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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a metal casing for a semiconductor device and method for manufacturing it, and more specifically to a metal casing suitable for a semiconductor device such as a photodiode, a laser diode, a microwave device for microwave communication, and a high power supply which has high thermal conductivity, high heat spreading and thermal expansion coefficient similar to those of a semiconductor, a ceramic or glass element disposed on the metal casing, and method for manufacturing the metal casing at low cost.
2. Description of Related Art
A metal casing for a high power supply and a semiconductor device used for optical communication or microwave communication generally comprises a base member on which the semiconductor device is mounted and an enclosure member which is fixed on the base member and which surrounds the semiconductor device and on which terminal pins for wiring are fixed by some particular ways. For example, terminal pins are mounted on ceramic mounting members and the ceramic mounting members are fixed to the enclosure member of the metal casing. In another case, terminal pins are fixed to holes of the enclosure member by using sealing glass.
In case of a metal casing for a semiconductor device for optical communication, the enclosure member comprises an opening for transmitting or receiving optical signals. Glass is usually fitted to the opening. An optical fiber is arranged near the outside of the opening.
In addition, a metal frame may be disposed on an upper edge of the enclosure member in order to fix a sealing cap.
The metal casing is heated while the semiconductor device mounted in it functions. As mentioned above, since the ceramic members and the glass part are fixed on the enclosure member, the enclosure member is preferably formed of a material having a thermal expansion coefficient similar to those of the ceramic members and the glass part. In addition, the enclosure member generally has a complicated shape, its material is required to have good machinability. Furthermore, the enclosure member should have certain rigidity.
In order to fulfill the above requirements, an enclosure member of a conventional metal casing is often formed of an iron-nickel alloy or an iron-nickel-cobalt alloy. On the contrary, a base member of the conventional metal casing is formed of a metal or an alloy having a good thermal conductivity and heat spreading such as copper or a copper-tungsten alloy in order to radiate heat generated by a semiconductor device mounted on it.
In the conventional metal casing, the enclosure member is jointed to the base member by brazing utilizing a silver-copper solder. However, since the enclosure member and the base member are formed of different metals or alloys, the conventional metal casing is liable to distort during the brazing. In particular warping of the base member is often caused.
If a semiconductor device for optical communication such as a laser diode or a photodiode is mounted in the distorted metal casing an optical coupling of the semiconductor device often deviates from that of an optical fiber so that a substantial optical power is decreased.
If a microwave semiconductor device is mounted in the distorted metal casing, the semiconductor device may be sometimes damaged or instability of a ground voltage and drop of heat radiation are caused so that the device becomes out of order.
In order to resolve the above problems, the base member of the metal casing is sometimes ground after the brazing so as to correct the warping. However, this work is of poor efficiency.
It can be considered that the metal casing is integrally formed of a base member and an enclosure member of an equal material in one-piece. In this case, the metal casing has been formed of a copper-tungsten alloy having a thermal expansion coefficient similar to those of some ceramic and glass materials, good thermal conductivity and heat spreading. However, in order to manufacture the metal casing integrally formed of the copper-tungsten alloy, it should be machined from a copper-tungsten alloy block. This results high cost and hard to conduct mass production.
The metal casing for a semiconductor device of a copper-tungsten alloy or a copper-polybdenum alloy is preferably manufactured by using powder metallurgical techniques such as one disclosed in Japanese Patent Application Laid-open No. 59-21032, in particular by sintering and infiltration. A metal injection molding process which is an improved sintering process is disclosed in International Patent Publication WO89/02803. In the metal injection molding process, copper powder and tungsten powder are mixed with an organic binder material to form an admixture. The admixture is molded by injection molding to form a predetermined green shape. The green shape is debinderized and sintered to produce a product.
However, the green shape should contract in volume equivalent to that of the binder included in it during the sintering so as to obtain a required density and thermal conductivity. In case of a product having a complicated shape such as a metal casing for a semiconductor device, the contraction does not uniformly occur, which is liable to cause distortion of the product so that it is difficult to obtained a high accuracy in shape.
In addition, the green shape includes 5 to 50 wt % copper powder, which melts and effuses to form a copper layer on a surface of the product so as to form a effused zone. The effused zone also spoils accuracies in shape and size. Therefore, the metal casing for a semiconductor device should be machined after the sintering in accordance the above prior art.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a metal casing for a semiconductor device formed of a copper-tungsten alloy or a copper-molybdenum alloy having high thermal conductivity, high heat spreading and thermal expansion coefficient similar to those of a semiconductor, a ceramic or glass element disposed on the metal casing which has overcome the above mentioned defect of the conventional one.
