 1000.
Representative test results appear in Table 2, Table 3, and Table 4 below. The test results in each of these tables demonstrate that the tested embodiment of the present invention consistently achieved ratings significantly below the FMVSS §213 limits. These limits cannot be achieved with the use of standard aircraft seat lap belts, on forward facing child safety seats.
TABLE 1
Channel 1
Sled
Acceleration measured by an accelerometer
Acceleration
mounted on the sled in the direction of sled
(g's)
travel
Channel 2
Aux Sled
Acceleration measured by a back up
Acceleration
accelerometer
(g's)
Channel 3
Chest X
Acceleration measured in the X (for-aft)
Acceleration
direction at the test dummy's chest center of
(g's)
gravity.
Channel 4
Head X
Acceleration measured in the X (for-aft)
Acceleration
direction at the test dummy's head center of
(g's)
gravity.
Channel 5
Head Y
Acceleration measured in the Y (left-right)
Acceleration
direction at the test dummy's head center of
(g's)
gravity.
Channel 6
Head Z
Acceleration measured in the Z (up-down)
Acceleration
direction at the test dummy's head center of
(g's)
gravity.
Calculated
Calculated
Total velocity change of the sled as derived
Channel 1
Velocity
from the sled accelerometer.
Calculated
Calculated HIC
Head Injury Criteria. An injury criteria
Channel 2
number calculated from the resultant head
acceleration (the vector sum of all three
accelerations).
TABLE 2
Test: A01005
Velocity = 45.06 ft/sec
Date: Feb. 13, 2001
Time = 11:25 AM
Channel
Identifier
Positive Peak
time
Negative Peak
Time
1
Sled
2.6
0.159
−18.2
0.095
2
Aux Sled
2.7
0.159
−18.1
0.095
3
Chest X
7.7
0.300
−35.5
0.131
4
Head X
1.5
0.071
−46.8
0.141
5
Head Y
5.5
0.151
−4.9
0.308
6
Head Z
51.4
0.147
−55.8
0.238
Cal 1
Velocity
0.0
.000
−47.7
0.350
Cal 2
HIC
482.0
TABLE 3
Test: A01006
Velocity = 45.06 ft/sec
Date: Feb. 13, 2001
Time = 2:40 PM
Channel
Identifier
Positive Peak
Time
Negative Peak
Time
1
Sled
1.5
0.170
−16.4
0.094
2
Aux Sled
1.6
0.170
−16.3
0.094
3
Chest X
7.4
0.293
−30.0
0.105
4
Head X
9.6
0.241
−34.8
0.139
5
Head Y
4.1
0.236
−5.0
0.231
6
Head Z
42.5
0.135
−68.2
0.232
Cal 1
Velocity
0.0
.002
−46.5
0.350
Cal 2
HIC
398.7
TABLE 4
Test: A01007
Velocity = 45.06 ft/sec
Date: Feb. 13, 2001
Time = 4:02 PM
Channel
Identifier
Positive Peak
Time
Negative Peak
Time
1
Sled
1.0
0.169
−16.5
0.098
2
Aux Sled
1.1
0.169
−16.4
0.098
3
Chest X
6.6
0.294
−37.6
0.116
4
Head X
2.1
0.305
−49.0
0.154
5
Head Y
4.5
0.181
−2.2
0.301
6
Head Z
76.8
0.151
−30.6
0.254
Cal 1
Velocity
0.0
0.000
−47.9
0.350
Cal 2
HIC
518.1
From the foregoing, it can be seen conclusively that child restraint system 50 of the present invention provides a significant improvement in the safety of small children flying commercial aircraft, and if used, would improve the probability of survival and reduce the severity of injury for children on aircraft in survivable crashes.
While this invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
All references herein, including as may be found in the claims, to “forward” are suggestive of the direction of the front of the aircraft seat, and not necessarily to the front of the aircraft. All references herein, including as may be found in the claims, to “aft” are suggestive of the direction of the rear of the aircraft seat, and not necessarily to the rear of the aircraft. All references herein, including as may be found in the claims, to “inboard” are suggestive of the aisle side of the aircraft seat. All references herein, including as may be found in the claims, to “outboard” are suggestive of the window side of the aircraft seat. | A child safety restraint system is disclosed for use on private and commercial aircraft. The invention includes a removable, portable strap assembly for safely securing automotive child safety seats to aircraft seats and frames in compliance with present and pending federal aviation safety regulations. A system is disclosed which includes a pair of anchors attached to the front beam on an aircraft seat. A pair of connectable and adjustable belt assemblies are attached one each, to the anchors. One belt assembly is passed through the frame of a child safety seat and connected to the other belt assembly. The combined length of the connected belt assemblies is then adjusted to place the system in tension, and thereby secure the child safety seat to the aircraft seat. The resulting system provides significantly improved safety for children over the use of the lap belts to secure child safety seats in commercial aircraft. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. National Stage Application of International Application No. PCT/EP2008/057463 filed Jun. 13, 2008, which designates the United States of America, and claims priority to German Application No. 10 2007 030 591.7 filed Jun. 27, 2007, the contents of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The invention relates to a process for coating the inner walls of pipes, in which a fluid containing the coating material is fed into the pipe. During the coating process, a mobile heating device is used to heat the pipe locally to a temperature required to form the coating until the layer formation process is completed locally. The heating device then continues to be moved until the layer to be formed is completed, i.e. the pipe is gradually heated in the entire inner region to be coated. After coating has been carried out, the remaining fluid is removed from the pipe again. The fluid has to be suitable as a carrier for the coating material. It can be both liquefied and gaseous. It is also possible for the fluid to be formed exclusively by the coating material itself, said coating material being deposited directly on the inner walls by subjecting the pipe to heat treatment.
BACKGROUND
[0003] A process of the type mentioned in the introduction is described, for example, in US 2005/0255240 A1, in which pipes having a relatively narrow cross section are intended to be coated from the inside. This is done by immersing these pipes in a solution containing the coating material, said solution being sucked into the pipes owing to the effective capillary forces. This process can be further assisted by applying a vacuum to the free end of the pipe. As soon as the pipe is filled with the fluid, a sleeve which surrounds the pipe is used to introduce thermal energy into said pipe, this treatment being started at the free end, i.e. the end which is not immersed in the fluid. The solvent is thereby evaporated and leaves the pipe at the top, while the polymer dissolved in the solvent is deposited on the inner walls of the pipe. When the heating sleeve reaches the opposite end of the pipe, the coating process is complete and the layer is completed. As soon as the sleeve has locally heated a point on the pipe and is moved on, this point cools down to room temperature again.
SUMMARY
[0004] According to various embodiments, a process for coating inner walls of pipes can be specified which makes it possible to influence the layer formation process in a comparatively effective manner.
[0005] According to an embodiment, in a process for coating the inner walls of pipes, —a fluid containing the coating material is fed into the pipe, —a mobile heating device is used to heat the pipe locally to a temperature required to form the coating until the layer formation process is completed locally, and the heating device continues to be moved until the layer to be formed is completed, and—the remaining fluid is removed from the pipe, and wherein a mobile cooling device supports the local cooling of the pipe after the layer has been formed.
[0006] According to a further embodiment, a plurality of heating devices and cooling devices can be used at the same time. According to a further embodiment, the at least one cooling device and the at least one heating device can be moved continuously along the longitudinal extent of the pipe, wherein the speed is selected subject to the local heating and cooling duration required. According to a further embodiment, the fluid may contain precursors for a ceramic which are chemically converted to give a metal compound which forms the ceramic, with the layer being formed. According to a further embodiment, the fluid can be liquefied and the pipe may have a straight profile, wherein the pipe is held at an angle of more than 0° and at most 90° to gravitational acceleration and is rotated during the coating process.
[0007] According to another embodiment, a combined heating and cooling device for a pipe, may have at least one heating region and at least one cooling region which are arranged in succession in the direction of the longitudinal extent of the pipe, wherein both the heating region and the cooling region are adapted to the cross section of the pipe in such a manner that the heating and the cooling are uniform over the circumference of the pipe in the region of influence of the heating region and of the cooling region.
[0008] According to a further embodiment, a cooling device can be arranged at each end of said device. According to a further embodiment, a plurality of heating regions and cooling regions can be arranged in succession. According to a further embodiment, the device may be in the form of a sleeve which surrounds the pipe. According to a further embodiment, the device can be in the form of a probe for the inside of the pipe. According to a further embodiment, a supply device for the fluid can be integrated in the probe and can be used to direct a stream of fluid onto the inner wall of the pipe.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Further details of the invention are described below with reference to the drawing. Identical or corresponding elements in the drawing are provided with the same reference symbols in each case and are explained repeatedly only where there are differences between the individual figures. In the drawing:
[0010] FIG. 1 schematically shows an exemplary embodiment of the process, with an exemplary embodiment of a sleeve-like heating and cooling device,
[0011] FIG. 2 shows another exemplary embodiment of the process, with an exemplary embodiment of the probe-like heating and cooling device being used, and
[0012] FIGS. 3 to 5 show various exemplary embodiments of the heating and cooling device.
DETAILED DESCRIPTION
[0013] According to various embodiments, a mobile cooling device supports the local cooling of the pipe after the layer has been formed. This means that it is not only possible to specifically influence the heating process by means of the heating device by modifying the coating parameters, but also the cooling process. This is advantageous in the case of layers with properties which depend on the cooling rate. Therefore, this advantageously makes it possible to additionally influence the layer formation process.
[0014] According to an embodiment, a plurality of heating devices and cooling devices are used at the same time. This makes it possible to carry out a layer formation process of the pipe at a plurality of points at the same time, it advantageously being possible to reduce the process duration, for example in the case of long pipes. The heating devices and cooling devices can also be arranged in a cascade-like manner, i.e. heating devices and cooling devices are guided along the pipe wall alternately such that a coating process is carried out repeatedly. This is advantageous particularly when only thin coating thicknesses can be produced by the layer formation process, and therefore said process has to be repeated several times. This advantageously makes it possible to reduce the process duration.
[0015] Another embodiment provides that the at least one cooling device and the at least one heating device are moved continuously along the longitudinal extent of the pipe, wherein the speed is selected subject to the local heating and cooling duration required. This means that the length of the heating or cooling device in the direction of movement has to be coordinated with the movement speed such that a specific point on the pipe wall is located underneath the heating or cooling device moving away over the pipe wall during the required time interval. In addition, the length ratio between the heating and cooling device has to be dimensioned such that it corresponds to the ratio of the required time intervals for the heating treatment or the cooling treatment. The advantage of a continuous movement of the heating or cooling device is that the layer is likewise continuously built up locally and therefore it is possible to produce a transition-free coating over the entire length of the pipe.
[0016] The process is particularly advantageous when the fluid contains precursors for a ceramic which are chemically converted to give a metal compound which forms the ceramic, with the layer being formed. Coatings of this type, which have also become known under the name C3 coatings, allow various outstanding layer properties to be set, it being possible to obtain these properties only if the required layer formation parameters are observed precisely. Therefore, it is particularly advantageous to use an additional cooling device to the heating device when producing these types of coating.
[0017] The process of applying ceramic precursors to metallic components in order to form ceramic layers on said components is known per se and is described, for example, in US 2002/0086111 A1, WO 2004/013378 A1, US 2002/0041928 A1, WO 03/021004 A1 and WO 2004/104261 A1. The processes described in these documents relate to the production of ceramic coatings on components in general, wherein the layer is produced using ceramic precursors of the ceramics to be produced which, after they have been applied, are converted to the ceramic to be formed by heat treatment.
[0018] The ceramic precursors contain the materials of which the ceramic material of the layer to be formed is composed, and furthermore have constituents which, during the chemical conversion which proceeds when the coating material is subjected to heat treatment, lead to crosslinking of the ceramic material. Examples of ceramic precursors can be gathered from the cited prior art documents and should be selected depending on the intended application.
[0019] By way of example, it is possible that the ceramic to be formed consists of an oxide and/or a nitride and/or an oxynitride. The formation of oxides, nitrides or oxynitrides advantageously makes it possible to produce particularly stable layers. The precursors of such ceramics have to provide the elements N and/or O in order to form the oxidic, nitridic or oxynitridic ceramic.
[0020] The invention also relates to a device suitable for coating the pipes using heat treatment.
[0021] Such a device is described in US 2005/0255240 A1 (mentioned in the introduction). This device comprises a heating sleeve, the internal diameter of which is greater than the external diameter of the pipe to be coated. This heating sleeve can therefore be guided along the pipe, which makes it possible to carry out heat treatment. Heat is input from the outside of the pipe toward the inside such that the heat introduced influences the layer formation process on the inside of the pipe.
[0022] According to various embodiments, a device can be specified which is intended for supporting a layer formation process on the inside of pipes and makes it possible to control the required temperature profile in a relatively accurate manner.
[0023] According to various embodiments, a combined heating and cooling device for a pipe may have at least one heating region and at least one cooling region, wherein these regions are arranged in succession in the direction of the longitudinal extent of the pipe. According to various embodiments, both the heating region and the cooling region are adapted to the cross section of the pipe in such a manner that the heating and the cooling are uniform over the circumference of the pipe in the region of influence of the heating region and of the cooling region. This is important particularly when the pipes to be coated do not have a circular cross section. By way of example, if the cross section is rectangular, it is also necessary for the heating region and the cooling region to at least substantially follow this contour.
[0024] One embodiment provides that a cooling region is arranged at each end of the heating and cooling device. In other words, there is one cooling device more than the number of heating devices. This has the advantage that the heating and cooling device can be guided along the pipe wall in both possible directions. Specifically, first the heating and then the cooling must be carried out in both directions, and therefore the cooling region must be downstream of the heating region, as seen in the direction of movement. This is advantageously the case for the embodiment discussed.
[0025] It can be also advantageous to arrange a plurality of heating regions and cooling regions in succession. As already explained, this makes it possible to produce a cascade-like layer structure and thereby to guide the heating and cooling device along the pipe wall only once.
[0026] According to an embodiment, the heating and cooling device may be in the form of a sleeve which surrounds the pipe. Another embodiment provides that the heating and cooling device is in the form of a probe for the inside of the pipe. The sleeve-like heating and cooling device is preferably suitable for pipes with a small cross section, whereas the probe-like heating and cooling device can preferably be used for pipes with a sufficiently large cross section. The probe-like heating and cooling device has the additional advantage that it can also be used in pre-installed pipe systems since it can be displaced unhindered in the inside of the pipe even over relatively large sections of the pipeline. Specifically, a sleeve could not be displaced unhindered owing to the pipe suspensions of the pipeline system.
[0027] A probe-like heating and cooling device can advantageously be developed by integrating a supply device for the fluid in the probe, which supply device can be used to direct a stream of fluid onto the inner wall of the pipe. This advantageously makes it possible to locally feed the fluid into the inside of the pipe precisely at that point where the coating process also takes place. Particularly in the case of relatively large pipeline systems, this makes it possible to carry out a coating process which saves a relatively large amount of material because it is not necessary to flood the entire pipe system with the fluid.
[0028] FIG. 1 shows a straight pipe 11 which, for coating of the inner walls (not shown), is accommodated in a coating device. For this purpose, there is a clamping device 13 which is mounted in a positionally fixed bearing 12 and can be made to rotate by means of a motor-driven drive 14 . One end of the pipe 11 is inserted into this clamping device 13 .
[0029] The other end of the pipe is located in a container 15 for a fluid 16 containing the coating material. A feed line 17 can be used to feed this fluid into the clamping device using a pump 18 , and this fluid then runs through the pipe to be coated back into the container 15 .
[0030] The rotary movement of the pipe ensures that the entire internal circumference of the pipe is wetted at least occasionally with the fluid 16 . A heating and cooling device in the form of a sleeve 19 which locally surrounds the pipe 11 is provided in order to initiate a coating process, i.e. the separation of the coating material from the fluid. A linear drive (not shown in more detail) can be used to move the sleeve 19 along the pipe along the double-headed arrow 20 indicated, a heating region 21 and a cooling region 22 , which follows said heating region as seen in the direction of movement, being used in each case in the heating and cooling sleeve. Since a cooling region 22 is provided at each of the two ends of the sleeve, the sleeve can be operated in both directions of the double-headed arrow 20 , in which case it is always possible for firstly local heating and then local cooling to be carried out.
[0031] As an alternative to using the heating and cooling device, it would also be possible, as indicated by the dashed-dotted lines, to use an individual heating device 23 and cooling device 24 . These likewise have a sleeve-like design (in the manner already described) and can be pushed onto the pipe independently of one another. It is also possible to use any desired number of individual heating devices 23 and cooling devices 24 , similar to a modular principle.
[0032] FIG. 2 schematically shows a sectional view of part of a pipeline system with the pipe 11 . A heating and cooling device 19 comprising two probes 25 connected in series is inserted into said pipe. These probes 25 are connected to a supply line 26 and have rollers 27 with which they can be guided at a constant distance from the inner walls of the pipe. These rollers are shown schematically; in the case of a round cross section of the pipe, at least three rollers each at an angle of 120° with respect to one another are required on the periphery of the probes. In the exemplary embodiment shown in FIG. 2 , four rollers are provided on the periphery each at an angle of 90° with respect to one another.
[0033] Analogously to the manner described in FIG. 1 , each of the probes 25 is provided in the middle with a heating region 21 and at the ends with two cooling regions 22 . The supply line 26 can be used to push the probes into the line system and then pull them back out. For this purpose, the supply line 26 has to be sufficiently rigid, but additionally has to have a sufficiently flexible design if curves are provided in the pipeline system. The supply line provides the probes with energy required for heating and cooling.
[0034] In addition, nozzle openings (not shown in more detail) through which a liquefied coating material can be atomized are provided in the probes. The spray jet 28 is directed at the inner wall of the pipe 11 to be coated, a fluid line also being provided in order to supply the coating material in the supply line.
[0035] FIG. 3 schematically shows the possible design of a probe, in which the rollers 27 are not shown. The heating region 21 and the cooling regions 22 are made of copper, for example, in order to ensure good conduction of heat and heat capacity. Peltier elements 30 , which serve both to heat the heating region 21 and to cool the cooling regions 22 , are arranged between the heating region 21 and the cooling regions 22 .
[0036] FIG. 3 also shows the supply line 26 which issues into a bore hole 31 which makes it possible to supply the coating fluid to the nozzles 32 .
[0037] FIG. 4 shows a sleeve-like heating and cooling device. In the cooling regions 22 , this has cooling ducts 33 which can be supplied with a coolant by means of a line system 34 (indicated). The heating regions 21 are provided with electrical heating wires 35 . In total, there are two heating regions 21 and three cooling regions 22 .
[0038] FIG. 5 shows a further exemplary embodiment of a probe-like heating and cooling device. This has a UV lamp 36 which can be used to provide a layer formation process with UV radiation as heating energy in the broader sense. Cooling ducts 33 are also provided in the probe. | In a method for coating the inner walls of pipes ( 11 ), and in a coating device suitable for coating, a combined heating and cooling device ( 19 ) having heating areas ( 21 ) and cooling areas ( 22 ) is used for the method. This device can be guided along the pipe ( 11 ) to be coated, wherein a fluid ( 16 ) containing the coating active agent is supplied to the interior of the pipe. The combined heating and cooling treatment for the pipe supports the process of coating formation. The cooling process is subject to a desired profile by the use of the cooling area ( 22 ) and is not determined by chance, in contrast to the cooling process in the prior art. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to the use of an Aspergillus oryzae protease preparation as an anti-inflammatory agent useful in the treatment of various diseases and conditions.
2. Background of the Invention
Proteolytic enzymes have been used extensively as therapeutic agents for decades. The earliest studies used pancreatic enzymes in the treatment of cancer. Later, proteolytic enzymes from non-animal sources such as the plant enzymes bromelain and papain and proteases derived from fungi such as Aspergillus sp. were investigated.
Proteases from Aspergillus oryzae are commercially used in the production of sake and soy sauce as well as in flavoring of other food products. Clinically, these enzymes have been shown to have an anti-thrombolytic/anti-hypertensive effect (Frish, E., “Clinical Review on Brinase, a Protease from Aspergillus oryzae,” Folia Haematol., 101(1):63-82 (1974), Mizuno, S., et al., “Release of Short and Proline-Rich Hypertensive Peptides from Casein Hydrolysate with an Aspergillus oryzae Protease,” J. Dairy Sci., 87:3183-3188 (2004), Sano, J., et al., “Effect of Caesin Hydrolysate Prepared with Protease Derived from Aspergillus oryzae , on Subjects with High-Normal Blood Pressure or Mild Hypertension,” J. Medicinal Food, 8(4):423-430 (2005)), anti-cancer effect (Smyth, H., et. al., “The Effects of Protease I of Aspergillus oryzae (Brinase) on Membrane Permeability and Growth of Landshutz Ascites Tumour Cells,” Int. J. Cancer, 7:476-482 (1971), U.S. Pat. No. 5,562,900), and an anti-viral effect (Knight, C., “Immunogenic Properties of PR9 Influenza Virus After Treatment with Acid Protease,” Intervirology, 14:37-43(1980), Roth, R., et al., “Proteolytic Action of Aspergillus niger Extract on Influenza Virus,” Intervirology, 14:167-172 (1980), Singh, S., et al. “Isolation, Structure, and HIV-1 Integrase Inhibitory Activity of Structurally Diverse Fungal Metabolites,” J. Ind. Microbiol. Biotechnol., 30:721-731 (2003)). In addition, proteases from Aspergillus oryzae have been shown to be potent anti-inflammatory mediators (Kolodny, A., “Double Blind Evaluation of Asperkinase, a New Proteolytic Enzyme,” Am. J. Orthopedics, 234-235 (1963), U.S. Pat. No. 6,413,512 B1, U.S. Pat. No. 3,932,618, EP 1390 542).