Another object of the present invention is to provide a method for manufacturing the metal casing formed of a copper-tungsten alloy or a copper-molybdenum alloy at low cost.
The above and other objects of the present invention are achieved in accordance with the present invention by a metal casing for a semiconductor device comprising a base member and an enclosure member arranged on the base member wherein the base member and the enclosure member are formed of an alloy including 20 to 50 percent by volume of copper, equal to or less than 1 percent by weight of nickel and remainder of tungsten.
The alloy of the metal casing in accordance with the present invention is preferably formed of a metal composite which has a tungsten-nickel admixture skeleton and copper infiltration filler.
According to another aspect of the present invention, there is provided a powder metallurgy injection molding process using infiltration to manufacture net-shape products comprising the steps of mixing tungsten powder and nickel powder having average particle sizes equal to or less than 40 μm so as to form mixed metal powder, kneading the mixed metal powder with an organic binder so as to form an admixture, injection molding said admixture so as to form a predetermined green shape, debinderizing said green shape and infiltrating copper into the green shape so as to produce a net-shape product.
The above and other objects, features and advantages of the present invention will be apparent from the following description of preferred embodiments of the invention with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a perspective view of a metal case for a laser diode module in accordance with the present invention;
FIG. 1B is a perspective view of the metal case of FIG. 1A to which elements are assembled;
FIG. 2A is a perspective view of a metal header for a laser diode in accordance with the present invention;
FIG. 2B is a perspective view of the metal header of FIG. 2A to which elements are assembled;
FIG. 3A is a perspective view of a metal header for microwave devices in accordance with the present invention;
FIG. 3B is a perspective view of the metal header of FIG. 2A to which elements are assembled;
FIG. 4 is a schematic sectional view illustrating the sealing test carried out in the Embodiment; and
FIG. 5 is a schematic side view illustrating the method for measuring laser power.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EMBODIMENT 1
Referring to FIGS. 1A and 1B, a first embodiment of the metal casing for a semiconductor device in accordance with the present invention will be explained. In FIG. 1A, there is shown a metal case for a laser diode module for optical communication which is one embodiment of the metal casing in accordance with the present invention.
The metal case shown in FIG. 1A comprises a base member 10 and an enclosure member 2 integrally formed of an alloy including copper, tungsten and nickel. The enclosure member 2 is composed of a front member 21 and a rear member 22 separately arranged on the base member 10. The front member 21 comprises an opening 4 for an window through which optical signals pass. The base member 10 comprises holes 6 for screw fixing before and after the enclosure member 2. The metal case is produced in net-shape so that no machinery is necessary.
FIG. 1B shows the metal case of FIG. 1A to which some elements and parts are assembled. In FIG. 1B, terminals 3 mounted on ceramic members 30 are inserted and hermetically fixed in gaps between the front member 21 and the rear member 22. A frame 5 is disposed on an upper edge of the enclosure member 2 which contributes fastening of the ceramic members 30 and a cap (not shown). In addition, glass 40 is hermetically fitted to the opening 4.
According to the present invention, the metal case is formed of an alloy including copper, nickel and tungsten or an alloy including copper, nickel and molybdenum or an alloy including copper, nickel, tungsten and molybdenum having high thermal conductivity and a thermal expansion coefficient similar to the ceramic and glass. The alloy has a content of 20 to 50 percent by volume of copper and equal to or less than 1 percent by weight of nickel and the remainder is tungsten and/or molybdenum. A ratio between tungsten and molybdenum can be arbitrarily selected.
If the copper content of the alloy is less than 20 percent by volume, inner pores are prone to be formed so that the alloy is hard to be packed. The alloy having such a composite does not have stable characteristics, in particular its thermal conductivity is unstable so that it is not suitable for the metal case.
If the copper content of the alloy excesses 50 percent by volume, the thermal expansion coefficient of the alloy becomes larger than 10×10 -6 /°C., so that difference in thermal expansion coefficient between the alloy and the ceramic and glass materials becomes too large.
The nickel of small content of equal to or less than 1 percent by weight give a preferable effect during the process for preparing the metal case so that the characteristics of the metal case is improved. However, if the nickel content of the alloy excesses 1 percent by weight, the thermal conductivity of the alloy becomes lower, which is not preferable.
The metal case shown in FIG. 1A was manufactured by the following process. At first, tungsten powder having an average particle diameter of 3 μm and nickel powder having an average particle diameter of 4 μm were admixed with a ratio of 99.9 to 0.1 by weight.