In many diseases and injuries there is a marked increase in circulating proinflammatory cytokine levels. This increase in cytokine expression is hypothesized to contribute to the pathology of these conditions. Infection, cancer and tissue injury can all trigger the production of cytokines, which can then enter the blood stream to alter the physiology of distant tissues, or act locally as paracrine mediators. In some diseases and injury states cytokines are beneficial to the host, but in others, cytokines are detrimental to the host. Proteases and cytokines are intimately interrelated in that cytokines are involved in regulating the production of proteases and proteases are frequently involved in the liberation of soluble cytokines, as well as in their destruction. Diseases in which cytokines play a pathological role include multiple sclerosis, type I diabetes, rheumatoid arthritis, soft tissue injury, and solid tumor malignancies. It would be beneficial therefore in these disease states to decrease the levels of circulating cytokines. This has been accomplished by treating patients with antibodies to specific cytokines, i.e. TNFα, soluble receptor antagonists, and also proteases from plant and microbial sources.
Cytokines play a major role in the manifestation of inflammation, which is a predominant biological reaction to a myriad of injurious agents and events. It is well-known that host defensive and reparative processes in inflammation can be harmful to the body's welfare. Common characteristics of inflammation are fever, swelling, bruising and pain. The body's defensive mechanisms can bring about the release of products toxic to the host or lead to destruction of its host tissues.
Detrimental consequences of inflammation include fibrin deposition, and reduction in vascularity causing changes in tissue permeability creating additional morphologic barriers to the penetration of antibodies or pharmacological agents into the injured area. Some of the autolysis products released by tissue necrosis often constitute a good medium for microorganisms and can even antagonize the antimicrobial activity of many pharmaceutical agents, thereby exacerbating the injury or infection and prolonging the recovery process.
Cytokines released in the immune response to tumor antigens, such as IL-1β and IL-6 can upregulate angiogenic factors such as vascular endothelial growth factor (VEGF) which leads to new blood vessel formation providing nutrition to the growing malignancy, thereby helping the tumor to grow.
In addition, cytokines are pathogenic mediators in many autoimmune conditions such as rheumatoid arthritis (RA), multiple sclerosis (MS) and Crohn's disease. Current treatments in RA focus on inhibiting tumor necrosis factor alpha (TNF-α) production and signaling. In animal models of MS, inhibition of interferon-γ has shown promise.
The absorption of orally-administered proteases in mammals has been extensively studied. The prevailing finding of these studies is that proteases can be partially absorbed intact, with activity preserved, from the digestive tract and subsequently distributed systemically in the blood. Proteolytic enzymes from Aspergillus oryzae are often used as digestive aids, and as such stimulate bowel movements, often times leading to diarrhea in the host.
Early in the study of proteases, it was observed that the administration of animal-derived proteases could accelerate the healing of inflamed sites. Therefore, a large database exists of clinical results from orally-administered, animal derived proteases establishing the effectiveness of these proteases as therapeutic agents for inflammatory conditions. However, a clear mechanism of physiological action for animal-derived proteases is yet to be determined. Plant proteases have also been found to have a positive effect on inflammation The largest body of evidence supporting the use of proteases for inflammatory conditions studied the effects of a mixture of papain, bromelain, trypsin, chymotrypsin, pancreatin and rutin. In most cases, the mixture was in addition to standard medical care.
It has long been established that a number of chemical compounds typically referred to as vitamins and minerals provide significant health value and treat specific medical conditions, particularly when supplied in therapeutic doses. Over the years, a number of such vitamins and minerals have been identified. For example, vitamins include A, C, D, E, and the family of B vitamins and minerals include iron, zinc, calcium and chromium. The human body does not synthesize most of these vitamins and minerals which are essential to maintaining the health of the human body. Thus these necessary vitamins and minerals must be obtained from an external source. The two most common external sources are foods and nutritional supplements. Food is typically the primary source of obtaining the necessary nutrients for maintaining health, however many people do not eat foods that consistently provide the necessary daily requirements of vitamins and minerals. Thus, vitamin and mineral nutritional supplementation has become a recognized method of meeting these daily requirements.
While certain vitamins and minerals have been shown to be essential for the maintenance an individual's health, the use of vitamin and mineral nutritional supplementation has afforded the possibility to include micro-nutrients which, although not absolutely essential to maintaining health, provide significant benefit toward maintaining health.
U.S. Pat. No. 6,413,512 B1 describes treating patients suffering from a disease resulting from increased cytokine production with a pharmaceutical composition comprising 2 or more proteases from a microbial source in an amount of between 20,000 HUT and 550,000 HUT. The protease described this patent is made using rice and/or wheat bran as the carbohydrate source.
In light of the above, the present invention is based on the surprising result that proteases from Aspergillus oryzae made using potato dextrin as the carbohydrate source are better absorbed by the proximal small intestine than proteases using rice or wheat bran as the carbohydrate source and thus are exceptionally potent anti-inflammatory mediators. Proteases made using potato dextrin as the carbohydrate source, in contrast to those made from rice and or wheat bran, reduce gastrointestinal side effects such as diarrhea. In addition, administering more than 2,000,000 HUT/day of Aspergillus oryzae protease made from potato dextrin, along with a specific multi-vitamin formulation, provides an optimal and therapeutic anti-inflammatory effect.
BRIEF SUMMARY OF THE INVENTION
The present invention provides a method of treating mammalian diseases and conditions by administering a protease preparation derived from Aspergillus oryzae made using potato dextrin as the carbohydrate source in an amount of more than about 2,000,000 HUT per day. The protease preparation is preferably given on an empty stomach four times daily. The mammalian disease treated by the method of the instant invention is preferably selected from the group consisting of rheumatoid arthritis, multiple sclerosis, Crohn's disease, viral infection, soft tissue injury, bacterial infection, solid tumor malignancy, osteoporosis, osteopenia, chronic obstructive pulmonary disease, and Alzheimer's disease.
Another embodiment of the invention provides a method of treating mammalian disease by adminstering a protease preparation derived from Aspergillus oryzae made using potato dextrin as the carbohydrate source at an amount of more than about 2,000,000 HUT per day, together with a nutritional supplement of vitamins and minerals. The nutritional supplement preferably contains vitamin A, vitamin B1, vitamin B2, vitamin B5, vitamin B6, vitamin B12, vitamin C, magnesium citrate, vitamin E, Vitamin D3, zinc citrate, manganese gluconate, copper gluconate, biotin, folate, chromium polynicotinate, citrus bioflavinoids, glucosamine sulfate, and boron sulfate. In the preferred embodiment, the dietary supplement is given 2-3 times per day with food while the protease preparation is given 4 times daily on an empty stomach.
In another embodiment an additional supplement of calcium is given. In the preferred embodiment calcium is given at a dose of 900 mg/day. It is preferred that the additional calcium supplement is given once daily in the evening.
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood that this invention is not limited to the particular methods, compositions and materials disclosed herein as such methods, compositions and materials may vary. It is also understood that the terminology employed herein is used for the purpose of describing particular embodiments only and is not intended to be limiting since the scope of the present invention will be limited only by the appended claims and equivalents thereof.
It must also be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a protease” includes references to two or more of such proteases and “a vitamin” includes reference to one or more of such vitamins, unless otherwise specified.
In general the present invention is directed to a method of alleviating the manifestations of mammalian inflammatory disease or injury. The method of the present invention may be used to treat any type of inflammatory disease wherein pro-inflammatory cytokines are produced and exacerbate disease. Diseases that may be treated by the current invention include without limitation, rheumatoid arthritis, multiple sclerosis, Crohn's disease, viral infection, soft tissue injury, bacterial infection, solid tumor malignancy, osteoporosis, osteopenia, chronic obstructive pulmonary disease, and Alzheimer's disease.
The present invention offers improvements over prior proteolytic products in that, unlike other protease compositions, the primary benefit is obtained from the use of a protease from a particular microbial source in a defined dosing regimen. The invention does not contain animal-derived products, and thus is acceptable to patients who may object to the ingestion of animal products. The invention focuses specifically on protease preparations prepared using potato dextrin as the carbohydrate source instead of maltodextrin, wheat or rice bran. Surprisingly, protease preparations prepared using potato dextrin are more readily absorbed by the proximal small intestine and lead to less undesirable gastrointestinal side effects than those prepared with maltodextrin, wheat or rice bran. In addition, the invention does not contain gluten and may be safely ingested by persons who have an allergy to wheat gluten.
The preferred dietary supplement of the current invention comprises vitamin A, vitamin B1, vitamin B2, vitamin B5, vitamin B6, vitamin B12, vitamin C, magnesium citrate, vitamin E, vitamin D3, zinc citrate, manganese gluconate, copper gluconate, biotin, folate, chromium polynicotinate, citrus bioflavinoids, glucosamine sulfate, and boron sulfate.
The preferred dietary supplement comprises vitamin A. Vitamin A functions as a regulatory hormone with effects on specific genes for differentiation and maintenance of epithelial tissue, and is important to reproduction, vision and immune function. Taken in excess vitamin A will cause birth defects, and in the active or athletically performing individual, can cause bone demineralization, loss of elasticity in connective tissue, muscle soreness and joint pain. The recommended daily allowance (RDA) for vitamin A is 5000 IU/day. In the preferred embodiment of the invention the dietary supplement contains 5000 IU/day of vitamin A in the form of retinyl palmitate.
The preferred dietary supplement comprises vitamin B1. Vitamin B1 is distributed widely in foods in low concentrations. Vitamin B1 is susceptible to destruction by refining processes, neutral and alkaline conditions, heat and oxidation. Vitamin B1 is important in energy production from food, especially carbohydrates, and plays a vital role in nerve function. Supplementation in large doses is safe and has shown some efficacy in the ability to control pain in connective tissue. The RDA for vitamin B1 is 1.5 mg/day. In the preferred embodiment the dietary supplement contains 100 mg/day in the form of thiamin mononitrate.
The preferred dietary supplement comprises vitamin B2. Vitamin B2 is essential to a large number of redox reactions, releasing energy from carbohydrates, fats and amino acids, and is thus important to the elderly, and the active or athletic individual. Vitamin B2 is highly water soluble and reactive to light. Strict vegetarians, pregnant and lactating women, and ill or trauma victims are also at risk for vitamin B2 deficiency. High oral doses of vitamin B2 are essentially non-toxic. The RDA for vitamin B2 is 1-1.5 mg/day. In the preferred embodiment the dietary supplement contains 50 mg/day vitamin B2.
The preferred dietary supplement comprises vitamin B3 (niacinamide, not niacin). Vitamin B3 plays an important role in energy production, cellular respiration, fat synthesis and joint pain and mobility. Vitamin B3 (niacinamide, not niacin) possesses no known side effects, and when supplemented several times during the day, demonstrates long-lasting objective improvements in joint mobility. The RDA for vitamin B3 (niacin) is 15-20 mg/day. In the preferred embodiment the dietary supplement contains 300 mg/day vitamin B3 (niacinamide).
The preferred dietary supplement comprises vitamin B5. Vitamin B5 plays a significant role in energy production from carbohydrates, fats and proteins. The toxicity of vitamin B5 is negligible. Active and elderly individuals in trauma or who suffer from rheumatoid arthritis have realized significant improvements in morning stiffness, disability and pain when supplemented with gram doses of vitamin B5. There is no RDA for vitamin B5, a provisional range of intake of 4-87 mg/day was established 1980. In the preferred embodiment the dietary supplement contains 1000 mg/day vitamin B5 in the form of panthothenic acid.
The preferred dietary supplement comprises vitamin B6. Vitamin B6 has recently been shown to be vital to bone health. However in high doses, vitamin B6 can be toxic. In low doses, vitamin B6 shows no efficacy. Pregnant and lactating women, oral contraceptive users and heavy drinkers are at risk for vitamin B6 deficiency. The RDA for vitamin B6 is 1.5-2 mg/day. In the preferred embodiment the dietary supplement contains 50 mg/day vitamin B6 in the form of pyridoxine hydrochloride.
The preferred dietary supplement comprises vitamin B12. Vitamin B12 deficiencies can interfere with normal cell division involving arrested synthesis of DNA causing cellular mutations leading to disease states, particularly in bone marrow and intestinal mucosa. Vitamin B12 has no appreciable toxicity, and is frequently deficient in strict vegetarians. The RDA for vitamin B12 is 2 μg/day. In the preferred embodiment the dietary supplement contains 100 μg/day vitamin B12.
The preferred dietary supplement comprises vitamin C. Most of the functions of vitamin C are directly applicable to the health of connective tissue and their response to injury. Vitamin C, however tends to change the valence of copper, rendering copper unavailable to the body. It is good nutritional practice to dose extra copper when using mega doses of vitamin C. The RDA for vitamin C is 50-60 mg/day. In the preferred embodiment the dietary supplement contains 500 mg/day vitamin C.
The preferred dietary supplement comprises magnesium. Magnesium is widely distributed in food. However, the refining and processing of foods tends to remove large amounts of magnesium. Magnesium fulfills so many essential functions that it is almost impossible to single out any one function as most critical. There is no established RDA for magnesium because it is ubiquitous in nature. Nonetheless, the food and nutrition board of the national academy of sciences has recommended intake based on age and gender of 40-400 mg/day as safe and adequate. In the preferred embodiment the dietary supplement contains 400 mg/day magnesium in the form of magnesium citrate.
The preferred dietary supplement comprises vitamin E. Vitamin E is synthesized only by plants, and therefore is found primarily in plant products, particularly in plant oils. Vitamin E affects almost every aspect of health to some degree in its role and function as a scavenger of free radicals. The RDA for vitamin E is 8-10 mg/day. In the preferred embodiment the dietary supplement contains 400 mg/day vitamin E.
The preferred dietary supplement comprises vitamin D3. Vitamin D3 is important in calcium, phosphate and magnesium absorption. Excess vitamin D causes hypercalcemia. Clinical signs are weakness, nausea, headaches, abdominal pain, cramps and diarrhea. Intake of vitamin D is not absolutely essential if adequate skin exposure to sunlight is available. The RDA for vitamin D3 is 400 IU/day. However, recent research has shown that the recommended dose of vitamin D3 should be 1000-2000 IU/day due to the newly discovered multiplicity of critical functions in metabolism other than simply bone health. In the preferred embodiment the dietary supplement contains 1000 IU/day vitamin D3.
The preferred dietary supplement comprises zinc. Zinc, in addition to cell growth and replication, has specific roles in sexual maturation, fertility, reproduction, night vision, immune function, taste and appetite. Zinc, with copper as a stabilizing influence, is vital to genetic stability and expression during cellular replication. Deficiencies or excesses of zinc can result in mutated cellular replication leading to disease states. Thus, zinc should be supplemented in balance with copper to protect the cellular reproductive function. The RDA for zinc is 12-15 mg/day. In the preferred embodiment the dietary supplement contains 25 mg/day of zinc in the form of zinc citrate.
The preferred dietary supplement comprises manganese. Manganese plays unique and vital roles in the synthesis of macromolecular components of connective tissues, especially for bone and cartilage. Since acute, severe deficiencies of manganese are rare, defects of manganese status appear to occur in active individuals during periods of stress, or from a life-long, chronic, intermittent, or marginal deficiency. Acute deficiency symptoms are not usually encountered but rather, as with copper and zinc, chronic or marginal deficiencies in manganese uptake results in decreased synthesis of connective tissues leading to loss of integrity for joints and bones. The RDA for manganese is 2.0 mg/day. In the preferred embodiment the dietary supplement contains 10 mg/day of manganese in the form of manganese gluconate.
The preferred dietary supplement comprises copper. Modest doses of copper as organic chelates are used to maintain physiologic levels of cuproenzymes important to connective tissue, particularly in the athletic or active individual. Copper has a long history of medicinal uses, including treatment of inflammatory conditions, osteoporosis, and arthritis. Copper functions primarily as a component of metalloenzymes with essential functions, and also activates other enzymes. There is no RDA for copper. Current research however, has established a beneficial, safe and adequate intake of 2-8 mg/day. In the preferred embodiment the dietary supplement contains 8 mg/day of copper in the form of copper gluconate.
The preferred dietary supplement comprises biotin. Biotin is important for energy production and fat metabolism. Biotin is rather widespread among foods and is synthesized by intestinal flora. Simple deficiencies of biotin in humans in the absence of other nutrient deficiencies are rare. However, those at risk for biotin deficiency include individuals on antibiotic therapy, alcoholics, pregnant and lactating women, surgical burn patients and the elderly. Relatively low levels of biotin have also been reported in physically active or athletic individuals. There is no RDA for biotin. However, the national academy of sciences food and nutrition board has published a nominal safe and adequate intake of 100-200 μg/day. In the preferred embodiment the dietary supplement contains 1000 μg/day of biotin.
The preferred dietary supplement comprises folate. Folate is important to blood cell formation as well as DNA and RNA synthesis. Deficiencies result in reduced cell division which is manifested as anemia, skin lesions and poor overall growth. Pregnant and lactating women, elderly persons and those taking certain folate antagonists such as aspirin, have an increased requirement for folate in the diet. The RDA for folate is 150-200 μg/day. In the preferred embodiment the dietary supplement contains 1000 μg/day of folate.
The preferred dietary supplement comprises chromium. Chromium is essential for optimal peripheral insulin action with respect to glucose intake. Studies of elderly and active adults with noninsulin-dependent diabetes mellitus showed improvement in glucose tolerance following a period of chromium supplementation. The RDA for chromium is 120 μg/day. In the preferred embodiment the dietary supplement contains 200 μg/day of chromium in the form of chromium polynicotinate.
The preferred dietary supplement comprises bioflavinoids. Bioflavinoids are a ubiquitous class of compounds found in plants. Most bioflavinoids exhibit antioxidant activity. Scavenging hydroxyl radicals, lipid peroxides, and reactive oxygen species has been repeatedly documented for many bioflavinoids. Bioflavinoids also reduce capillary fragility and/or permeability. This effect “spares” vitamin C, and is likely due to flavinoid chelation and antioxidant properties, particularly important to the physically active or elderly individual. Bioflavinoids appear to render other nutrients more effective as anti-inflammatory agents, especially vitamin C and proteolytic enzymes. There is no RDA for bioflavinoids. In the preferred embodiment the dietary supplement contains 1000 mg/day of bioflavinoids in the form of citrus bioflavinoids.
The preferred dietary supplement comprises glucosamine. Glucosamine is a naturally occurring amino sugar found in glycoproteins and glycosaminoglycans. Increased availability of glucosamine through supplements accelerates or enhances synthesis of hyaluronan, glycosaminoglycans and proteolysis There is no RDA for glucosamine. In the preferred embodiment the dietary supplement contains 1000 mg/day of glucosamine in the form of glucosamine sulfate.
The preferred dietary supplement comprises boron. Maintenance of boron intake by dietary manipulation and/or supplementation is recommended for bone loss conditions such as osteoporosis, fracture healing, arthritis and other degenerative joint diseases. There is no RDA for boron, however research has indicated that a boron intake of 3-6 mg/day is beneficial, safe and adequate. In the preferred embodiment the dietary supplement contains 3 mg/day of boron in the form of boron citrate.
In one embodiment, the dietary supplement is taken with an additional calcium supplement. Calcium should be given as a single dose, once per day in the evening. Calcium requirements should be provided by dietary means first. When increasing calcium intake through supplemental means to reach the recommended levels of 800-1200 mg/day, doses of 900 mg elemental calcium should be taken once daily with the evening meal. Supplementing calcium in the evening is preferred because calcium metabolizes differently in the early evening and is better absorbed at that time.
The present invention will be further illustrated by the following examples that are not limited.
EXAMPLES
A suitable Aspergillus oryzae protease preparation made with potato dextrin as the carbohydrate source is Protease A-DS, obtained from Amano Enzyme U.S.A. Co., Ltd., Elgin, Ill. This enzyme preparation contains not less than 300,000 HUT/gram. The protease extract can be given dissolved or suspended in water or in capsular form.
The dietary supplement employed in the following examples is comprised of the following vitamins in the indicated amounts:
AMOUNT
PER SERVING
VITAMIN/MINERAL
(serving size 9 capsules)
Vitamin A (as retinyl palmitate)
5,000
IU
Vitamin B1 (as thiamin mononitrate)
100
mg
Vitamin B2 (as riboflavin)
50
mg
Vitamin B3 (as niaciniaminde)
300
mg
Vitamin B5 (as pantothenic acid)
1,000
mg
Vitamin B6 (as pyridoxine
50
mg
hydrochloride)
Vitamin B12 (as cyanocobalamin)
100
mcg
Vitamin C (as ascorbic acid)
500
mg
Magnesium citrate
400
mg
Vitamin E (as d-alpha-tocopherol)
400
IU
Vitamin D3 (as cholecalciferol)
1000
IU
Zinc Citrate
25
mg
Manganese Gluconate
10
mg
Copper Gluconate
8
mg
Biotin (as d-biotin FCC)
1
mg
Folate (as folic acid)
1
mg
Chromium polynicotinate
200
mcg
Citrus bioflavinoids
1,000
mg
Glucosamine Sulfate (13.2%
1,000
mg
potassium)
Boron Citrate
3
mg
Example 1
A 55-year-old female was admitted to the hospital for emergency bowel/appendix surgery. Three days later she underwent surgery to excise a short segment of bowel including two sites of abscess. Postoperatively, she had a prolonged course of bowel recovery. On post operative day 10, she continued to exhibit abdominal distension and nausea. She remained on clear liquids and it was suggested by the surgeon that a port be inserted into her upper chest for ease of treatment with fluids and antibiotics. On post operative day 11 in lieu of the port placement, the patient was placed on the enzyme therapy regimen of the present invention. The patient was immediately dosed with six grams (2,400,000 HUT) of the Aspergillus oryzae protease preparation described herein dissolved in water. This dose was repeated 3 more times throughout the day for a total daily dose of 9,600,000 HUT. At the end of post operative day 11, radiological reports illustrated that small bowel dilation may have been slightly less than was seen on the previous study. On post operative day 12, the patient again received 4 doses of 6 grams (2,400,000 HUT) of the Aspergillus oryzae protease preparation described herein dissolved in water for a total daily dose of 9,600,000 HUT. The scan taken on post operative day 12 illustrated that air was in the transverse and descending colons but not definitely seen in the rectum. The scan taken at post operative day 13, after the second full day of treatment illustrated that the dilation of small bowel loops had decreased and air was now observed in the region of the rectum in addition to the transverse and descending colons. According to the radiologist, these findings were consistent with a resolving partial small bowel (inflammatory) obstruction. The next morning, on post operative day 14, after 3 full days of treatment, the symptoms had resolved sufficiently as to allow the patient to be discharged.
Example 2
A 60-year-old female with relapsing-remitting multiple sclerosis (MS) began taking the protease preparation of the invention following a MS relapse involving numbness and weakness of her legs and hands. The patient received six grams of the claimed Aspergillus oryzae protease preparation dissolved in water on an empty stomach four times daily for a total daily dose of approximately 9,600,000 HUT. Concurrently, the patient received three nutritional supplement capsules three times daily given with food and two calcium capsules given once per day with the evening meal. The patient regained the strength and feeling she lost in her right leg. In addition, an unexplained stiffness and pain in her right hand also improved.
Example 3
A 79-year-old male sustained a back injury and was advised by doctors that the physical trauma of the injury would take approximately six months to heal. The patient, in hopes of a shortened healing time, began taking the Aspergillus oryzae protease preparation and nutritional supplement regimen of the present invention. The patient received six grams of Aspergillus oryzae protease preparation of the present invention dissolved in water four times daily on an empty stomach, for a total daily dose of approximately 9,600,000 HUT. Concurrently, the patient received three nutritional supplement capsules three times daily given with food. Within 1 month of beginning the protocol described herein, the patient was pain free and regained both flexibility and range of motion.
Example 4
An 84-year-old woman diagnosed as having severe Alzheimer's disease was unable to communicate with her family, was confined to a chair and necessitated the use of diapers. The patient was placed on the protease and dietary supplement protocol of the present invention. She received six grams of the claimed Aspergillus oryzae protease preparation dissolved in water four times daily on an empty stomach, for a total daily dose of approximately 9,600,000 HUT. Concurrently, the patient received three nutritional supplement capsules three times daily given with food. Within two weeks, the patient was able to walk, participate in conversations and recognized family members.
Example 5
A 54-year-old female patient was diagnosed with chronic obstructive pulmonary disease (COPD) based on a chest X-Ray, breathing test and physical exam by a pulmonologist. The patient was placed on a tiotropim bromide inhaler and a levalbuterol inhaler. In addition to these therapies, the patient also began taking six grams of the Aspergillus oryzae protease preparation of the present invention dissolved in water four times daily on an empty stomach, for a total daily dose of approximately 9,600,000 HUT. Concurrently, the patient received three nutritional supplement capsules three times daily given with food and two calcium capsules given once per day with the evening meal. After one week, her fatigue was drastically decreased and energy and concentration markedly increased. Approximately 1 month later, the patient increased her nutritional supplement dose to 4 capsules three times daily. Within days of increasing the dose, the patients energy and concentration further improved to the point where day-time naps were no longer necessary.
Example 6
A 55 year-old-female patient was diagnosed with osteopenia, a reduction in bone tissue and density. The patient was placed on the protease and dietary supplement protocol of the present invention. She received six grams of the claimed Aspergillus oryzae protease preparation dissolved in water four times daily on an empty stomach, for a total daily dose of approximately 9,600,000 HUT. Concurrently, the patient received three nutritional supplement capsules three times daily given with food and two calcium capsules given once per day with the evening meal. Since beginning the protease and nutritional supplement protocol claimed herein, the patient has exhibited complete reversal of bone and tissue loss associated with bone density loss.
Example 7
A 57 year-old-female patient was diagnosed with a sub-retinal hemorrhage. The patient was placed on the protease protocol of the present invention. She received six grams of the claimed Aspergillus oryzae protease preparation dissolved in water once daily on an empty stomach, for a total daily dose of approximately 2,400,000 HUT. Concurrently, the patient received three nutritional supplement capsules three times daily given with food and two calcium capsules given once per day with the evening meal. One week after beginning the protocol, an improvement of 25% was noted. Sixty days after onset of treatment, an improvement of 90% was noted.
Example 8
A 64 year-old-male patient accidentally scalded his left hand with boiling water leading to blistering, edema, inflammation and swelling along with severe pain. After placing the scalded hand under cold water for approximately 14 minutes, the patient took 1,000 mg of Paracetamol tablets. The wound was bandaged with a Urgutol dressing. The patient then received six grams of the claimed Aspergillus oryzae protease preparation dissolved in water, on an empty stomach. Within 30 minutes, the severe pain was eliminated and within 30 minutes the swelling and inflammation had been considerably reduced. Approximately 7 hours after receiving the first dose of the claimed Aspergillus oryzae protease preparation, the patient was administered a second dose of 6 grams of the claimed preparation dissolved in water, for a total daily dose of 4,800,000 HUT. Within 35 minutes of receiving the second dose, the discomfort was completely eradicated and the areas of inflammation were noticeably disappearing. Two days later, when the dressings were removed, the hand appeared to be completely normal, with virtually no signs of the accident.
Example 9
A 3-year-old thoroughbred fully was treated with the Aspergillus oryzae protease preparation of the present invention after suffering with tying up syndrome. The horse received a single dose of the enzyme preparation claimed herein at a dose of 27 grams, 10,800,000 HUT, dissolved in water on an empty stomach. Within minutes the horse exhibited relaxed muscularity and walked out of the severe cramping discomfort.
Example 10
A mare suffering from a hematoma was administered the protease preparation of the present invention. The Aspergillus oryzae protease preparation was administered at a dose of 27 grams four times daily on an empty stomach for a total daily dose of 43,200,000 HUT per day. No other treatment was used in this case. Within four days of treatment the hematoma was no longer detectable.
Example 11
An adult male horse was diagnosed with a severely injured coffin joint in his right forelimb. According to the horse's veterinarian, there was no chance for recovery and it was suggested that the horse be euthanized. The horse went from lame to crippled to being forced to lay down only standing to urinate and sometimes eat. It was at this time that the horse was placed on the Aspergillus oryzae protease preparation of the present invention. The horse received 27 grams of Aspergillus oryzae protease preparation four times daily on an empty stomach for a total daily dose of approximately 43,200,000 HUT per day. In addition, the horse received the equivalent of 45 capsules of the nutritional supplement in powder form twice daily with feedings. Within six weeks he began standing for a significantly longer period of time putting all of his weight on his two back legs. Two months later, he began supporting himself on three limbs. Six weeks following that, he began slowly adding weight back to his injured right forelimb. Five months after beginning the protocol the grating and popping sound of bone on bone contact was almost totally gone. The horse soon regained the ability to walk on all four legs.
Example 12
An 8-year-old Jack Russell terrier was diagnosed with Lyme's Disease. Upon examination the dog was found to be suffering badly from renal failure. The veterinarian gave the dog a very poor prognosis stating that she had never seen a dog doing as badly as this dog recover from renal failure. The dog began receiving three grams of Aspergillus oryzae protease preparation of the present invention on an empty stomach three times daily (3,600,000 HUT). In addition, the dog received two nutritional capsules twice daily with meals. Within two months the dog made a complete recovery and was back to digging and hunting as she was before the illness.
Example 13
A 9-year-old Welsh Corgi was diagnosed with chondrosarcoma in his right nasal cavity. The veterinarians gave the dog between one week and one month to live. The dog also received pain relieving medications from the veterinarian. Soon after this, the dog began treatment with the protease and nutritional supplement protocol of the present invention. He received three grams of Aspergillus oryzae protease dissolved in water on an empty stomach four times daily for a total daily dose of approximately 4,800,000 HUT per day. In addition, the dog also received three nutritional capsules three times daily with meals. After only a few of days of taking the enzyme and nutritional supplement protocol the dog markedly improved so that he was taken off the pain relieving medication. After three-four weeks the dog was breathing through his nostrils freely again and regained both energy and appetite. After six months the enzyme dose was discontinued and reinstituted as a maintenance dose of 3 grams three times daily. One year later the dog exhibited no evidence of chondrosarcoma.
Example 14
A 7-year-old female Rottweiler was diagnosed with osteosarcoma. According to the veterinarian unless limb salvage procedures were to be undertaken, the most rapid and potentially curable option was partial or total limb amputation. The elective surgery was declined and the dog was placed on the enzyme protocol of the present invention. The dog received six grams of the Aspergillus oryzae protease preparation dissolved in water or in capsule form on an empty stomach four times daily, for a total daily dose of approximately 9,600,000 HUT per day. In addition, the dog received three nutritional supplement capsules three times daily with food. On day 50 after beginning the enzyme protocol a small fluid filled mass was found. On day 56 the small mass was drained. On day 63 post enzyme treatment, the dog was taken to another veterinarian. This veterinarian noticed that the primary tumor had become soft and ulcerated. A second mass was found to be totally necrotic. The dog was maintained on the enzyme protocol and was given Baytril for possible infection associated with the large amount of necrotic tissue sloughing-off from the tumor mass. On day 65 post enzyme treatment the dog was taken to the emergency room for massive bleeding from the tumor which could not be stopped after routine bandage change. The dog was given a sedative to lower blood pressure. The necrotic tissue was removed and the area was packed with sterile gauze and the pressure bandage was replaced. Surgery was scheduled for day 68 after the commencement of enzyme therapy. Surgery was performed to remove additional necrotic tissue. At this time laser surgery was also performed to cauterize the main feeder vein to the primary tumor in hopes of controlling the bleeding. During the surgery, the surgeon found that the second mass has also become totally necrotic as well as the surrounding tissue. The second mass was removed. The primary tumor was found to be full of pus and serous fluid.
Example 15
A 13-year-old Black Labrador Retriever developed a mass on his limb. Upon noticing the mass, the dog began treatment with the protease protocol of the present invention. He received six grams of Aspergillus oryzae protease dissolved in water on an empty stomach four times daily for a total daily dose of 9,600,000 HUT per day. After 4 weeks of treatment, the dog was scheduled for surgery to remove the mass. Upon removal of the mass, the, the pathologist that removed the mass noted that the tumor was >90% necrotic. | A method for treating various diseases, conditions and injuries with a protease preparation derived from Aspergillus orzyze and made using potato dextrin as the carbohydrate source is described. The method comprises orally administering the Aspergillus oryzae protease preparation on an empty stomach and in an amount greater than about 2,000,000 HUT per day. Additionally, a method for treating various diseases, conditions and injuries with a protease derived from Aspergillus oryzae made using potato dextrin as the carbohydrate source along with a nutritional supplement of vitamins and minerals is also described. The method comprises orally administering the Aspergillus oryzae protease preparation on an empty stomach in an amount of greater than 2,000,000 HUT per day and administering the dietary supplement of vitamins and minerals orally with food. | 0 |
This is a division of application Ser. No. 401,494, filed July 26, 1982 now U.S. Pat. No. 4,511,706.
BACKGROUND OF THE INVENTION
The present invention relates to poly[alkylene-4,4'-(ethylenedioxy)bis benzoate] copolymers as well as surgical devices formed therefrom. More particularly, this invention relates to flexible monofilament surgical sutures having unique handling and knot-tying characteristics.
Many natural and synthetic materials are presently used as surgical sutures. These materials may be used as single filament strands, i.e. monofilament sutures, or as multifilament strands in a braided, twisted or other multifilament construction. Natural materials such as silk, cotton, linen, and the like, do not lend themselves to the fabrication of monofilament sutures and are accordingly used mostly in one of the multifilament constructions.
Certain synthetic materials which are extruded in continuous lengths can be used in monofilament form. Common synthetic monofilament sutures include polypropylene, polyethylene and nylon 6. Such monofilament sutures are preferred by surgeons for many surgical applications due to their inherent smoothness and noncapillarity to body fluids.
Available synthetic monofilament sutures all suffer to a greater or lesser degree from one particular disadvantage, that is relative stiffness. Besides making the material more difficult to handle and use, suture stiffness or low compliance can adversely affect knot-tying ability and knot security. It is because of the inherent stiffness of available monofilament sutures that many suture materials are braided or have other multifilament constructions with better handling, flexibility and conformity.
Most monofilament sutures of the prior art are also characterized by a high degree of stiffness. This makes knot-tying difficult and reduces knot security. In addition, the low compliance and limited ductility prevent the suture from "giving" as a newly sutured wound swells, with the result that the suture may place the wound tissue under greater tension than is desirable, and may even cause some tearing, cutting or necrosis of the tissue.
The problems associated with the use of low compliance sutures in certain applications were recognized in U.S. Pat. No. 3,454,011, where it was proposed to fabricate a surgical suture composed of Spandex polyurethane. Such sutures, however, were too elastic and did not find general acceptance in the medical profession.
Recently issued U.S. Pat. No. 4,224,946 describes a monofilament suture with good flexibility and knot strength, which suture is composed of segmented polyetheresters which contain (1) a polymeric block of polyalkylene ethers and (2) a polymeric block of aromatic dicarboxylic acids or cycloaliphatic acids with short chain aliphatic or cycloaliphatic diols. Similar subject matter is disclosed in Belgian Pat. No. 880,486.
The ethylene glycol polyester of the subject diacid moiety, 4,4'-(ethylenedioxy)bis benzoic acid, has been known for some time, (C.A. Registry No. [24980-45-8] if prepared from the acid, [26373-72-8] if prepared from the dimethyl ester) and, in fact, its ethylene glycol/polytetramethylene oxide copolymers (C.A. Registry Nos. [9071-04-9] and [51884-53-8] have been prepared:
CA 76 11461Oy
CA 80 83814u mentioned in index only
CA 81 171028s
CA 81 P12175g
CA 83 P195002w manufacture of elastic fiber
CA 84 P75556d polyester composite fibers with rubber-like elasticity)
as well as copolymers based on polyethylene oxide. These polyesters have been described as possessing improved crimpability, dyeability, and moisture absorption properties.
The 1,4-butanediol polyester of the subject diacid moiety is disclosed in Chemical Abstracts [52826-06-9]. In a 1978 paper (C.A. 89 60077c) which relates to the transesterification of dimethyl esters of aromatic dicarboxy acids with α-hydro-ω-hydroxy poly(oxyethylene)s and α,ω-alkanediols, a polytetramethylene oxide/1,4-butanediol copolymer based on the subject diacid moiety was made.
In spite of the fact that several polyethers could be incorporated chemically to toughen and lower the modulus of related polyesters, it is generally accepted that linear thermoplastics possessing a high initial modulus are more difficult to modify to increase compliance. Fibers of the (all hard) homopolymers of the subject invention were found to possess moduli in excess of 1.5 million psi, which renders it unsuitable for producing monofilament sutures.
Patents that relate to (2-alkenyl or alkyl)succinates are U.S. Pat. No. 3,542,737 and U.S. Pat. No. 3,890,279. None of these patents discloses the present copolymers or modifications thereof.
Theory and experience in the art of fiber chemistry predict that branching (such as that present in the instant copolymers) may inhibit fiber formation and will exert a deleterious effect on the tensile properties of any resulting fibers due to the inability of the unoriented branch to contribute to the load bearing capacity of the fiber; and by the stearic interference posed by the branch to chain alignment during fiber orientation. It is therefore surprising that strong fibers, in particular strong, flexible compliant fibers may be formed from the present copolymers with pendant hydrocarbon chains. As will be seen from Table 1, Example (i), homopolymers prepared from the 1,4-butanediol polyester of the subject diacid moiety, have a modulus of 1,678,000 psi. It is surprising that the modulus of certain of the copolymers of the present invention is reduced to only 64,000 psi.
It is an object of the present invention to provide a novel copolymer of poly(alkylene-4,4'-(ethylenedioxy)bis benzoate) as well as surgical devices formed therefrom. It is a further object of the present invention to provide a novel flexible, thermoplastic monofilament suture or ligature of said copolymer, having a diameter of from about 0.1 to 50 mil and possessing unique and desirable physical properties. Yet a further object of the present invention is to provide a Cobalt 60 sterilizable monofilament with lower modulus, better hand and more desirable tie-down characteristics than those of monofilaments of polypropylene. It is a further object of this invention to provide a monofilament suture with a desirable degree of ductility to accommodate changing wound conditions. It is yet another object of this invention to provide a monofilament suture with the flexibility and knot-tying characteristics of a braided suture. These and other objects will be made apparent from the ensuing description and claims.
SUMMARY OF THE INVENTION
The present invention relates to a copolymer comprising a multiplicity of recurring A and B units having the following general formula: ##STR1## wherein
x and y are numbers having average values such that the B units comprise from 1 to 55 weight percent of the copolymer, and the A units comprise the remainder,
n is 2 to 8, and
R represents a linear or branched alkyl or alkenyl radical with a chain length of 4 to 30 carbon atoms, or a mixture of such radicals with different chain lengths.
In accordance with an embodiment of the invention, n is 4 and R has a chain length of 14-18 carbon atoms, the copolymer having an inherent viscosity of between 0.5 and 2.2 and a melting temperature of between 100° and 200° C. Preferably B comprises from 20-40 weight percent of the copolymer. A preferred copolymer composition has an inherent viscosity of between 0.8 and 1.5, and a melting temperature of between 135° and 170° C.
The most preferred embodiments of this invention include those copolymers in which R is a hexadec-2-enyl group CH 2 CH═CH--(CH 2 ) 12 CH 3 , and the A and B units are present on about a 72/28 mole basis; and R being a mixture of tetradec-2-enyl and octadec-2-enyl groups, the latter two R groups being present in about a 50/50 ratio (molar), the A and B units being present on about a 72/28 mole basis.
The invention also comprises surgical devices (especially sutures and clips) formed from the copolymer.
A size 3/0 strand of a filament of the present invention, has the following combination of mechanical properties:
Knot strength--at least 20,000 psi
Tensile strength--at least 30,000 psi
Young's modulus--less than about 600,000 psi
Elongation--from about 20% to 80%
Monofilament sutures of the present invention (having a size 3/0 strand) are preferably characterized by the following combination of mechanical properties:
Knot strength--30,000 to 65,000 psi
Tensile strength--45,000 to 100,000 psi (more preferably 60,000 to 100,000 psi)
Young's modulus--75,000 to 600,000 psi (more preferably 75,000 to 250,000 psi)
Elongation--from 20% to 55%
Sutures possessing the above characteristics may be prepared by melt extrusion, forming a continuous filamentry strand, and drawing the extruded filament to obtain the desired suture properties.
Monofilament sutures having physical properties in accordance with the present invention are particularly useful in many surgical procedures where the suture is used to close a wound which may be subject to later swelling or change in position. The combination of low Young's modulus and moderate to high elongation provides the suture with an appreciable degree of ductility and high compliance under low applied force. As a result, the suture is able to "give" to accommodate swelling in the wound area. In addition, the ductility and high tensile strength of the suture allow the suture to stretch during knot tie-down so that the knot "snugs down" for improved tying ability and knot security with a more predictable and consistent knot geometry regardless of variations in suture tying technique or tension.
Within the scope of the present invention is a filament as described above having a surgical needle attached to at least one end and useful as a surgical suture. Also within the scope of the present invention is such a filament or surgical suture in a sterile condition, and in addition such filament or sterile suture, packaged in a sterile enclosure. Also within the scope of the present invention is a method of closing a wound by approximating and securing the wound tissue with a filament or surgical suture of the present invention.
As may be seen from the attached Table 1, the copolymers of the present invention may be melt extruded into filaments suitable for use as synthetic sutures which are compliant and yet strong. Table 1 compares the properties of fibers formed from the present copolymer with those formed from other polymers. Specifically, Example (i) is the homopolymer of the 1,4-butanediol polyester of the subject diacid moiety. The remaining copolymers listed in Table 1 are, in each case, copolymers of the 1,4-butanediol polyester of the subject diacid moiety, with different types of non-crystallizable chain sequences (a) (known as soft-segments) which are listed at the bottom of Table 1. It will be noted that the homopolymer of Example (i) gives rise to fibers possessing moduli in excess of 1.5 million psi. Copolymers based in part on dimer acids (4G-D) according to Example (iv) as well as copolymers based in part on polyether [Examples (ii) and (iii)] give rise to values between about 250,000 and 500,000 psi even though the weight percent of the "soft" non-crystallizable portion ranges from 20% to 30%. Indeed even a polymer made to contain 30 weight percent of tetramethylene-2-octadecenyl succinate (Example IX) gives rise to fibers exhibiting a 350,000 psi Young's modulus. Polymers of Examples I, II and X provide unexpected results. The copolymer of Example I which contains 30 weight percent tetramethylene-2-hexadecenyl succinate moieties and the copolymer of Example II in which the "soft" segment is based on a mixture of tetramethylene-2- tetradecenyl succinate and tetramethylene-2-octadecenyl succinate give rise to compliant yet relatively strong fibers.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The copolymers of the present invention are prepared by the polycondensation of a 4,4'-(ethylenedioxy)bis benzoate (preferably the dimethyl ester); a diol (preferably 1,4-butanediol); and a (2-alkenyl or alkyl) succinic anhydride. A (2-alkenyl or alkyl) succinic acid or a suitable derivative, such as a dialkyl ester [for example, dimethyl(2-alkenyl or alkyl)succinate], may be substituted for the anhydride and, in addition, a mixture of more than one(2-alkenyl or alkyl) succinic anhydride may be used. The diacid, 4,4'-(ethylenedioxy)bis benzoic acid, may be used instead of the corresponding ester. ##STR2## The diacid 4,4'-(ethylenedioxy)bis benzoic acid is prepared by reaction of 1,2-dihaloethane and p-hydroxybenzoic acid in the presence of a suitable base, the reaction being followed by acidification to produce the free acid (which, after purification, can be used in a direct polymerization). The dimethyl ester is prepared by Fisher esterification and purified by recrystallization from ethyl acetate. Alternatively, the diester can be prepared directly by the reaction of a 1,2-dihaloethane with methyl p-hydroxy benzoate, prepared in a nonaqueous medium in the presence of a suitable base. The dimethyl ester is used to prepare by polycondensation techniques the polyesters listed in Table 1.
The required diols are commercially available. The substituted succinic anhydrides can be prepared by the "ene" reaction of maleic anhydride and an olefin (preferably a terminal olefin): ##STR3## wherein R' is alkyl.
In the instance wherein R is alkyl, rather than alkenyl, the reactant may be prepared by hydrogenation of the corresponding alkenyl-succinic anhydride.
The polymerization may be run in the absence or, preferably, in the presence of stabilizers such as hindered phenols, {e.g., Irganox 1098 sold by Ciba-Geigy [N,N'-hexamethylene bis(3,5-ditertbutyl-4-hydroxy hydrocinnamide)]} or secondary aromatic amines, {e.g., Naugard 445 sold by Uniroyal [4,4'-bis(α,α-dimethylbenzyl)diphenylamine]}. Acetates, oxides and alkoxides of numerous polyvalent metals may be employed as the catalyst such as, for example, zinc acetate, or magnesium acetate in combination with antimony oxide, or zinc acetate together with antimony acetate. However, the preferred catalyst for the polymerization is a mixture of about 0.04 to 0.1% (based on total charge weight) tetrabutyl orthotitanate and about 0.004 to 0.006% magnesium acetate. If a dyed product is desired, a compatible dye such as, for instance, D&C Green No. 6, can be added to the polymer or monomer mixture in concentrations of up to 0.5% based on expected polymer yield.
The polymerization is run in two stages. In the first stage, run under nitrogen at temperatures ranging from about 160° to 250° C., polycondensation via transesterifica-tion and esterification occurs, resulting in lower molecular weight polymers and oligomers. These are converted to higher molecular weight materials in the subsequent step run at about 220° to 255° C., at pressures of less than 1 mm of mercury. The resulting polymers, exhibit inherent viscosities (measured at a 0.1 g/dl concentration in hexafluoroisopropyl alcohol at 25° C.) of 0.5 to 2.2, and crystallinity of about from 20% to 50%. The Tm of the polymers (by microscopy), depending on composition, varies from about 90° to 230° C.
A summary of polymer properties is set forth in Table 1.
The polymers are readily extruded in a ram-type extruder, as for an example an Instron Capillary Rheometer at about 10° to 70° C. above the resin Tm, depending on the polymer's molecular weight. The resulting extrudates can be drawn and the total draw ratio may vary from 3X to 7X.
The unique oriented fibers exhibit an unexpected combination of properties. For example, strands of about 6 to 8 mil diameter displayed knot strenghts of 23,000-37,000 psi, straight tensile strengths of 50,000-69,000 psi and a Young's modulus of less than 350,000 psi. Percent elongations range from 23% to 37%.
In summary, the polymers described lend themselves to ready extrusion and drawing to strong and supple fibers which are useful as high compliance "ultra limp" sutures. The fibers are Cobalt 60 sterilizable without significant change in properties (in contrast to polypropylene fibers) and retain their strength in aqueous biological environment (in contrast to nylon 6 fibers).
The present polymers may also be used to prepare solid products (molded or machined) such as clips.
General Polymerization Procedure
The desired amounts of dimethyl 4,4'-(ethylenedioxy)bis benzoate, a 2-alkenyl succinic anhydride (or an alkyl succinic anhydride), a 1.3 to 2.0 molar excess of an alkylene diol per mole of diacid moieties (benzoate plus anhydride) and a given stabilizer are placed under nitrogen into a dry reactor fitted with an efficient mechanical stirrer, a gas inlet tube and a takeoff head for distillation. The system is heated under nitrogen to 160° C. and stirring is begun. To the stirred reaction mixture the required amount of catalyst is added. (Alternatively, the catalyst may be added along with the other reagents at the start, if they are dry). The mixture is then stirred and heated under nitrogen for given time periods at 190° C. (2 to 4 hours) and 220° C. (1 to 3 hours). The temperature is subsequently raised to 230° to 255° C. and over a period of 0.4 to 0.7 hours, the pressure is reduced in the system to about 1 mm/Hg (preferably 0.05 mm to 0.1 mm). (Alternatively, after reaction under nitrogen, the mixture may be allowed to cool to room temperature, vacuum applied at a later date and the batch heated to the reaction temperature). Stirring and heating under the above conditions is continued to complete the polymerization. The endpoint is determined by either (a) estimating visually the attainment of maximum melt viscosity, (b) measuring inherent viscosity or melt indices of samples removed from the reaction vessel at intermediate time periods, or (c) using a calibrated torquemeter (attached to the stirrer of the reactor).
At the end of the polymerization cycle the molten polymer is extruded and pelletized (or slow cooled in the glass reactor, isolated and ground in a mill). The polymer is dried at 80° to 110° C. for 8 to 16 hours under reduced pressure. One alternate method of polymerization is set forth in U.S. Pat. No. 3,890,279.
General Extrusion Procedure
Extrusion using the Instrom Capillary Rheometer produces an extrudate which upon drawing (3x to 7x ratio) yields fibers in the 7 to 13 ml diameter range. The polymers are packed in the extrusion chamber and extruded through a 40 mil die after a dwell time of 9 to 13 minutes at the extrusion temperature. The ram speed is 2 cm/minute. While extrusion temperatures depend both on the polymer Tm and on the melt viscosity of the material at a given temperature, extrusion at temperatures of 10° to 70° C. above the Tm is usually satisfactory. The extrudate is taken up at a speed of about 18 to 24 feet per minute.
General Drawing Procedure
The extrudate (diameter range, 19-23 mils) is passed through rollers at an input speed of four feet per minute and then over a hot shoe or into a heated draw bath of glycerine. The temperatures of the hot shoe or draw bath vary from about 50° C. to 120° C. The draw ratio in this first stage of stretching varies from 3x to 6x. The drawn fibers are then placed over another set of rollers into a glycerine bath (second stage) kept at temperatures ranging from 60° C. to 100° C. Draw ratios of up to 2x are applied but usually only a slight amount of fiber extension (1.25x) is found desirable at this stage. Finally, the fiber is passed through a water wash, dried and taken up on a spool.
The copolymers of the present invention may be spun as multifilament yarn and woven or knitted to form sponges or gauze, (or nonwoven sheets may be prepared) or used in conjunction with other compressive structures as prosthetic devices within the body of a human or animal where it is desirable that the structure have high tensile strength and desirable levels of compliance and/or ductility. Useful embodiments include tubes, including branched tubes, for artery, vein or intestinal repair, nerve splicing, tendon splicing, sheets for tying up and supporting damaged kidney, liver and other abdominal organs, protecting damaged surface abrasions, particularly major abrasions, or areas where the skin and underlying tissues are damaged or surgically removed.
In more detail, the surgical and medical uses of the filaments of the present invention include, but are not necessarily limited to:
Knitted products, woven, or nonwoven including velours
a. burn dressings
b. hernia patches
c. medicated dressings
d. fascial substitutes
e. gauze, fabric, sheet, felt or sponge for liver hemostasis
f. gauze bandages
In combination with other components -
a. arterial graft or substitutes
b. bandages for skin surfaces
c. burn dressings (in combination with polymeric films)
Solid products, molded or machined
a. orthopedic pins, clamps, screws and plates
b. clips
c. staples
d. hooks, buttons, and snaps
e. bone substitutes (e.g., mandible prosthesis)
f. needles
g. intrauterine devices
h. draining or testing tubes or capillaries
i. surgical instruments
j. vascular implants or supports
k. vertebal discs
l. Extracorporeal tubing for kidney and heart-lung machines
m. artificial skin and others.
TABLE 1__________________________________________________________________________Physical Properties of Fibers of Poly[tetramethylene-4,4'-(ethylenedioxy)bis benzoate]and its Corresponding Polyether, Dimerate and Alkenyl SuccinateCopolymers Example No. (i) (ii) (iii) (iv) I II VIII IX X__________________________________________________________________________Type of non-crystallizable None.sup.(b) PTMO- PTMO- 4G- 4G- 4G- 4G 4G 4Gchain segment.sup.(a) EDBB EDBB D S.sub.16 S.sub.14 /S.sub.18 S.sub.18 S.sub.18 S.sub.18Wt. % of non-crystallizable 0.00 20 30 25 30 14 25 30 40chain segment 16Mole % of non-crystallizable 0.00 7 11 16 28 14 22 27 36chain segment 14Polymer Inherent Viscosity, 1.40 1.70 1.13 0.99 1.06 0.88 0.78 0.66 0.72dl/g (HFIP, 25° C., 0.1 g/dl)Polymer Tm (by 198 180 173 166 150 150 158 163 150microscopy), °C.Extrusion Temperature, °C. 260 240 200 250 200 200 240 175 185Drawing ConditionsOne Stage "Hot-Shoe":Ratio 5 × 5 × -- -- -- -- -- -- --Temp., °C. 101 101 -- -- -- -- -- -- --Multi-Stage Glycerin Draw Bath:1st Stage:Ratio -- -- 5 × 5 × 5 × 5 × 5 × 7 × 5 ×Temp., °C. -- -- 53 55 55 52 55 58 502nd Stage:Ratio -- -- 1.2 × 1.3 1.2 × 1.2 1.3 × -- 1.2 ×Temp., °C. -- -- 70 70 70 70 75 -- 75Overall Draw Ratio 5 × 5 × 6 × 6.5 × 6 × 6 × 6.5 × 7 × 6 ×Physical Properties of FibersDiameter, mil 9.5 9.3 8.9 7.5 7.7 7.9 6.6 6.5 8.1Straight Tensile Strength, 59 65 51 71 65 65 69 53 50psi × 10.sup.-3Knot Tensile Strength, 48 39 31 30 31 35 37 28 23psi × 10.sup.- 3Elongation, % 27 45 42 24 31 36 26 23 37Modulus, psi × 10.sup.-3 1678 471 283 356 166 140 314 350 64__________________________________________________________________________ .sup.(a) PTMOEDBB = polytetramethylene oxide4,4(ethylenedioxy)bis benzoat 4GD = tetramethylene dimerate (from oleic acid dimerization) 4GS.sub. 16 = tetramethylene2-hexadecenylsuccinate (i.e. n = 4 and R = 2hexadecenyl) 4GS.sub. 14 = tetramethylene2-tetradecenylsuccinate (i.e. n = 4 and R = 2tetradecenyl) 4GS.sub. 18 = tetramethylene2-octadecenylsuccinate (i.e. n = 4 and R = 2octadecenyl) .sup.(b) The 1,4butanediol based homopolymer, poly[tetramethylene4,4(ethylenedioxy)bis benzoate
The following are specific examples for producing new copolymers in accordance with the present invention.
EXAMPLE I
To a flame dried mechanically stirred, 100 ml two-neck glass reactor, suitable for polycondensation, is charged 19.60 g of dimethyl 4,4'-(ethylenedioxy) bis benzoate (59.34 mmoles), 7.41 g of 2-hexadecenylsuccinic anhydride (23.0 mmoles), 14.83 g of 1,4-butanediol (164.6 mmoles), and 0.1510 g Erganox 1098 (0.5% of expected weight of formed polymer).
After purging the reactor and venting with nitrogen, the reactor is immersed in a silicone oil bath and connected to a gas supply to maintain nitrogen at 1 atmosphere of pressure. The stirred mixture is heated to 160° C.; the side neck is unstoppered and under a flush of nitrogen, 0.16 ml of an alcoholic tetrabutyl orthotitanate/magnesium acetate solution is carefully injected. (Preparation of catalyst solution: to 0.5000 g of anhydrous magnesium acetate is added 16.5 ml of methanol and 33 ml of a tetrabutyl titanate in n-butyl alcohol solution, previously prepared by mixing 12.3 ml of tetrabutyl titanate in 100 ml of n-butyl alcohol). After restoppering, the stirred mixture is heated to and maintained at 190°, 200°, and 220° C. for 1, 2, and 3 hours respectively, during which time the distillate is collected. The reactor is allowed to cool to room temperature. Some time later, the reactor is evacuated and heated to 150° C. to melt the reaction mass. Over the course of one hour, the temperature is slowly raised to 240° C. which is maintained for 6 hours. The collection of distillates is continued during the low pressure (less than 100 microns) stage of the polymerization. The reactor is removed from the oil bath and allowed to cool. The formed polymer is isolated, ground and then dried at 80° C. for 8 hours in vacuo. The polymer has an inherent viscosity of 1.06 dl/g as determined in hexafluoroisopropanol at 25° C. and a concentration of 0.1 g/dl.
EXAMPLES II TO X
A polymerization is carried out as described in Example I except that the reactor is charged with the ingredients listed in Table 2. The temperature at which the polymers melt is dependent on the composition so that in the transition from reaction under nitrogen to reaction under vacuum, a higher or lower temperature may have to be employed to melt the cooled reaction mass.
Table 3 lists the types of A and B units present in the copolymers obtained according to each of Examples I through X, as well as the weight and mole percent of each unit present in each copolymer.
TABLE 2__________________________________________________________________________Amount of DimethylExample4,4'-(ethylenedioxy) Anhydride DiolNo. bis benzoate (g) Type Amount (g) Type Amount (g)__________________________________________________________________________I 19.60 2-hexadecenylsuccinic 7.41 1,4-butanediol 14.83II 19.60 2-tetradecenylsuccinic 3.38 1,4-butanediol 14.83 2-octadecenylsuccinic 4.03III 19.60 2-butenylsuccinic 6.17 1,4-butanediol 17.91IV 19.60 2-triacontenylsuccinic 7.96 1,4-butanediol 13.46V 26.60 2-decenylsuccinic 1.16 1,4-butanediol 15.39VI 14.00 2-hexadecenylsuccinic 12.34 1,4-butanediol 14.54VII 21.28 2-hexadecenylsuccinic 7.97 ethylene glycol 11.06VIII 21.00 2-octadecenylsuccinic 6.26 1,4-butanediol 14.68IX 19.60 2-octadecenylsuccinic 7.52 1,4-butanediol 14.56X 16.80 2-octadecenylsuccinic 10.02 1,4-butanediol 14.32__________________________________________________________________________ In addition to the diester, the anhydride, and the diol, to each run is charged 0.1510 g of Erganox 1098 and 0.16 ml of a catalyst solution. Preparation of catalyst solution: to 0.5000 g of anhydrous magnesium acetate is added 16.5 ml of methanol and 33 ml of a tetrabutyl titanate i nbutyl alcohol solution, previously prepared by mixing 12.3 ml of tetrabutyl titanate in 100 ml of nbutyl alcohol.
TABLE 3__________________________________________________________________________Example Weight Percent Mole PercentNo. Type of A Unit Type of B Unit A B A B__________________________________________________________________________I Tetramethylene-4,4'- Tetramethylene-2-hexadecenylsuccinate 70 30 72 28(ethylenedioxy) bisbenzoateII Same as in I Tetramethylene-2-tetradecenylsuccinate 70 14 72 14 Tetramethylene-2-octadecenylsuccinate 16 14III Same as in I Tetramethylene-2-butenylsuccinate 70 30 60 40IV Same as in I Tetramethylene-2-triacontenylsuccinate 70 30 79 21V Same as in I Tetramethylene-2-decenylsuccinate 95 5 94 6VI Same as in I Tetramethylene-2-hexadecenylsuccinate 50 50 53 47VII Ethylene-4,4'- Ethylene-2-hexadecenylsuccinate 70 30 72 28(ethylenedioxy)bisbenzoateVIII Same as in I Tetramethylene-2-octadecenylsuccinate 75 25 78 22IX Same as in I Tetramethylene-2-octadecenylsuccinate 70 30 73 27X Same as in I Tetramethylene-2-octadecenylsuccinate 60 40 64 36__________________________________________________________________________
EXAMPLE XI
Ten grams of the copolymer described in Example I are packed into the extrusion chamber of an Instron Rheometer equipped with a 40 mil die and, after 10 minutes of dwell time, the sample is extruded at a ram speed of 2 cm/minute, and a temperature of 200° C. The takeup speed of the extrudate is 18 ft/minute and the extrudate is quenched in ice water. The diameter of the extrudate is 19 to 23 mils.
The extrudate is drawn at 5x through a glycerine bath held at a temperature of 55° C. and at 1.2x through a second glycerine bath heated to 70° C. The resulting fiber is washed in a water bath (room temperature) to remove the glycerine and taken up on a spool. The total draw ratio for both the first and second drawing stage is 6x. Tensile data for fiber obtained by this and other extrusion and draw experiments are shown in Table 1. | Copolymers of an (ethylenedioxy)bis benzoate, an alkylene diol and a (2-alkenyl or alkyl) succinic anhydride, as well as surgical devices formed therefrom; especially, flexible monofilament surgical sutures having unique handling and knot-tying characteristics. | 2 |
BACKGROUND
1. Technical Field
The disclosure generally relates to portable electronic devices, and particularly to a portable electronic device which cannot be started when the portable electronic device is disassembled.
2. Description of Related Art
Manufacturers usually need much time and money to design and make new products. However, once a new product is on the market, commercial competitors of the manufacturer may reverse engineer the new product. That is, a competitor may disassemble the new product to learn the electronic and mechanical structures of the new product. The competitor can further analyze the functions of the new product after starting to disassemble the new product.
Therefore, there is room for improvement within the art.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the disclosure.
FIG. 1 is a schematic, exploded view of a portable electronic device, according to an exemplary embodiment.
FIG. 2 is a partially disassembled view of an assembly module and a circuit board of the portable electronic device of FIG. 1 .
FIG. 3 is an assembled view of the assembly module and the circuit board of FIG. 2 .
DETAILED DESCRIPTION
FIG. 1 is a schematic, exploded view of a portable electronic device 100 , according to an exemplary embodiment. The portable electronic device 100 includes a housing 10 , a circuit board 20 , a starting module 30 , and an assembly module 40 . The assembly module 40 assembles the housing 10 and the circuit board 20 together. When the assembly module 40 is disassembled from the housing 10 and the circuit board 20 , the portable electronic device 100 cannot be started by the starting module 30 .
The housing 10 includes a case 11 and a cover 12 . The case 11 includes a bottom wall 111 , and four side walls 112 extending perpendicularly up from four sides of the bottom wall 111 . The four side walls 112 together with the bottom wall 111 form a receiving space 113 for receiving the circuit board 20 . A plurality of positioning posts 114 extend up from two sides of the bottom wall 111 .
The cover 12 is matched with the case 11 , and can be attached to the case 11 with the help of the assembly module 40 . A plurality of positioning holes 121 are defined in two sides of the cover 12 , corresponding to the positioning posts 11 .
The circuit board 20 is a substantially rectangular board, which is received in the receiving space 113 . A plurality of mounting holes 21 are defined in the circuit board 20 . The mounting holes 21 correspond to the positioning posts 114 and the positioning holes 121 . When the circuit board 20 is received in the receiving space 113 , the mounting holes 21 are aligned with the positioning posts 114 and the positioning holes 121 . A plurality of pad groups 22 are attached on the circuit board 20 , corresponding to the mounting holes 21 . Each pad group 22 includes two opposite pads 221 surrounding the corresponding mounting hole 21 . Each pad 221 is substantially a semi-annular conductive sheet.
The starting module 30 includes a first starting member 31 , a second starting member 32 , a first connecting wire 33 , and a second connecting wire 34 . The first starting member 31 may be a central processing unit (CPU). The second starting member 32 may be a power supply for the CPU. The first and second starting members 31 , 32 may be integrated circuits for starting the portable electronic device 100 . The first and second starting members 31 , 32 are set on the circuit board 20 and are connected to the pads 221 in one of the pad groups 22 by the first and second connecting wires 33 , 34 . In particular, the first connecting wire 33 connects the first starting member 31 to one pad 221 of the one pad group 22 . The second connecting wire 34 connects the second starting member 32 to the other pad 221 of the one pad group 22 . The first and second connecting wires 33 , 34 are set inside the circuit board 20 , and are invisible from the outside of the circuit board 20 . When the two pads 221 of the pad group 22 are electrically connected, that is, the first starting member 31 is electrically connected to the second starting member 32 , the portable electronic device 100 can be started. Otherwise, the portable electronic device 100 cannot be started.
The assembly module 40 includes a conductive member 41 , and an assembly member 42 . The conductive member 41 may be a metallic annular sheet or washer. The conductive member 41 can be attached to the pad group 22 to electrically interconnect the two pads 221 . The assembly member 42 may be a screw or bolt, etc. The assembly member 42 can extend through the corresponding positioning hole 121 , the conductive member 41 , and the corresponding mounting hole 21 , and engage with the corresponding positioning post 114 . Thus, the case 11 , the cover 12 , and the circuit board 20 can be assembled together with the help of the assembly member 42 . In addition, the conductive member 41 is sandwiched between the circuit board 20 and the cover 12 , and attached to the pad group 22 . Thereby, electrical connection between the first starting member 31 and the second starting member 32 is completed by the conductive member 41 , and the portable electronic device 100 can be started.
When the assembly member 42 is disengaged from the positioning post 114 and the portable electronic device 100 is disassembled, the conductive member 41 is detached from the pad group 22 . Thus, the first starting member 31 is electrically disconnected from the second starting member 32 , and the portable electronic device 100 cannot be started. Therefore even though the portable electronic device 100 is disassembled, the working principles of the portable electronic device 100 cannot be easily further analyzed.
In other embodiments, the conductive member 41 can be omitted. When the case 11 , the cover 12 , and the circuit board 20 are assembled together with the help of the assembly member 42 , the assembly member 42 contacts the pads 221 surrounding the mounting hole 21 , and thereby electrically interconnects the first connecting wire 33 and the second connecting wire 34 . Thus, the portable electronic device 100 can be started.
In the above-described alternative embodiment, when the assembly member 42 is disengaged from the positioning post 114 and detached from the pads 221 , the first connecting member 31 is electrically disconnected from the second connecting member 32 . Thus, the portable electronic device 100 cannot be started by the starting module 30 .
It is believed that the exemplary embodiments and their advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the disclosure or sacrificing all of its material advantages, the examples hereinbefore described merely being preferred or exemplary embodiments of the disclosure. | An exemplary portable electronic device includes a housing, a circuit board, starting module set on the circuit board for starting the portable electronic device, and an assembly module. The assembly module helps assembles the housing and the circuit board together and forms a part of circuitry associated with the starting module. When the assembly module is disassembled from the housing and the circuit board, the starting module cannot start the portable electronic device. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This Application claims priority of Taiwan Patent Application No. 098107620, filed on Mar. 10, 2009, the entirety of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a navigation device, and in particular relates to a method for adjusting displayed navigation direction and a navigation device using the same.
2. Description of the Related Art
Due to application convenience and lower costs for GPS chips and modules, more and more navigation functions are being applied in consumer products such as mountain climbing navigation systems, personal tracking systems, and car navigation systems. Of the consumer product applications, car navigation systems are very popular.
Car navigation systems can be classified as embedded and portable navigation systems. Portable navigation devices can be further classified as GPS navigation devices, and personal navigation devices, wherein the GPS is built into portable devices such as personal digital assistants (PDA) or smart phones.
There are two ways to display information for conventional portable car navigation devices: one is North Up, wherein a map in a display is always displayed facing north; the other is Heading Up, wherein a map in a display is always displayed facing the direction of travel. The Heading Up display is the most commonly used.
However, requirements of users may not be met if a user needs to use a conventional portable car navigation device to point a direction as walking.
BRIEF SUMMARY OF INVENTION
A detailed description is given in the following embodiments with reference to the accompanying drawings. The object of the present invention is to provide a method for adjusting displayed navigation direction using sensors and a navigation device using the same.
The present invention provides a method for adjusting displayed map using sensors, applied in a navigation device. The method comprises: calculating a GPS-based rotating angle of the navigation device based on location information detected by a GPS module of the navigation device when a coordinate error value of the navigation device is less than a predetermined value; using a sensor of the navigation device to detect the sensor-based rotating angle of the navigation device when the coordinate error value of the navigation device is greater than the predetermined value; rotating a map on the screen according to one of the GPS-based rotating angle and the sensor-based rotating angle depending on the coordinate error value.
The present invention further provides a navigation device. The navigation device comprises: a screen for displaying a map; a GPS module for calculating a GPS-based rotating angle of the navigation device based on a location information detected by the GPS module of the navigation device when a coordinate error value of the navigation device is less than a predetermined value; a sensor for detecting a sensor-based rotating angle of the navigation device when the coordinate error value of the navigation device is greater than a predetermined value; and a microprocessor for rotating a map according to one of the GPS-based rotating angle and the sensor-based rotating angle depending on the coordinate error value.
BRIEF DESCRIPTION OF DRAWINGS
The present invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
FIG. 1 is a flowchart illustrating the method for adjusting displayed navigation direction using sensors according to an embodiment of the present invention; and
FIG. 2 is a diagram showing the structure of a navigation device of the present invention.
DETAILED DESCRIPTION OF INVENTION
The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
An embodiment of the present invention discloses a method for adjusting displayed navigation direction using sensors and a navigation device using the same.
The method for adjusting displayed navigation direction which uses sensors (sensors may be G-sensors and M-sensors which is abbreviated as G/M sensors, or gyroscopes herein) providing “what you see is what you get”, which is abbreviated as WYSIWYG. That is, when the navigation device is in a walk/jog mode, the interface of the navigation device displays a navigation map matching the direction of a user and when the user changes direction, the navigation map also correspondingly changes direction.
FIG. 1 is a flowchart illustrating the method for adjusting displayed navigation direction using sensors according to an embodiment of the present invention.
First, a current angle of a navigation device is defined as θ cur , the angle θ GM of the G/M sensor in the navigation device is initialized as zero, and a map direction Map rot of navigation interface of the navigation device is set (rotated) as θ cur (step S 11 ). It is determined whether a coordinate error value (i.e. Horizontal Dilution of Precision, HDOP) is less than a predetermined value such as 5 (HDOP<5) (step S 12 ).
The HDOP is a root-mean-square value derived from latitude value and precision error value. The smaller the root-mean-square value is, the higher the precision value is. In the embodiment, when the HDOP is smaller than the predetermined value, the precision is increased such that fine-tuning is executed. On the other hand, when the HDOP is larger than or equal to the predetermined value, the precision is lowered such that coarse-tuning is executed.
When the coordinate error value is smaller than the predetermined value, then a rotation angle θ gps of the navigation device is obtained by a GPS module of the navigation device (step S 13 ). Next, the current angle θ cur of the navigation device is subtracted from the rotation angle θ gps of the navigation device to obtain an angle variation value θ GMD therebetween (θ GMD =θ gps −θ cur ). The rotation angle θ GM of the G/M sensor is set as zero and the current angle θ cur of the navigation device is assigned as the rotation angle θ gps of the navigation device (θ cur =θ gps ) (step S 14 ). When the above-mentioned angle information is obtained, the map direction is set (rotated) as the current angle θ cur of the navigation device (Map rot =θ cur ) (step S 15 ).
When the coordinate error value is larger than or equal to the predetermined value, the angle θ GM1 of the navigation device is obtained by the G/M sensor of the navigation device (step S 16 ). Next, the rotation angle θ GM is subtracted from the rotation angle θ GM1 of the navigation device to obtain a angle variation value θ GMD therebetween (θ GMD =θ GM1 −θ GM ), the rotation angle θ GM of the G/M sensor is set as θ GM1 (θ GM =θ GM1 ) and the current angle θ cur of the navigation is assigned as the current angle θ cur plus the angel variation value θ GMD (θ cur =θ cur +θ GMD ) (step S 17 ). When the above-mentioned angle information is obtained, the map direction in the interface of the navigation device is set (rotated) as the current angle θ cur of the navigation device (step 15 ).
FIG. 2 is a diagram showing the structure of a navigation device of the present invention.
An embodiment of the present invention discloses a navigation device 200 . The navigation device includes a microprocessor 210 , a GPS module 220 , a G/M sensor 230 and a screen 240 .
When the navigation device 200 is initialized, the microprocessor 210 defines a current angle θ cur of the navigation device 200 according to satellite signals obtained from a GPS module 220 , initializes the rotation angle θ GM of the G/M sensor 230 as zero, and sets (rotates) a map direction Map rot in the screen 240 as the current angle θ cur (Map rot =θ cur ).
Next, the microprocessor 210 determines whether a coordinate error value (i.e. GDOP) of the navigation device is smaller than a predetermined value (e.g. 5, HDOP<5) according to the GPS module 220 . When the coordinate error value is smaller than the predetermined value, the microprocessor obtains a rotation angle θ GPS of the navigation device 200 by GPS module 220 .
Next, the microprocessor 210 subtracts the current angle θ cur of the navigation device 200 from the rotation angle θ gps of the navigation device 200 to obtain a angle variation value θ GMD therebetween (θ GMD =θ gps −θ cur ), sets the rotation angle θ GM of the G/M sensor 230 as zero, and assigns the current angle θ cur as the rotation angle θ gps (θ cur =θ gps ). When the above-mentioned angle information is obtained, the microprocessor 210 sets (rotates) the map direction as the current angle θ cur of the navigation device 200 (Map rot =θ cur ).
When the coordinate error value is larger than or equal to the predetermined value, the microprocessor 210 obtains the angle θ GM1 of the navigation device by the G/M sensor of the navigation device. Next, the microprocessor 210 subtracts the rotation angle θ GM from the rotation angle θ GM1 of the navigation device to obtain a angle variation value θ GMD therebetween (θ GMD =θ GM1 −θ GM ), sets the rotation angle θ GM1 of the G/M sensor as θ GM (θ GM =θ GM1 ) and assigns the current angle θ cur of the navigation as the current angle θ cur plus the angel variation value θ GMD (θ cur =θ cur +θ GMD ). When the above-mentioned angle information is obtained, the microprocessor 210 sets (rotates) the map direction in the interface of the navigation device as the current angle θ cur of the navigation device 200 .
It is noted that when the measurement of the GPS module is not accurate enough, the G/M sensor is used to assist measurement of displacement or rotation angle. Therefore, when the GDOP is small, the displacement or rotation angle may be measured accurately by only employing the GPS, in this case, the function of the G/M sensor may be ignored hence the angle measured by the G/M may be set as zero. On the contrary, when the GDOP is large, it is necessary to employ the G/M sensor to measure displacement or rotation angle. It is noted that in the embodiment, the method for adjusting displayed navigation direction is mainly applied in a walk mode, but it may also bee applied in a drive mode or other navigation modes.
The present invention, and its method and particular implementation can be presented in a type of program code. The program code may be contained in concrete medium such as soft disc, compassed disc, hard disc or any other machine-readable (e.g. computer-readable) storage medium. When the code is executed by a machine such as a computer, the machine is turned into a device of the present invention. The program code is also may be transmitted by certain transmitting medium such as wire, cable, optical fiber, or any other type of transmission. When the code is received, loaded into and executed by a machine such as a computer, the machine is turned into a device of the present invention. When implemented in a general purpose processing unit, the processing unit associated with the program code may be a particular device operated as the application-specific integrated circuit.
While the invention has been described by way of example and in terms of the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements. | A method for adjusting displayed map using sensors is disclosed, applied in a navigation device. The method includes steps of: calculating a GPS-based rotating angle of the navigation device based on location information detected by a GPS module of the navigation device when a coordinate error value of the navigation device is less than a predetermined value; using a sensor of the navigation device to detect the sensor-based rotating angle of the navigation device when the coordinate error value of the navigation device is greater than the predetermined value; rotating a map on the screen according to one of the GPS-based rotating angle and the sensor-based rotating angle depending on the coordinate error value. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an apparatus and method for decreasing drag force by controlling turbulent flow on a hull surface of a ship, and more particularly, to an apparatus and method for decreasing drag force by controlling turbulent flow on the hull surface by performing suction and ejection of fluid flowing around the hull surface to decrease friction resistance thereon.
[0003] 2. Description of the Related Art
[0004] When a ship is out at sea, friction resistance is caused on a hull surface of the ship due to vortex flow on the hull surface. This friction resistance generally takes a significant portion of the total resistive drag force which a ship is subject to at sea. For example, in case of an oil carrier, the friction resistance takes about 80% of the total drag force.
[0005] There has been a development in techniques of decreasing the friction resistance occurring on a hull surface of a ship. A widely used method is ejecting air or syrupy liquid from a bow side of a ship. However, there have been difficulties in decreasing the friction resistance in the conventional methods and apparatuses.
BRIEF SUMMARY OF INVENTION
[0006] The present invention provides an apparatus and method for decreasing drag force based on a control of turbulent flow on a hull surface of a ship, in which fluid flowing around the hull surface of a ship is sucked and ejected, and an ejection angle with respect to the hull surface is adjusted, to thereby control the turbulent flow on the hull surface.
[0007] The present invention also provides an apparatus and method for decreasing drag force by controlling turbulent flow on a hull surface of a ship, in which suction and ejection of fluid flowing around the hull surface extended from the inside of the hull of a ship is repeatedly performed by installing a pipe housing including a flexible air pipe or plates along the hull surface of a ship, to thereby control a turbulent flow boundary layer on the hull surface.
[0008] The present invention further provides an apparatus and method for decreasing drag force by controlling turbulent flow on a hull surface of a ship, in which the turbulent flow is locally controlled by installing an apparatus having a flexible air pipe or plates at a bow or stem of the ship.
[0009] In an exemplary embodiment of the present invention, there is provided a method for decreasing drag force by controlling turbulent flow in a hull surface of a ship in which fluid flowing around the hull surface of a ship is sucked and ejected to vary turbulent field of the fluid flow, and friction resistance is decreased by controlling an ejection angle with respect to the hull surface of a ship.
[0010] In another exemplary embodiment of the present invention, there is provided an apparatus for decreasing drag force by controlling turbulent flow on a hull surface of a ship, which includes a pipe housing which is installed on the hull surface of a ship and includes a plurality of slits, a flexible air pipe which is installed in the interior of the pipe housing and performs a contracting and/or expanding operation in association with an air pumping operation, and a pump which is connected to the flexible air pipe, for sucking and discharging the air.
[0011] In another exemplary embodiment of the present invention, there is provided an apparatus for decreasing drag force by controlling turbulent flow on a hull surface of a ship, which includes a pipe housing which is installed on the hull surface of a ship and includes a plurality of slits, plates which are installed in the pipe housing and positioned in the upper and lower portions of the respective slits, a first rod connected with the plates positioned in the upper portions of the respective slits, a second rod connected with the plates positioned in the lower portions of the respective slits, and a motor which is installed in the interior of the ship and connected to the first and second rods to drive the first and second rods.
BRIEF DESCRIPTION OF DRAWINGS
[0012] The present invention will become better understood with reference to the accompanying drawings which are given for illustration purpose, and thus the present invention is not limited to the exemplary embodiments in the drawings, wherein;
[0013] [0013]FIG. 1 is a view illustrating an apparatus for performing local suction and ejection operation according to the present invention;
[0014] [0014]FIG. 2 is a graph illustrating distribution of wall surface friction coefficients under various suction conditions according to the present invention;
[0015] [0015]FIG. 3 is a graph illustrating distribution of wall surface friction coefficients under various ejection conditions according to the present invention;
[0016] [0016]FIG. 4 is a graph illustrating distribution of wall surface friction coefficients under various ejection angles according to the present invention;
[0017] [0017]FIG. 5 is a schematic view illustrating a drag force decreasing apparatus by controlling turbulent flow on a hull surface of a ship according to the present invention;
[0018] [0018]FIG. 6 is a cross-sectional view illustrating a pipe housing of the drag force decreasing apparatus in FIG. 5;
[0019] [0019]FIG. 7 is a front cross-sectional view for explaining a connection state of a pump for the drag force decreasing apparatus according to the present invention;
[0020] [0020]FIG. 8 is a schematic view for explaining a drag force decreasing apparatus according to another embodiment of the present invention;
[0021] [0021]FIG. 9 is a cross-sectional view illustrating a pipe housing of the drag force decreasing apparatus in FIG. 8;
[0022] [0022]FIG. 10 is a front cross-sectional view for explaining a connection state of a motor for the drag force decreasing apparatus according to another embodiment of the present invention; and
[0023] [0023]FIG. 11 is a cross-sectional view illustrating a state that a pipe housing of a drag force decreasing apparatus by controlling turbulent flow in a hull surface of a ship is installed in the interior of the ship according to the present invention.
DETAILED DESCRIPTION OF INVENTION
[0024] A turbulent flow variation of a turbulent boundary layer is analyzed based on local disturbance and a detailed description thereof follows.
[0025] [0025]FIG. 1 is a view illustrating an apparatus for performing local suction and ejection operation according to the present invention, FIG. 2 is a graph illustrating distribution of wall surface friction coefficients under various suction conditions at a selected frequency according to the present invention, FIG. 3 is a graph illustrating wall surface friction coefficients under various ejection conditions at a selected frequency according to the present invention, and FIG. 4 is a graph illustrating distribution of wall surface friction coefficients under various ejection angles according to the present invention.
[0026] As shown in FIG. 1, the apparatus for local suction and ejection includes a flat plate 10 having a slot 11 , which may be used as a hull surface of a ship. A trip line 20 is installed at an end portion of an upper surface of the flat plate 10 . A piece 30 having rough surface is installed beside the trip line 20 . A speaker 40 for performing local suction and ejection is installed in a lower portion of the slot 11 of the flat plate 10 .
[0027] In addition, local suction and ejection by using the speaker 40 are performed through the slot 11 of the flat plate 10 in such a manner that a turbulent flow boundary layer is formed by a turbulent flow on the upper side of the flat plate 10 in which the trip line 20 is installed. In the above local suction and ejection operations, the ejection operation is well performed. However, the suction operation is not well performed due to a compression effect of air.
[0028] Numerical value analysis according to the degree of suction is performed. As shown in FIG. 2, as the amount of suction is increased in a portion near the slot, a stronger turbulence with a certain turbulent energy comes down to near the wall surface to increase the wall surface friction coefficient. When the amount of suction is increased over a certain degree, since the turbulent layer mixed by ejection is changed to a reverse direction turbulence near the slot, so that the average friction coefficient is slightly decreased. In the downstream far from the slot, as the amount of the suction is increased, the wall surface friction coefficient is decreased.
[0029] As shown in FIG. 3, the wall surface friction coefficient according to the variation of the amount of the ejection is not affected by an increase in the ejection amount in the downstream far from the slot. As the ejection amount is increased, the wall surface friction coefficient is gradually decreased near the slot. The above phenomenon occurs due to a reverse flow direction near the slot at the time when the ejection starts. As the ejection is increased, the reverse direction turbulence is more increased, and the average friction coefficient is gradually decreased.
[0030] As shown in FIG. 4, according to a correlation between the ejection angle and the wall surface friction coefficient for the local turbulence, a friction coefficient decreasing effect occurs in more regions when the ejection is performed at the angle of 60°, compared with when the ejection is performed vertically to the wall surface. In the case that the ejection angle is above 90°, the speed of the convection current generated in the slot is decreased and does not reach to the downstream. Therefore, as the ejection angle is increased, the regions in which the friction coefficient is decreased are decreased. In the case that the ejection angle is below 60°, since the occurrence of a re-circulation region which is formed during the ejection is restricted, the regions in which the friction coefficient is decreased are reduced.
[0031] The exemplary embodiments of the apparatus according to the present invention will be explained based on a result of the analysis with respect to the numerical analysis.
[0032] [0032]FIG. 5 is a schematic view illustrating a drag force decreasing apparatus based on a control of turbulent flow in a hull surface of a ship according to the present invention, FIG. 6 is a cross-sectional view illustrating a pipe housing of the drag force decreasing apparatus based on a control of turbulent flow in a hull surface of a ship according to the present invention, FIG. 7 is a front cross-sectional view for explaining a connection state of a pump of the drag force decreasing apparatus based a control of turbulent flow in a hull surface of a ship according to the present invention, FIG. 8 is a schematic view of another embodiment of the drag force decreasing apparatus based on a control of turbulent flow of a hull surface of a ship according to the present invention, FIG. 9 is a cross-sectional view illustrating a pipe housing of the drag force decreasing apparatus based on a control of turbulent flow in a hull surface of a ship according to the present invention, FIG. 10 is a front cross-sectional view for explaining a connection state of a motor for the drag force decreasing apparatus based on a control of turbulent flow in a hull surface of a ship according to the present invention, and FIG. 11 is a cross-sectional view illustrating a state that a pipe housing of a drag force decreasing apparatus based on a control of turbulent flow in a hull surface of a ship is installed inside a ship according to the present invention.
[0033] The drag force decreasing apparatus using a control of turbulent flow in a hull surface of a ship according to the present invention has, for example, two types of structures. One is using a flexible air pipe installed in the interior of a pipe housing, and the other is using a plate in the interior of a pipe housing, which is operated by a mechanical driving operation.
[0034] As shown in FIGS. 5 through 7, in the case that the flexible air pipe is used, a pipe housing 110 in which a plurality of slits 111 are formed along the hull surface 101 of the ship 100 is vertically installed in a string shape. The pipe housing 110 is formed in a hollow aerodynamic shape. The pipe housing 110 may also be formed in various shapes such as a semi circle shape or elliptical shape. The slit 111 may be formed in the shape of a circle hole and formed at a certain portion in such a manner that the ejection angle with respect to the hull surface 101 is 60° based on the kinds and speed of the ship.
[0035] A flexible air pipe 120 is installed in the interior of the pipe housing 110 in which the slits 111 are formed, and is connected with a pump 130 for sucking and compressing the air for a contraction and expansion of the flexible air pipe 120 . The pump 130 connected with the flexible air pipe 120 is installed in the interior of the ship 100 .
[0036] As shown in FIGS. 8 through 10, in the case that the plate is used, a pipe housing 210 in which a plurality of slits 211 are formed along the hull surface 101 of the ship 100 is installed vertically in a strip shape. Here, the pipe housing 210 is formed in a hollow aerodynamic shape and may also be formed in various shapes such as a semi circular shape or an elliptical shape. The slits 211 may be formed in a circular hole shape and installed at an ejection angle of about 60°˜120° with respect to the hull surface 101 based on the kinds and speed of the ship.
[0037] The plate 220 is installed in the interior of the pipe housing 210 . An upper plate 220 a and a lower plate 220 b are positioned in the upper and lower sides of each slit 211 , respectively.
[0038] A first rod 230 is connected with the plate 220 installed in the interior of the pipe 210 in such a manner that only the upper plates 220 a positioned in the upper portion of the slits 211 are connected. A second rod 240 is connected with the plate 220 in such a manner that only the lower plates 220 b positioned in the lower portion of the slits 211 are connected.
[0039] The first and second rods 230 and 240 are connected with the motor 250 in such a manner that the first and second rods 230 and 240 are driven by the motor 250 . As the first and second rods 230 and 240 are lifted or lowered according to the operation of the motor 250 , the plates 220 a and 220 b opposite to each other are contracted or expanded, so that sea water is discharged or sucked through the slits 211 . The motor 250 is installed in the interior of the ship.
[0040] The drag force decreasing apparatus for a ship employing the flexible air pipe 120 or the plates 220 may be locally installed in the bow portion 102 and the stem portion 103 of the ship.
[0041] The operation of the drag force decreasing apparatus using a control of turbulent flow in a hull surface of a ship according to the present invention will be explained with reference to the accompanying drawings.
[0042] Referring again to FIGS. 5 - 7 , in the case that the flexible air pipe 120 is used, when the pump 130 installed in the interior of the ship 100 is driven, the flexible air pipe 120 installed in the interior of the pipe housing 110 is contracted. Therefore, it is expanded in the pipe housing. When the air is discharged from the air pipe 120 , the operation in which the fluid is discharged or sucked into the housing through the slits 111 is repeatedly performed.
[0043] Namely, as the flexible air pipe 12 compresses and discharges the air, the flexible air pipe 120 is expanded and contracted. When the flexible air pipe 120 is contracted, the fluid surrounding the hull is sucked into the empty space of the interior of the pipe housing 110 through the slits 11 . When the flexible air pipe 120 is expanded, the interior space of the pipe housing 110 is expanded, and the thusly sucked fluid is flown into the interior of the pipe housing 110 through the slits 111 . The slit 111 preferably has about 60°˜120° ejection angle range with respect to the hull surface 101 .
[0044] Referring again to FIGS. 8 - 10 , in the case that the plate 220 is used, when the motor 250 is driven, the first and second rods 230 and 240 connected with the motor 250 are upwardly and downwardly operated in the opposite direction, so that the upper plates 220 a connected to the first rod 230 are downwardly moved and compressed, and the lower plates 220 b connected to the second rod 240 are upwardly moved, so that the plates are compressed in the upward and downward directions with respect to the slits 211 . When the plates are compressed in the upward and downward directions, the interior fluid is discharged to the outside through the slits 211 . On the contrary, when the first rod 230 is upwardly moved and the second rod 240 is downwardly moved, the portion between the plates 220 a and 220 b is widened, so that the fluid near the slits 211 is sucked.
[0045] The slits 211 formed in the pipe housing 210 eject the fluid at about 60°˜120° ejection angle with respect to the hull surface 101 .
[0046] The above pipe housing may be installed in the interior of the hull in such a manner that the pipe housing communicates with the outside through the slits between the hull surface.
[0047] Therefore, the apparatus for sucking and ejecting fluid over the entire outer surface of the hull of a ship using the flexible air pipe 120 or the plates 220 according to the present invention disturbs the fluid flow along the hull surface by using the suction and ejection of fluid at an optimum ejection angle. As a result, the friction resistance is decreased by preventing occurrence of the stream wise vortex flow on the hull surface of a ship.
[0048] In addition, in the case that the apparatus for decreasing the drag force by using a control of turbulent flow in a hull surface of a ship according to the present invention is installed in a rudder of a ship, it is possible to prevent cavitation of the rudder by controlling the turbulent flow of fluid around the rudder.
[0049] As described above, in the apparatus and method for decreasing a drag force by using a control of turbulent flow in a hull surface of a ship according to the present invention, it is possible to vary a turbulent field of the turbulent flow based on suction and ejection of fluid by operations of the flexible air pipe or the plates. In addition, it is possible to decrease the friction resistance by controlling the ejection angle with respect to the hull surface. Thus, the stream wise vortex flow is prevented in the hull surface to decrease the drag force of ocean current which affects the advance of a ship.
[0050] In addition, the apparatus for decreasing a drag force of a ship using the flexible air pipe or plates is installed in the steering gear of the ship, so that it is possible to control turbulence of fluid around the rudder, to prevent cavitation of the rudder.
[0051] As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the meets and bounds of the claims, or equivalences of such meets and bounds are therefore intended to be embraced by the appended claims. | The present invention relates to an apparatus and method for decreasing drag force by controlling turbulent flow in a hull surface of a ship. The method and apparatus according to the present invention are directed to sucking and ejecting the fluid flowing along a hull surface of a ship, varying the turbulent field of the turbulent flow, controlling the ejection angle with respect to the hull surface and decreasing the friction resistance by providing a pipe housing which is installed in a hull surface of a ship and includes a plurality of slits, a flexible air pipe which is installed in the interior of the pipe housing and performs contracting and expanding operation based on air pumping operation, and a pump which is installed in the hull for contracting and expanding the air pipe and providing air to the air pipe. The pipe housing including the flexible air pipe is installed inside or outside the hull surface for thereby contracting or expanding the air pipe using the pump, so that the fluid from the slits is sucked and ejected to vary the turbulent field of the turbulent flow formed on the hull surface and decreasing the friction resistance. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a spine fixing apparatus capable of suitably fixing an unstable spine caused by a fracture or disease by adjusting angle and width between rods of the apparatus according to a curvature shape of the spine, and simplifying assembly process thereof so as to reduce overall assembly time.
[0003] 2. Description of the Related Art
[0004] Generally, when a spine is fractured or diseased, the spine must be fixed. As such, a number of methods for fixing unstable spine have been developed. Among them is to place the spine as it were and fix it with a spine-fixing device. Typically, the spine-fixing device has two rods arranged along the spine so as to be fixed with screws thereon and connectors bridging the rods for fixing each other such that the spine is supported by the rods.
[0005] In the conventional spine fixing device, however, the screws are coupled to the spine integral with the rods and the two rods are fixedly coupled each other using the connectors such that the connector cannot be adjusted in a lateral and vertical directions thereby failing to fix the spine in the suitable position.
[0006] Furthermore, since the connector has a fixed length, the connector cannot bridge the two rods when the distance or angle between the rods are changed.
SUMMARY OF THE INVENTION
[0007] The present invention has been made in an effort to solve the above problems.
[0008] It is an object of the invention to provide a spine-fixing apparatus capable of reliably fixing the unstable spine, caused by a fracture or disease, by adjusting distance and angle between rods, which arranged along the spine, of the fixing-apparatus according to a shape of the spine.
[0009] It is another object of the present invention to provide a spine fixing-apparatus which enables each fixing nut to correctly fastened with the upper end of each spine screw member thereby preventing any erroneous coupling therebetween.
[0010] It is further another object of the present invention to provide a spine-fixing apparatus capable of simplifying installation process and reducing overall installation time as well as reliable installation by integrally forming a screw portion of a spine screw member, a supporting member for supporting a rod, and a cover for the supporting member of the spine-fixing apparatus.
[0011] To achieve the above objects, a spine-fixing apparatus of the present comprises a plurality of spine screw members fixed to a spine in a predetermined interval, a pair of rods coupled to the spine screw members for supporting the spine, a plurality of fixing nuts coupled to the spine screw members, and a plurality of pressing pieces interposed between the fixing nuts and the spine screw members for pressing and fixing the rods.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention, and together with the description, serve to explain the principles of the invention.
[0013] [0013]FIG. 1 is a front elevation view of a spine-fixing apparatus installed on a spine according to a first embodiment of the invention;
[0014] [0014]FIG. 2 is a perspective view of the spine-fixing apparatus of FIG. 1;
[0015] [0015]FIG. 3 is an exploded perspective view of a pressing portion of the spine-fixing apparatus of FIG. 1;
[0016] [0016]FIG. 4 is an assembled perspective view of the pressing portion of the spine-fixing apparatus according to a first embodiment of the present invention;
[0017] [0017]FIG. 5 is a top view of a bridge member of the spine-fixing apparatus of FIG. 1;
[0018] [0018]FIG. 6 is a perspective view of the spine-fixing apparatus for illustrating an operation of the bridge member of the spine-fixing apparatus;
[0019] [0019]FIG. 7 is an exploded perspective view of a pressing portion of the spine-fixing apparatus according to a second embodiment of the invention;
[0020] [0020]FIG. 8 is an assembled perspective view of the pressing portion of FIG. 7;
[0021] [0021]FIG. 9 is a front elevation view of a spine-fixing apparatus installed on spine according to a third embodiment of the invention;
[0022] [0022]FIG. 10 is a perspective view of the spine-fixing apparatus of FIG. 9;
[0023] [0023]FIG. 11 is an exploded perspective view of a spine screw member of the spine-fixing apparatus of FIG. 9; and
[0024] [0024]FIG. 12 is a perspective view of the spine-fixing apparatus for illustrating an operation of the bridge member of the spine-fixing apparatus according to the third embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] A preferred embodiment of the present invention will be described hereinafter with reference to the accompanying drawings.
[0026] [0026]FIG. 1 and FIG. 2 are respective front elevation view perspective view of the spine-fixing apparatus according to a first preferred embodiment of the present invention.
[0027] Generally, when the spine 1 is unstable caused by a fracture or disease, a fixing apparatus is used to stably fix the spine 1 .
[0028] Referring to FIG. 1 and FIG. 2, spine screw members 10 are coupled to certain portions of each of the spine 1 in a predetermined interval. The spine screw members 10 are continuously arranged in two rows along the spine 1 . The spine screw members 10 fixed to the spine 1 are connected by a pair of rods 5 , which support the spine 1 in the longitudinal direction through the spine screw members 10 . On the spine screw members 10 are separatively installed pressing members 30 to press the rods 5 toward the spine screw members 10 .
[0029] As shown in FIG. 3 and FIG. 4, each of the pressing member 30 comprises a pressing piece 32 inserted into an opening formed at the upper end of the spine screw member 10 for pressing the upper surface of the first or second rod and a fixing nut 31 for being coupled with the spine screw member 10 at the upper periphery while surrounding the pressing piece 32 .
[0030] The pressing piece 32 comprises a pressing protrusion 32 a inserted into the opening at the upper end of the spine screw member 10 , a catch plate 32 b stepped on the top of the pressing protrusion 32 a for being caught by the upper end of the spine screw member 10 , and a guide protrusion 32 d on the top of the catch plate 32 b for guiding the fixing nut 31 .
[0031] The pressing protrusion 32 a has a shape of a short cylinder so as to be easily inserted into the opening at the upper end of the spine screw member 10 , and an end surface of the cylinder is formed having a grid pattern so as to prevent the rod 5 from sliding to and fro after the fixing nut 31 is screwed down. Also, the guide protrusion 32 d has the shape of a cylinder such that the fixing nut 31 can be guided along the guide protrusion 32 d in order for the fixing nut 5 to be accurately coupled with the spine screw member 10 , and a neck 32 c is formed around the guide protrusion at its lower end connected to the catch plate 32 b such that the guide protrusion 32 d can be removed after fastening the fixing nut 31 to the spine screw member 10 .
[0032] The rods 5 arranged along the spine 1 are mutually connected by the bridge member 100 in such a way that a distance between the two rods 5 can be by the bridge member 100 .
[0033] [0033]FIG. 5 shows the bridge member 100 of the spine fixing apparatus according to the invention.
[0034] Referring to FIG. 5, the bridge member 100 is comprises a first and second bridge members 110 and 120 . The first bridge member 110 is bent inward at its distal end so as to partially grip the rod 5 and is provided with extended portion at its proximal end toward the other rod 5 . It is preferred that the distal end of the bridge member 110 is bent as much as 180° enough so as to prevent the rod 5 from being separated therefrom.
[0035] Further, the first bridge member 110 has a screw hole at its distal end portion such that a fixing screw 112 is penetrated and contacted the rod 5 to fix the rod 5 . It is preferred that the fixing screw 112 is slightly inclined toward the rod 5 , and more preferably, inclined at about 5°. Further, the fixing screw 112 has a curved end 114 corresponding to a round surface of the rod so as to enlarge the friction surface therebetween, resulting in more reliable fixation.
[0036] The distal end of the first bridge member 110 is tapered while extending around the rod 5 . Here, it is structurally preferable that the end of the first bridge member 110 is roundly finished while surrounding the rod 5 for easy coupling with the rod 5 .
[0037] The first bridge member 110 has an extension 116 with a slot 118 formed along the longitudinal direction of the extension 116 (see FIG. 6). The slot 118 is long as much as one third of the length of the extension 116 and rounded at both ends thereof. Furthermore, uneven portions 116 a are formed on an upper and lower surfaces of the extension 116 around the slot 118 . so as to enhance friction force.
[0038] The second bridge member 120 is substantially arranged in the opposite direction to the first bridge member 110 and has a screw hole at its distal end such that a fixing screw 122 is penetrated and contacted the other rod 5 to fix the rod. The fixing screw 122 of the second bridge 120 is longer than the first fixing screw 112 corresponding to the thickness of the second bridge member 120 . Also, the fixing screw 122 of the second connector 120 preferably has curved end corresponding to a round surface of the rod so as to enlarge the friction surface therebetween, resulting in more reliable fixation.
[0039] The second bridge member 120 has a upper and lower extensions 126 and 128 extended toward the rod 5 coupled with the first bridge member 110 . The upper and lower extensions 126 and 128 are formed with a predetermined distance therebetween such that the extension 116 of the first bridge member 110 is placed between the upper and lower extensions 126 and 128 . It is preferred that the extension 116 of the first bridge member 110 and the upper and lower extensions 126 and 128 of the second bridge member 120 preferably have the same thickness.
[0040] The upper and lower extensions 126 and 128 of the second bridge member 120 have holes at the same positions thereof such that an adjustment screw 130 penetrates through the hole of the upper extension 126 of the second bridge member 120 , the slot 118 of the extension of the first bridge member 110 , and hole of the lower extension 128 of the second bridge member 120 in order. The hole of the lower extension 128 is threaded on its inner wall such that the adjustment screw 130 is screwed into the lower extension 128 . Accordingly, when the adjustment screw 130 is screwed down, the upper and lower extensions 126 and 128 of the second bridge member 120 are fixedly coupled with the extension 116 of the first bridge member 110 . It is preferred that the hole of the upper extension 126 has the diameter slightly larger than that of the lower extension 128 .
[0041] Since the slot of the first bridge member 110 is elongated in longitudinal direction of the extension 116 , it is possible to adjust the distance between the rods 5 by sliding the adjustment screw 130 along the slot 118 while the adjustment screw is loosed.
[0042] Also, the first bridge member and the second bridge member is pivotally connected on the axis of the adjustment screw 130 such that the first and second bridge members can be adjusted according to the shape of the spinebefore being fixed. The upper and lower surfaces of the first bridge member around the slot 118 have the uneven portions 116 a so that the first bridge member and the second bridge member can be tightly coupled to each other.
[0043] [0043]FIG. 7 and FIG. 8 are respective the exploded perspective view and assembled perspective view of the spine-fixing apparatus according to a second embodiment of the invention.
[0044] As shown in FIG. 7 and FIG. 8, the spine-fixing apparatus according to the second embodiment of the invention comprises spine screw members 10 fixedly coupled to the spine in a predetermined interval, a first and second rods 5 coupled to the spine screw members 10 for supporting the spine, and pressing members 40 for respectively pressing the first and second rods 5 toward the spine screw members.
[0045] Each of the pressing members 40 comprises a fixing nut 41 and a pressing piece 42 inserted into an opening formed at a head of each of the spine screw members 10 so as to press the upper surface of each of the first and second rods 5 .
[0046] Each of the spine screw members 10 has a guide portion 10 a upwardly extended for guiding the fixing nut 41 . The fixing nut 41 has an inner diameter slightly greater than that of the guide portion 10 a so that the guide portion 10 a of the spine screw member 10 can be inserted into the fixing nut 41 .
[0047] The pressing piece 42 is provided with a pressing plate 42 c for pressing the upper surface of the rod 5 , and a cylindrical supporting portion 42 b formed on an upper surface of the pressing plate 42 c for being guided along the inner surface of the spine screw member 10 .
[0048] Also, the pressing plate 42 c and the supporting portion 42 b of the pressing piece 42 is provided with a through hole 42 a formed at the center thereof such that an internal fixing screw 43 is screwed therein for fixing the rods 5 .
[0049] The guide portion 10 a of the each spine screw member 10 allows the fixing nut 41 to be guided onto the upper end of the spine screw member 10 . After the fixing nut 41 is fastened, the guide portion 10 a can be removed from the spine screw member 10 after the installation of the spine-fixing apparatus because a grooved neck is formed between the guide portion 10 a and the spine screw member 10 . Further, the rod 5 can be further pressed by the internal fixing screw 43 being inserted into a central hole of the pressing piece 42 .
[0050] [0050]FIG. 9 and FIG. 10 are respective front elevation and perspective views of the spine-fixing apparatus according to a third embodiment of the invention, FIG. 11 is an exploded perspective view of a spine screw member of the spine-fixing apparatus according to the third embodiment of the invention, and FIG. 12 is a perspective view of the of the spine fixing apparatus for illustrating an operation of the bridge member of the spine-fixing apparatus according to the third embodiment of the invention.
[0051] Referring to FIG. 9 to FIG. 12, each of spine screw members 20 comprises a screw portion 11 to be inserted into the spine 1 in a predetermined depth, a supporting portion 13 formed on top of the screw portion 11 for receiving and supporting rod 5 ( 6 ), and a cover 15 pivotally mounted on top of the supporting portion 13 for fixing the rod 5 ( 6 ) received in a groove which divides the supporting portion 13 into two branches.
[0052] The supporting portion 13 has a recess 13 a at upper end of one branch thereof and the cover 15 has a coupling protrusion 15 a at one end corresponding to the recess 13 a such that the coupling protrusion 15 a of the 15 and the recess 13 a of the supporting portion 13 are engaged each other and pivotally connected by means of a hinge pin 14 . Also, in order to fasten the other side of the cover 15 to the supporting portion 13 , the supporting portion 13 has a fastening hole 13 b at upper end of other branch thereof, the cover 15 has a threaded hole 15 b formed at an opposite end portion of the coupling protrusion 15 a corresponding to the threaded hole 15 b such that the cover 15 is fixed to the supporting portion 13 by a fastening screw 16 being screwed into the threaded hole 15 b and the fastening hole 13 b.
[0053] The cover 15 has another threaded hole 15 c formed at a center thereof in parallel with the thread hole 15 b such that another internal fixing screw 17 is screwed down into the threaded hole 15 c in order to fixedly press the upper surface of the rod 5 ( 6 ).
[0054] The operation of the above structured spine-fixing apparatus will be described hereinafter.
[0055] Firstly, the screw portions 11 of the spine screw members 20 are fixedly screwed into the spine 1 to be supported. The first and second rods 5 and 6 are received in the U-shaped grooves 13 c formed on the supporting portions 13 such that the rods 5 and 6 are settled on the bottom of the U-shaped grooves 13 c.
[0056] After the first and second rods 5 and 6 are arranged in the grooves 13 c , the covers 15 on the top of the spine screw members are pivoted so as to cover the upper ends of the spine screw members 20 .
[0057] Next, the fastening screw 16 is screwed down through the threaded hole 15 b of the cover and the screw hole 13 b of the supporting portion 13 so as to fix the cover 15 to the supporting portion 13 . After the cover 15 is fixed to the supporting portion 13 , the internal fixing screw 17 is screwed down through the screw hole 15 c of the cover of the spine screw member 20 so as to fixing the rod 5 ( 6 ) by the lower end of the internal fixing screw pressing the upper surface of the fixing rod( 6 ).
[0058] After the spine screw members 20 are completely assembled like this, as shown in FIG. 12, the distance and angle between the first and second rods 5 and 6 are adjusted using a bridge 100 so that the spine 1 can be reliably supported in the optimum conditions.
[0059] The present invention described hereinbefore is not limited to the foregoing description of the embodiments, whereas various variations and modifications can be made by those skilled in the art without departing from the spirit and scope of the invention defined by the appended claims.
[0060] As described above, in the spine-fixing apparatus of the present invention the distance and angle between the rods can be adjusted such that the spine-fixing apparatus can be installed in optimal formation according to the shape of the spine.
[0061] Also, since the spine-fixing apparatus of the present invention is provided with a guide member at the upper end of the spine screw member, the fixing nut can be guided such that the spine-fixing apparatus provide reliable fixation of the spine.
[0062] Furthermore, the screw portion of the screw member, supporting member for supporting the rod, and the cover for fixing the rod to the supporting member of the spine-fixing apparatus are integrally formed, the installation process of the spine-fixing apparatus is simplified, resulting in reducing overall installation time. | A spine-fixing apparatus includes a plurality of spine screw members fixed to a spine in a predetermined interval, a pair of rods coupled to the spine screw members for supporting the spine, a plurality of fixing nuts coupled to the spine screw members, and a plurality of pressing pieces interposed between the fixing nuts and the spine screw members for pressing and fixing the rods. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates generally to bicycle handlebars.
[0003] 2. Description of Prior Art and Related Information
[0004] FIG. 1 shows a conventional handle structure in a typical bicycle. As illustrated in FIG. 1 , in the typical handle structure two fork legs 108 , on the left and the right, having a mechanism for steering while supporting the axle of a front wheel 114 , are connected by a fork crown 113 above the front wheel 114 . Given this, the upper portion of the fork crown 113 is connected to a single steering column, or steering tube, 111 . Additionally, the top end of the steering column 111 is connected to the handlebar 100 , at a center portion 102 , through a connecting component of a stem 109 .
[0005] Moreover, the steering column 111 is borne rotatably in a front frame 17 through a head tube 10 of a front frame 17 (structured from a head tube 10 , a top tube 15 , and a down tube 16 ). Moreover, the axle of the front wheel is supported by dropouts (not shown) positioned at the bottom ends of the fork legs 108 .
[0006] In this way, usually the typical bicycle handlebar is secured by a single stem at one location in the center portion thereof (for example, see Japanese Unexamined Patent Application Publication H7-300088). Because of this, the center portion of the handlebar, which serves as the position for attaching the stem, is subjected to strong loads through operation of the handle during riding. Moreover, along with the load due to operation of the handle, there are stresses because the handlebar is secured by the stem, and stresses due to the stem attaching position acting as a lever fulcrum. At these points, the center portion, which is the position in the conventional handlebar for attaching the stem, must have strength and rigidity greater than that of other portions.
[0007] That is, because in existing handlebars the design assumes that the handlebar will be secured using a stem in a single location in the center portion, it is necessary to increase the strength of the handlebar overall. Therefore, the diameter of the conventional handlebar is necessarily large, and the thickness of the material also large, making the prior art handlebar heavy.
[0008] FIG. 2 illustrates a handlebar that is attached to a stem in a single location in the center portion. As illustrated in FIG. 2 , the handlebar 201 is a handlebar having a height difference between a center portion 202 and grip portions 4 a and 4 b , where a stem attaching position 203 is provided in a single location in the center portion 202 . Because of this, if the strength of the center portion 202 , which is at the stem attaching position 203 , were reduced, then it would not be possible to maintain the strength of the handlebar. Consequently, in a handlebar of a shape wherein the stem is attached to a single location at the center portion, the structure of the present invention cannot be used.
SUMMARY OF THE INVENTION
[0009] In accordance with the present invention, structures and associated methods are disclosed which address these needs and overcome the deficiencies of the prior art.
[0010] As described above, when the handlebar is secured by two stems at positions other than the center portion of the handlebar, the load that is applied to the center portion between the stems is reduced. So a reduction in strength, stiffness and/or durability of the center portion of the preferred handlebar will not cause problems. However, because a conventional handlebar is manufactured without discriminating between the locations where strength, stiffness or durability is and is not required, the wall thickness of the material is thick even at locations that do not require strength, stiffness or durability, which wastes material and adds weight.
[0011] As used herein, “stiffness” is a relative term. When an element (such as a portion of a handlebar) exhibits less temporary deformation while a given force is applied, this element is considered “stiffer” than another such element.
[0012] As used herein, “Strength” is a relative term. When an element (such as a portion of a handlebar) exhibits less permanent deformation for a given force (applied once and then removed), this element is considered “stronger” than another such element. Moreover, when an element withstands a greater force (applied once and then removed) before it exhibits any measurable permanent deformation, it is considered “stronger” than another such element.
[0013] As used herein, “durability” is a relative term. When an element (such as a portion of a handlebar) exhibits less permanent deformation for a given cycle of force (repeatedly applied and removed), this element is considered “more durable” than another such element. Likewise, when an element withstands a greater number of cycles of force (repeatedly applied and removed) before it exhibits any measurable permanent deformation, this element is considered either “more durable” or “stronger” than another such element.
[0014] For simplicity, the term “strength”, as used herein below, may generically refer to “stiffness”, “Strength” and/or “durability” as defined above.
[0015] When an element, such as a portion of a handlebar, has an ability to resist a greater force before failure, this portion of the handlebar may have a greater “stiffness”, a greater “Strength”, and/or a greater “durability” as compared to another element. This force could include, for example, shear, axial, bending, moment and twisting moment. Various forces may be used to determine “stiffness”, “Strength” and/or “durability” of a particular portion of the handlebar. Failure could refer to any change in the element, such as deformation, bending, twisting, breaking, separating, or the like.
[0016] In contemplation of the situation described above, the object of the present invention is to provide a handlebar that is able to achieve a reduction in weight while maintaining strength and rigidity when secured by a plurality of stems.
[0017] In order to solve the problem set forth above, in the handlebar according to the present invention the strength of the center portion is not at a maximum. As described above, when the handlebar is secured by two stems, respective stems are attached to positions that have predetermined distances to the left and the right of the center portion, rather than attaching a stem to the center portion of the handlebar. In the stem attaching positions there is the need for high strength and rigidity due to the application of the stresses caused by the handlebar being secured by the stem and the stresses applied through the attaching position for the stem acting as a lever fulcrum. However, on the other hand, these loads do not act on the center portion positioned between one stem and the other, so the strength of the center portion may be reduced to some degree since there is no need for the strength of the center portion to be at a maximum.
[0018] Moreover, the handlebar according to the present invention may be coupled to two stems, while the strength of a center portion between stem attaching portions may be less than the strength at a handlebar portion positioned to the outer side of the stem attaching portions.
[0019] Here the strength of the center portion of the handlebar not being high is because, rather than the handlebar being secured by a single stem, it is secured by two stems, provided at the top ends of the left and right fork legs, so that all that is necessary is to be formed with high strength at the securing locations. A similar strength material may also be used from the securing locations to both end portions. The methods for increasing strength may comprise increasing the outer diameter of the pipe, increasing the thickness of the pipe material, or using a material with high strength. Moreover, the method for increasing strength may be that of adding a reinforcing material. Specifically, the method may be one wherein a plate member is inserted into the pipe, or wherein the empty cavity of the pipe is filled.
[0020] In the handlebar according to the present invention, a marker for indicating unsuitability for securing a stem may be provided on the center portion positioned between the two stem attaching portions. If a high-strength portion and a low-strength portion are provided in the handlebar, and the stem is attached accidentally to the low-strength portion, there the handlebar might bend, or the like, during riding, which could cause an accident. Given this, a marker is provided at the low-strength location displaying that the location is unsuitable for attaching to the stem.
[0021] The marker may comprise printing indicating unsuitability for attachment, a sticker, one or more colors different from the colors of other portions, or a cross-sectional shape unsuitable for securing to a stem.
[0022] The center portion of the handlebar according to the present invention may be structured so as to be unsuitable for securing to a stem.
[0023] Here the structure that is unsuitable for securing may be one wherein the cross-sectional shape is not a circle or a regular polygonal (i.e., equal length sides and equal angles). The cross-sectional shape may have dimensions different from an existing standard dimension. The cross-section may also be non-uniform in the lengthwise direction of the handlebar. Because there is a standard for stems, forming the cross-sectional shape of the center portion of the handlebar with a shape that does not fit with the standard, as described above, makes attachment difficult, thereby preventing accidental attachment of the stem to a weaker location.
[0024] In the handlebar according to the present invention, a portion other than the center portion may be formed with a larger pipe outer diameter, with a thicker wall thickness of the pipe material, or with a material of a higher strength, when compared to that of the center portion.
[0025] Moreover, in the handlebar according to the present invention, a reinforcing material may be added to portions other than the center portion.
[0026] The handlebar according to the present invention has a reduced weight while preserving strength and rigidity when the handlebar is secured to a plurality of stems.
[0027] In summary, a lightweight handlebar configured to be coupled to a plurality of stems is characterized by the strength of the center portion not being at a maximum. Moreover, the design may be such that a single handlebar is attached between two stems, wherein the strength at a center portion that is positioned between stem attaching positions is less than the strength of the portions that are positioned toward the outsides of the stem attaching portions. Moreover, a marker for indicating unsuitability for securing to a stem may be provided at the center portion of the handlebar.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a perspective view of a prior art handlebar in a typical bicycle.
[0029] FIG. 2 is a perspective view of a prior art handlebar attached to a stem at one location.
[0030] FIG. 3 is a structural diagram of a handlebar according to a first embodiment.
[0031] FIG. 4 is an enlarged view of the left side of a handlebar according to the first embodiment.
[0032] FIG. 5 is a diagram ( 1 ) of the attached state of the handlebar according to the first embodiment.
[0033] FIG. 6 is a diagram ( 2 ) of the attached state of the handlebar according to the first embodiment.
[0034] FIG. 7 is a diagram of the attached state of a handlebar according to a second embodiment.
[0035] The invention and its various embodiments can now be better understood by turning to the following detailed description wherein illustrated embodiments are described. It is to be expressly understood that the illustrated embodiments are set forth as examples and not by way of limitations on the invention as ultimately defined in the claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] Preferred embodiments according to the present invention will be described in detail below, referencing the drawings. Note that the scope of the present invention is not limited to the embodiments or drawings set forth below, but rather may be altered and modified in many ways.
[0037] FIG. 3 illustrates a first preferred embodiment of a handlebar apparatus, or simply handlebar, 1 configured to be attached to stems at two locations. As illustrated in FIG. 3 , the handlebar 1 comprises a center portion 2 , stem attaching portions 3 a and 3 b , grip portions 4 a and 4 b , and bent portions 5 a and 5 b , where the bent portions 5 a and 5 b are provided so as to elevate the grip portions 4 a and 4 b when attached to the stem. While a particular shape for the handlebar 1 is shown, including bent portions 5 a and 5 b , the present invention may include handlebars of various shapes, with or without bent portions 5 a and 5 b , or with bent portions 5 a and 5 b having various and different bends formed therein.
[0038] Unlike the prior art handlebar, the preferred handlebar 1 is configured to be coupled to stems at two locations. Thus the strength will be adequate if the stem attaching portions 3 a and 3 b are attached securely, and the handlebar 1 is formed so as to have high strength from the stem attaching portions 3 a and 3 b to both end portions.
[0039] FIG. 4 presents an enlarged view of the left side of the first preferred embodiment of the handlebar 1 . As illustrated in FIGS. 3 and 4 , in the handlebar 1 , no difference in thickness is provided on the outer surface 6 a . However, as illustrated in FIG. 4 , a difference in thickness is provided in the inner surface 6 b , to cause uneven portions at the boundaries between the center portions 2 and the attaching portion 3 a and 3 b.
[0040] Moreover, the thickness 7 b of the stem attaching portion 3 b , the thickness 7 c of the bent portion 5 b , and the thickness 7 d of the grip portion 4 b are thicker than the thickness 7 a of the center portion 2 . This is because although strength is required from the stem attaching portions 3 a and 3 b to the grip portions 4 a and 4 b , because the handlebar 1 is attached to stems at the stem attaching portions 3 a and 3 b , no load acts on the center portion 2 . Therefore, not as much strength is required in the center portion 2 . Moreover, a weight reduction can be achieved, and raw materials costs can also be reduced, through having the center portion 2 be thin.
[0041] The thickness and diameter of the handlebar 1 , including the center portion 2 , stem attaching portions 3 a , 3 b , and the grip portions 4 a , 4 b may vary according to material and application. For example, tubing diameters from about 22.2 mm to about 31.8 mm may be used for one or more of the components of the handlebar 1 . In some embodiments, the tubing diameters may be constant among each component (such as the center portion 2 , stem attaching portions 3 a , 3 b , and the grip portions 4 a , 4 b ), and in other embodiments, the tubing diameters may vary between the components. For example, the tubing diameters in the grip portions 4 a , 4 b may be less than 22.2 mm. The present invention contemplates tubing diameters described above as well as variations thereof. The tubing thickness may also vary depending on material and application. For example, steel tubing may be about 1.0 mm thick while aluminum may be about 0.7 mm or more in thickness. Of course, the present invention contemplates tubing thicknesses described above as well as variations thereof.
[0042] FIGS. 5 and 6 are operative views of the first preferred embodiment of the handlebar 1 attached to a bicycle. FIG. 5 is a front perspective view of the front fork and handlebar 1 . In the first preferred handle structure 1 , a steering column 11 that is borne rotatably on a head tube 10 of a front frame 17 , and left and right fork legs 8 a and 8 b , are provided attached, in parallel, on the left and right of the steering column 11 . The axle of the front wheel 14 is borne rotatably by dropouts (not shown) on the bottom ends of the left and right fork legs 8 a and 8 b . The top ends of the left and right fork legs 8 a and 8 b protrude adequately upward from the position of the top end 11 a of the steering column 11 . Two stems 9 a and 9 b are attached to the respective top ends of the left and right fork legs 8 a and 8 b , and a single handlebar apparatus 1 is coupled to these two stems 9 a and 9 b.
[0043] FIG. 6 is a rear perspective view of the front fork and handlebar apparatus 1 . The left and right fork legs 8 a and 8 b protrude above the top end 11 a of the steering column 11 , through holes provided in the left and right end portions of a fork crown 13 a . The two stems 9 a and 9 b are provided on the top ends of the left and right fork legs 8 a and 8 b . Given this, the handlebar 1 is secured to the top ends of the left and right fork legs 8 a and 8 b by the two stems 9 a and 9 b at the stem attaching portions 3 a and 3 b.
[0044] FIG. 7 is a rear perspective view of a second preferred embodiment of a handlebar apparatus 301 . As illustrated in FIG. 7 , the handlebar apparatus 301 is formed from a center portion 302 , stem attaching positions 303 a and 303 b , grip portions 304 a and 304 b , and bent portions 305 a and 305 b , similar to the first preferred embodiment of the handle apparatus 1 .
[0045] However, unlike the first embodiment, a marker 318 is provided in the center portion 302 , indicating that the center portion 302 is a part where the strength is weak. The marker 318 is provided through providing a pattern that is different from other portions; however, the marker 318 may instead comprise printing indicating unsuitability for attachment, a sticker, coloring different from other portions, or a cross-sectional shape that is unsuitable for attachment to a stem.
[0046] The stems 309 a and 309 b are attached to stem attaching portions 303 a and 303 b where there is no marker 318 . The provision of this marker clearly distinguishes the strong portions from the weak portions, making it possible to prevent a stem from being connected to a weak portion by accident.
[0047] The preferred handle apparatuses are useful for sports use, used by bicycle users who attach and remove handlebars.
[0048] Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiments have been set forth only for the purposes of examples and that they should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different ones of the disclosed elements.
[0049] The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification the generic structure, material or acts of which they represent a single species.
[0050] The definitions of the words or elements of the following claims are, therefore, defined in this specification to not only include the combination of elements which are literally set forth. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.
[0051] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.
[0052] The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted and also what incorporates the essential idea of the invention. | A lightweight handlebar configured to be coupled to a plurality of stems is characterized by the strength of the center portion not being a maximum. Moreover, the design may be such that a single handlebar is attached between two stems, wherein the strength at a center portion that is positioned between stem attaching positions is less than the strength of the portions that are positioned toward the outsides of the stem attaching portions. Moreover, a marker for indicating unsuitability for securing to a stem may be provided at the center portion of the handlebar. | 1 |
CROSS-REFERENCE TO OTHER PATENT APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 60/720,977, filed Sep. 27, 2005, the entire content of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention is directed to methods and systems for determining and validating accessibility and currency, i.e., the actual status, of data replicated in a networked environment.
[0003] Data replication is a technique commonly used for achieving high data availability. When multiple replicas of a data set are created and stored at different locations, a replica of the data will more likely be available to a client application even when some components fail or some data sets are corrupted.
[0004] In computing systems many techniques exist for copying data and for managing multiple replicas. Replication techniques can be classified to two main categories: synchronous and asynchronous replication. Synchronous replication processes enforce continuous full synchronization between the source data set and the replicas. This involves strong transactional guarantees and ensures that any update to a source data set is consistently and immediately reflected in all the synchronous replicas. However, achieving synchronous replication can in some environments be prohibitively expensive in terms of the overhead it imposes on computing resources, and in some cases not be possible at all (for example due to temporary failure of some component in the environment).
[0005] Asynchronous replication, on the other hand, requires a much less stringent time-consistency between replicas by creating copies only periodically. Thus a replica may represent some past state of the data source rather than the current state of the data source. Depending on how far back in the past that reference point is, such discrepancy may still be acceptable for some client applications under some exceptional circumstances (e.g., when recovering from a catastrophic failure). Asynchronous replication imposes a much lower overhead on the computing resources and is commonly used in many environments, such as maintaining geographically remote copies of application data for Disaster-Recovery (DR) purposes.
[0006] However, ensuring continuous conformance of the data sets and their replicas with the applications requirements is a difficult challenge for a number of reasons: different applications may have different minimal currency requirements for replicated-data (that is, there are typically differences in their cost/currency trade-off considerations); there may be multiple data-copiers in a typical environment that may be executing concurrently; copy activities may be based on replicas (which may themselves not be fully current) rather than on the original data set, thus creating chains of dependencies; individual copy activities may fail entirely, and a replica at a remote site may be inaccessible to a host due for example to a network or component configuration problem.
[0007] Consequently an application may not have a replica of sufficient currency accessible to it at a remote site, if required. Currently, such a deficiency may not be detected until an application actually requires that replica. Present replication technologies focus on the actual correctness of individual copy mechanism, but not on continuous end-to-end validation of the currency and accessibility of multiple replicas of data.
[0008] It would therefore be desirable to provide systems and processes for continuously validating replicated data sets in networks as being in conformance with defined application requirements for currency and accessibility, and for identifying and notifying a user of any discrepancies so that corrective actions can be taken before any undesirable consequences.
SUMMARY OF THE INVENTION
[0009] The invention is directed to systems and processes for continuously validating replicated data sets in networks as being in conformance with a replicated-data policy.
[0010] According to one aspect of the invention, a process for validating replicated data residing on network devices in a network includes the steps of defining a replicated-data policy for replicating data in the network, monitoring access paths between network devices or between applications running on the network devices, monitoring data replication activities in the network, and comparing currency and accessibility of a replica with the requirements in the replicated-data policy to identify discrepancies with the replicated-data policy.
[0011] According to another aspect of the invention, a replication validation manager for validating replicated data residing on network devices in a network includes a policy engine that stores replicated-data policy for replicating data in the network and a validation engine that monitors access paths between network devices or between applications running on the network devices. The validation engine further monitors data replication activities in the network and compares currency and accessibility of a replica with the requirements in the replicated-data policy to identify discrepancies with the replicated-data policy. The replication validation manager also includes a notification engine that provides a violation notification if a replica cannot be validated.
[0012] Embodiments of the invention may include one or more of the following features. The replicated-data policy may specify an access path between a host or application and a replica, and/or a number of replicas in a network, locations of the replicas, one or more access paths between the replicas, and/or a maximum age of a corresponding replica at each location. The data replication activities may include monitoring at least one of synch, split, copy start, copy complete, source data volume, target data volume, and a time of the replication.
[0013] Each replica may be associated with a tag which may include at least one of a source data set name, the copy status, and a time stamp. The tag of a replica may be updated in response to a copier event.
[0014] Access path attributes may include redundancy and/or number of intermediate components and/or performance and/or security and/or interoperability, sharability, or capacity. Discrepancies may be identified from a currency violation and/or missing access path and/or unauthorized access path, and/or path attribute violation.
[0015] In another embodiment, replication reports may be generated which may include properties of applications, replicas and replication events, and their impact on replicas; replication violations and time to correct them; replication resource utilization over time, or a combination thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The following figures depict certain illustrative embodiments of the invention in which like reference numerals refer to like elements. These depicted embodiments are to be understood as illustrative of the invention and not as limiting in any way.
[0017] FIG. 1 shows a schematic diagram of an exemplary replicated-data environment and a replicated-data validation manager according to the invention;
[0018] FIG. 2 is a schematic high level flow diagram for replicated-data validation;
[0019] FIG. 3 shows a view of an exemplary replicated-data policy;
[0020] FIG. 4 shows an exemplary visualization of a timeline of replication events;
[0021] FIG. 5 shows schematically an exemplary diagram of replication violations; and
[0022] FIG. 6 shows schematically an exemplary diagram of a root-cause analysis of a replication violation.
DETAILED DESCRIPTION
[0023] In the context of the invention, the following terminology will be used for classifying components of replicated data environments:
Definitions
[0024] Host Components are platforms on which application software programs can execute to achieve some useful purpose. At any point in time each host can have one or more applications executing on it. Each application can be executing on one or more host components. In addition each host may contain control programs which control the access to host resources and to external components.
[0025] Storage Components are platforms on which data can be stored and retrieved. Each storage device contains a memory sub-component containing multiple addresses in each of which one or more bits can be stored. Data is read from and written to storage devices in units which are referred to as volumes. A volume may contain any amount of data represented by any number of bits. Volumes are stored on storage devices, each starting with a particular start address on a particular storage component. In addition, each storage component may also contain a controller sub-component which controls access to the data in the memory sub-component.
[0026] Network components are platforms via which data can be transferred and routed from any source component to any target component. Each network component can control the flow of data depending on the source, destination and status circumstances
[0027] Each of the aforementioned components have a unique identifier (name) associated with it. Moreover, each of the components has one or more ports which enable input and output data to flow to and from that component. Each component can furthermore have a local state which represents a current “Control Configuration” of that component defining certain information flow characteristics such as which data flow can be enabled based on the source and the target components.
[0028] Different components can be connected to each other by “Communication Links” via which data can flow from one component to another. Such communication links can connect components located in very close proximity at single site, or at remote geographical locations. Example communication channels can include a cable a point-to-point connection, a local area network, a wide area network and others.
[0029] An Access Path exists between two end points (components, data sets, etc) if there is communication links connectivity, and if each intermediate component as well as the end point themselves are configured to enable data flow between these end points.
[0030] Environment Configuration Events that can occur in an environment can be classified to different classes including among others: components configuration changes, components addition and deletion, components failed and recovered, data send and receive, data volumes reads and writes, and others.
[0031] Applications running on hosts can generate new “Data Volumes” and submit them for storage on storage devices, as well as update or read existing data volumes stored on storage devices.
[0032] A Data Copier is a program which at certain points in time reads a volume from a storage device and writes an identical copy of that volume to another location (address) on the same storage device or a different storage device. A copier can execute on any component (host component, storage component, or network component). An initial source volume updated by an application is referred to a source volume, and any volume which was generated by a copier is referred to as a replica volume.
[0033] FIG. 1 depicts an exemplary environment of a replicated-data environment with three host-components 102 , 108 110 , a number of network components, such as switches or routers, 112 , 114 , 116 in a storage area network and a network component 118 in wide area network, two storage components 104 and 106 , as well as several data volumes and replicas, of which, for example, 128 is a source volume, 130 is a local replica of source volume 128 , 132 is a remote replica of source volume 128 , and 134 is local replica of remote replica 132 and hence a remote copy of source volume 128 . The copy activities for each of the replica are performed independently at different points in time. The sequential configuration of devices 102 , 114 , 128 , 130 , 118 , 132 , 134 , 108 is an example of a Disaster-Recovery (DR) access path—provided all the local components are properly configured to enable data transfer along that DR access path.
[0034] A Replicated-Data Validation Manager 101 is connected to the networks, as indicated by arrows 172 , 174 , 176 , 178 , and performs the process described below in order to validate the currency and accessibility of all data replicas in accordance with a specified application data-replication policy.
[0035] FIG. 2 shows a high-level process flow 200 of a replicated-data validation process. Process 200 starts at step 202 (initial set-up) where the target environment (components, links, data copiers etc) is initially discovered.
[0036] At step 204 , a replicated-data application policy is defined. For each data volume the policy defines: application access path (and attributes) to that volume, access path between replicas of that volume, and attributes, access paths from replicas to other hosts, required minimal currency (or maximally tolerable age) requirements of replicas at different locations (also referred to as Recovery Point Objectives (RPO))
[0037] At step 206 , information is obtained about events in the environment that affect the currency of replicas or their accessibility. For example, information may be received indicating that a copy action was successfully completed from replica 130 to replica 132 ( FIG. 1 ) at time T which is relevant for determining the currency status of replica 132 . Information may be received about a disruption in the link between host component 108 and replica 134 which is relevant for determining the accessibility of replica 134 .
[0038] At step 208 , an analysis is performed to derive from the event information about the status of currency and accessibility of the volumes and replicas.
[0039] At step 210 , the conclusions of the analysis performed at step 208 are compared with the currency and accessibility requirements that are specified in the policy and if violations are detected, at step 212 , notifications are provided regarding these violations. Such violations can be associated with the status or level of currency, for example all replicas of source volume 128 located at a remote location are at the moment less current than the minimum currency specified in the currency and accessibility requirements. Such violations can also be associated with accessibility, for example, if no remote replicas of source volume 128 are currently accessible by remote host-components as required.
[0040] FIG. 3 shows an exemplary view of part of an application data-replication policy. Such policy is set up in step 202 of the data-replication validation process outlined above. The policy would include for each volume and each replica the type of access path needed to be associated with that access path 301 , such as level of path redundancy 302 , the number of replicas and the type of copy activities 303 (e.g., synchronous, asynchronous) as well as other attributes.
[0041] In general, an applications replicated-data policy can specify for each volume in the environment: (1) which hosts and application should have an access path to that volume; (2) how many replicas should it have, where should they reside, and what should be the access path between these replicas; (3) what should be the maximum age of the replica at each location (what is the RPO); and (4) should any remote hosts have an access path to any of the replicas.
[0042] Thus the policy can represent many types of application requirements including, for example, the following exemplary requirements:
An application data volume should have at least a certain number (e.g. K) of replicas; At least one of the replicas of that application volume should reside on a storage component which is geographically remote from the location where the application host component resides; At least one remote replica should be accessible by another host-component at a remotely geographical location to the one the current application host component resides; At least one remote replica of that application volume should represent a snapshot time (Recovery Point) of no longer than T time units before the current time; The access path from the application host-component to the remote replica should have certain access-path attributes (for example should be dual-fabric redundant); All data volumes of a given application should be remotely replicated with snapshots that are no longer than T time units before the current time; All data volumes of a given application should be remotely replicated with snapshots associated with the same point in time, and that points should be no longer than T time units before the current time.
[0050] The next step in the replicated-data validation process (represented by step 206 in FIG. 2 ) involves collecting replication events information and configuration event information.
[0051] Data copier replication events information include for example:
A “Synch” event by a copier—together with the source volume (storage device and memory address), destination volume (storage device and memory address) and the time of the event. A synch event represents the start of a copy of the state source to the destination followed by continuous copy of each consequent source update to the destination; A “Copy-Completed” event by a copier—together with the source volume (storage device and memory address), destination volume (storage device and memory address) and the time of the event. A copy completed event represents the successful completion of a copy from the source to the destination. From that point any consequent update performed by any entity at the source volume will trigger a consequent copy of that update to the destination volume; A “Split” event by a copier—together with the source volume (storage device and memory address), destination volume (storage device and memory address) and the time of the event. A split event represents the end of the synch relationship between the volumes. Following a split event no further copies (of state or updates) are performed between the source volume and the destination volume (until a consequent synch event).
[0056] A conventional asynchronous copy of one volume to another volume may also be represented by a Synch event followed by a simultaneous Copy-Completed and Split events. Any volume generated or updated by a Synch event of a copier is referred to as a Replica Volume.
[0057] FIG. 4 shows an exemplary visualization of replication events.
[0058] At point in time 401 , a synch copy event occurs between volume 1 and 2 , at point in time 402 the copy is completed, and at point in time 403 a split event occurs. If a copy is initiated between volume 2 and 3 at point in time 404 and the copy is completed and a split is performed at point in time 405 . In order to determine the currency of volume 3 after point 405 the history of previous copy events need to be considered. Note also that between the time a copy is started (for example, point in time 401 ) to the point in time it is successfully completed (for example, point in time 402 ), the state of the target replica is inconsistent.
[0059] Environment configuration events may also affect access paths. Event information collected include:
Any access-control configuration change on any host-component, network-component, or storage-component. Such events, which include for example lun-masking changes or zoning changes, affect whether the component will enable data flow from a particular source component to a particular destination component. Any addition, deletion, or migration of a host-component, network-component, and storage component. Any addition or deletion of a communication link between components. Any addition, deletion, or migration of an application at a host-component. Any addition, deletion, or migration of a volume at a storage device. Any addition, deletion, or migration of a copier at any component.
[0066] The next step in the replication validation process (represented by step 208 in FIG. 2 ) involves analyzing the collected event information to derive currency and accessibility results.
[0067] The currency conclusions are derived from the replication event information in the following way. An association is maintained between each replica volume and a Replica Header Tag, which may include among others the following attributes:
Original Source Volume—name (storage device and address). Status—In-synch, Snapshot, or Inconsistent. Timestamp—Snapshot time.
[0071] The Replica Header Tag of a replica is updated in response to different copier events, as described above. These Tag updates can, for example, adhere to the following principles:
When a Synch event occurs in which this replica is a destination and the source volume is an original source volume (not a replica) then
The “Original Source Volume” attribute in the Tag is set to the name of the source name of the Synch event The “Status” attribute in the Tag of the destination is set to “Inconsistent”
When a Synch event occurs in which this replica is a destination and the source volume is a replica then
The “Original Source Volume” attribute in the Tag is set to the name of the original source name of the Tag of the source replica The “Status” attribute in the Tag of the destination is set to “Inconsistent”
When a Copy-Completed event occurs in which this replica is a destination and the source volume is an original source volume (not a replica) then
The “Status” attribute in the destination Tag is set to “In-synch”
When a Copy-Completed event occurs in which this replica is a destination and the source volume is replica then
The “Status” attribute in the destination Tag is set to be the same as the “Status” attribute of the source Tag The “Timestamp” attribute in the destination Tag is set to be the same as the “Timestamp” attribute of the source Tag
When a Split event occurs in which this replica is a destination and the source volume is an original source volume (not a replica) and the destination Tag Status is not “Inconsistent” then
The “Status” attribute in the destination Tag is set to “Snapshot” The “Timestamp” attribute in the destination Tag is set to the current time
When a Split event occurs in which this replica is a destination and either the status in the Source or the Destination Tag is “Inconsistent” then
The “Status” attribute in the destination Tag is set to “Inconsistent”
When a Split event occurs in which this replica is a destination and the source volume is a replica then
The “Status” attribute in the destination Tag is set to “Snapshot” The “Timestamp” attribute in the destination Tag is set to set to be the same as the “Timestamp” attribute of the source Tag
[0091] Accessibility conclusions are derived from the environment configuration events information by determining all the access paths in the environments. That is, deriving all the volumes and replicas at all storage devices that each initiating component can obtain data from or provide data to. The analysis is performed repeatedly after each event using the following underlying principles:
[0092] An access path exists between an initiator component and a target component if there exists a communication connectivity (at least one communication link and possible additional intermediate components interconnected with communication link) between the initiator component and the target, and the access control configuration on each component in the sequence (starting with the host and ending with the storage device) is set to enable data flow between the sources in the prefix of the sequence to the destinations in the postfix of that sequence.
[0093] Furthermore, the current step in the process derives for each identified access paths various end-to-end attributes of that access-path as determined by cumulative analysis of all the state information and events information associated with components in that access path. These derived access path attributes represent various service dimensions such as level of redundancy in the path, level of access performance within the path, number of intermediate components between host and target volume, storage capacity, among others.
[0094] This analysis may also establish in a similar way the existence of appropriate access paths between data copiers and data volumes (source and target volumes).
[0095] An extended type of an access path is a Disaster-Recovery Access-Path (DR-Path) which represents an access relationship between host-components and a sequence of a number of replica volumes (local and remote).
[0096] Such a notion of a DR-Path is a useful way to specify and enforce both the host to volume required access attributes as well as the volume to replica and replica to replica required access attributes.
[0097] Such DR-Paths can be formally defined in a number of ways, for example, as follows:
[0098] Let v 1 . . . v n be data sets. Each data set v i is of a certain type t k that belongs to a set of types {t 1 , . . . , t m }.
[0099] A path segment exists between v i and v i+1 if there is physical connectivity between v i and v i+1 and also logical connectivity between them. v i and v i+1 have logical connectivity if the physical path/s between them complies with certain set of rules that are a function of v i and v i+1 's types.
[0100] A path exists from v k . . . v l if for every k≦i≦l there exists a path segment from v i to v i+1 .
Another Exemplary Definition:
[0101] Let v 1 . . . v n be computing nodes. Each node v i is of a certain type t k that belongs to a set of types {t 1 , . . . , t m }.
[0102] A Stored-Data Access-Path v k . . . v l exists if there is physical connectivity from v k to v l , and if the logical state of each node v i k≦i≦l in the sequence is set to enable data flow along that sequence to or from a longer-term storage type node (in response to an initiation action by one of the other nodes in the sequence).
Another Exemplary Definition:
[0103] Let H i denote hosts, Let D j denote Storage Area network (SAN) devices (switches, routers, HBAs, etc.—local area or wide area networks), and let 14 denote stored data sets (volumes on storage devices)
[0104] A DR path is a sequence H a −V m - . . . -V n [−H b ], such that:
V m , . . . V n —are either identical copies of the same data sets or are derived copies (older snapshot, processed data mining version, etc) There is physical connectivity (local cables, remote links, intermediate SAN devices etc) between each consecutive member of the sequence, Each intermediate SAN device is properly configured (e.g. zoning, lun-masking, etc) to allow data flow along that sequence (Optionally) information flow is similarly enabled (physically and logically) between H b and V m , . . . , V n (or a subset of these)
[0109] Multiple types of DR-Paths can be predefined, each representing a particular permutation of replica types, and potentially a remote host associated with a specific sequence at the other end.
[0110] For example, EMC Corporation, Hopkinton, Mass. (USA) supplies infrastructure storage components. EMC's technology refers to specific names for replica types (e.g. BCVs, R1s, and R2s representing local and remote synchronous and asynchronous replicas respectively) and imposes certain constraints on the replica type copy sequence relationship.
[0111] In the context of EMC infrastructures, the following are examples of possible predefined DR-Paths types which can be used and enforced:
Host-R1-BCV
Host-R1-R2
Host-R1-R2-RemoteHost
Host-R1-R2-RemoteBCV-RemoteHost
[0112] Host-R1-BCV-R2
Host-R1-BCV-R2-RemoteBCV
Host-R1-BCV-R2-RemoteBCV-RemoteHost.
[0113] Each represents an access-path relationship between a host and a volume, between a volume and replica, possibly between a replica and a replica, and between a replica and a host.
[0114] The next step in the replicated-data validation process (represented by step 210 in FIG. 2 ) involves comparing the derived accessibility and currency conclusions and comparing these to the policy. That is, the analysis enables to establish continuously for each application that the state of the replicated data of this application fully adheres, at all times, to the appropriate replicated-data requirements of that application.
[0115] These requirements and others can be established with the replication analysis and access-path analysis mechanisms outlined above as follows:
Establishing the number of replicas of a given data volume of a given application, corresponds to identifying all the replicas which have a Tag in which the original source volume is the given volume. Establishing which of these replicas is currently accessible by the given application corresponds to deriving which access path exist between the application on the host components and each of the replica volume on the storage components. Establishing which of the replicas is geographically remote corresponds to determining that the location of the storage component is at a sufficiently long distance relative to the location of the host component (or to the location of the storage device with the original source volume). Establishing that a given remote replica is accessible by a remote host corresponds to identifying an access path between that host component and that replica volume, and that the locations of both the host-component and the storage-component are sufficiently remote geographically from the original application host-component (or from the original source volume storage-component). Establishing that at least one remote replica of an application volume represents a snapshot time (Recovery Point) of no longer than T time units before the current time, corresponds to determining that in its Tag the original source volume attribute corresponds to the required one, that the status attribute is In-Synch, or the status attribute is Snapshot and the current time minus the Timestamp attribute is no greater than T time units. Establishing that all the replicas of a given application should reflect a state which is at most T time units in the past (Recovery point for the application) corresponds to performing the above process for each of the volumes of the applications, determining the minimal timestamp in all tags who are not in a state of In-Synch, and establishing that the current time minus this minimal timestamp is no greater than T time units. Establishing that all the replicas of a given application should reflect a state which is at the same point in time, which at most T time units in the past (Recovery point for the application) corresponds to performing the above process for each of the volumes of the applications, and determining that either they are all in status of In-Synch, or they are all in a status of Snapshot and with the same timestamp for all the replicas, and that timestamp is no longer that T time units prior to the current time
[0123] Any discrepancy between the derived conclusions and the policy requirements is considered a violation. Thus a replicated data violation can represent a case in which a volume is not accessible to a host or to another replica in a manner consistent with its DR-Path specification in the policy, that one of the attributes of the existing access path or DR-path is different than the one specified in the policy, or that the most current replica of that volume beyond a specified distance is older than the Recovery Point Objectives (RPO) specified by the policy.
[0124] FIG. 5 shows schematically an exemplary diagram of a replication violation, with row 501 providing a description of an exemplary violation. This violation is of a type “DR Path Outage” and involves the disruption of accessibility between a volume on storage component 502 to its replica on storage component 505 . The access path between these two storage components also include network components 503 , 504 . An event has occurred somewhere along that path and prevents the flow of information between storage components 502 and 505 , and thereby prevents any copy activity involving volumes and replicas on these two storage components from occurring—potentially rendering the replica at storage component 505 as not sufficiently current, or not consistent (if the disruption occurred during a copy activity).
[0125] The next step of the replication-validation process (represented by step 212 in FIG. 2 ) involves generating an appropriate notification for each violation together with relevant context information. The context information can include, for example, the type of violation, the volume and application affected, the time of the violation, and the root-cause of the violation. The event that triggered the violation is referred to as the root cause of the violation, either by the fact that the event occurred, or by the fact that it did not occur. Based on such context information, violations can be classified and appropriate filtering mechanisms can determine which violation notification should be forwarded to which party.
[0126] FIG. 6 shows schematically an exemplary diagram of a root-cause analysis of a replication violation.
[0127] row 602 identifies the event as the root cause of the violation 601 (depicted also as 501 in FIG. 5 ) and displays context information. The event occurred at Apr. 24, 2005 at 2:50 pm and involved a zoning configuration update on network component 503 ( FIG. 5 ), which had the effect of preventing any further data traffic between storage component 502 and storage component 505 . With this context information in hand, a system administrator can immediately take corrective action to correct the violation simply by issuing another zoning configuration update to component 503 .
[0128] The violation and the context information are listed and stored, and appropriate notification messages may be generated and sent to appropriate parties based on filtering rules that are applied to the violation information. The correction of a violation is also automatically detected by the mechanisms described, and the stored repositories are updated and appropriate notification messages can be sent.
[0129] The current process also stores received event information (from components and from data copiers) in a history structure in a database, and associates with each event the derived access path conclusion results. That history database represents the complete evolution of the access paths status in the environment is available for further analysis and summary reporting.
[0130] Another possible embodiment of the invention enables planning and simulation of future changes, events, and failures to determine their expected impact on the replication requirements, and prevent problems before they occur.
[0131] The events that can be specified are possible future component change actions, possible data copiers action, or possible component failure or site failure.
[0132] The analysis performed is analogous to the one described above using the current state of the environment components and replicas, and considering the simulated event input as if this is the event information that was collected from the environment (represented by step 204 of FIG. 2 ) simulating the cumulative effect of the specified actions, and determining whether any violation will be generated if these actions were to actually occur in the environment.
[0133] The context information of each such future violation is generated and provided in the same way provided for regular violations (see above). Once validated, the innovation can actually track the execution of any corresponding change events, track implementation progress, and reports upon successful completion (or notify of any resulting violations).
[0134] Yet another embodiment of the invention enables summary reporting of the information accumulated and processed during the replication validation process. The information collected and analyzed by the current innovation enables the generation of a wide variety of useful data replication validation summary reports and trending reports.
[0135] The types of reports that can be generated include for example the following, among many others:
All replica volumes of selected applications and their attributes The number of replica volumes for each application in relation to the requirements (too many represent potentially wasted capital resources, too few represent a potential risk) All current replication violations with context information parameters All replication violations that occurred within any given window of time Average time to correct replication violations—trending over time Accessible replica status in the face of a failure scenario (such as a catastrophic site failure) Trending over time of number of replicas of an application, capacity of storage taken by replicas, and others.
[0143] While the invention has been disclosed in connection with the preferred embodiments shown and described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art. Various aspects of access path, their validation and management, are described, for example, in commonly assigned U.S. patent application Ser. No. 10/693,632, filed 23 Oct. 2003; and Ser. Nos. 11/112,942 and 11/112,624, both filed 22 Apr. 2005, the contents of which is incorporated herein by reference in their entirety. Accordingly, the spirit and scope of the present invention is to be limited only by the following claims. | Systems and processes for determining and validating accessibility and currency, i.e., the actual status, of data replicated in a networked environment are disclosed. According to the disclosed process, a replicated-data policy for replicating data is defined, and access paths between network devices or between applications running on the network devices are monitored, for example, by a replicated-data monitor. Also monitored are the data replication activities in the network. The currency, i.e., timeliness, and accessibility of a replica by a network device is then compared with the requirements in the replicated-data policy and discrepancies with the replicated-data policy are identified, optionally accompanied by a notification. | 7 |
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