Molybdenum powder, a mixture of tungsten powder and molybdenum powder and a tungsten-molybdenum alloy powder can be used instead of the tungsten powder. The average particle diameters of the metal powders are preferably equal to or smaller than 40 μm. If the average particle diameters are larger than 40 μm, products will be too brittle.
Then, an organic binder of 75 parts by volume of wax having a melting point of 80° C. and 25 parts by volume of polyethylene having a decomposition temperature of 550° C. was prepared.
The wax preferably have a melting point equal to or lower than 100° C. The organic binder is preferably composed of the wax and an organic material which hardly leaves ash.
The mixed metal powder of the tungsten powder and nickel powder and the organic binder were mixed with a ratio of 38 to 62 by volume and kneaded. The kneaded admixture was injection molded so as to form a green shape of the metal case.
The ratio between the mixed metal powder and the organic binder are determined so that the green shape will have porosities of 20 to 50 percent by volume after it is debinderized.
The green shape was debinderized by a two-stage treatment. At first, the green shape was debinderized by vapor of methylene chloride (boiling point: 40° C.) for 5 hours. Then, the green shape was debinderized by heating to 800° C. for 30 minutes in hydrogen gas.
After the two-stage treatment, the green shape had a good appearance and there was no distortion and warping so that a configuration of each part was maintained. A porosity rate of the green shape was 38 percent by volume.
According to the present invention, an organic binder composed of a wax having a low melting point and a organic material which hardly leaves ash is used. The organic material is stable at the melting point of the wax. At the first stage of the debinderization process, the green shape is debinderized by vapor of an organic solvent, which removes the wax and debinderizes surfaces of the green shape and forms guide porosities. At the second stage of the debinderization process, the green shape is heated so as to vaporize the organic material so that the green shape is completely debinderized.
The organic solvent preferably has a boiling point lower than a melting point or a softening point of the organic material to avoid distortion of the green shape during the vaporization of the binder. The organic solvent is preferably selected from ethanol, acetone, trichlorothane, carbon tetrachloride, methylene chloride, etc.
According to the present invention, the heat treatment is preferably conducted under an atmosphere which does not include oxygen, for example, hydrogen atmosphere in order to oxidize the green shape.
The porosity rate of the green shape should be 20 to 50 percent by volume. If it is smaller than 20 percent by volume, a copper content of the products will be lower than 20 percent by volume. If the porosity rate is larger than 50 percent by volume, a copper content of the products will be higher than 50 percent by volume so that thermal expansion coefficients of the products become higher than 10×10 -6 /°C.
Thereafter, boron nitride powder dispersed in water was sprayed to all the surface of the green shape excluding the back to a thickness of 10 μm. The boron nitride powder prevented effusion of copper in the successive process.
The powder for preventing copper effusion should be formed of a material or materials which is not wetted by molten copper, is physically and chemically stable at the infiltration so that it does not react with the porous green shape and is easily removed after the infiltration. For example, the material of the powder can be one or ones selected from carbides, nitrides and oxides, in particular, Al 2 O 3 , TiO 2 , SiO 2 , ZrO 2 , AlN, BN, Si 3 N 4 , TiN, ZrN, SiC, ZrC and TiC. Powders of other materials could not prevent the effusion of copper adequately or were too hard to remove after the process.
The green shape was placed on a copper plate having sides equal to the base member and a thickness of 1 mm, so that copper was infiltrated into the green shape in a continuous furnace under hydrogen atmosphere at a temperature of 1150° C. During the infiltration, the boron nitride powder prevents effusion of molten copper.
After the infiltration, the boron nitride powder was removed by liquid honing and residual molten copper was removed by plane grinding, so that the metal case in accordance with the present invention was completed.
The metal case was formed of a specified metal tissue composite having a tungsten-nickel admixture skeleton and copper infiltration filler. No copper effusion occurred on the surfaces of the metal case on which the effusion preventive boron nitride powder had been applied. After the infiltration, the dimensions of the product contracted at a rate of 0.8 percent.
In the above process according to the present invention, copper is infiltrated into the porosities of the green shape, which are formed by debinderizing. Therefore, the green shape does not contract so as to obtain high accuracy of shape and dimension. In addition, a high enough density of the products can also be obtained.
There are shown particulars of the metal cases manufactured by the above method in accordance with the present invention in the following Tables 1--1 and 1-2.
TABLE 1-1__________________________________________________________________________ DebinderizingRatio of Ratio of Temperature PorosityW/Ni Binder/ Solvent* of heat treatment of porousor Mo/Ni Metal powder used in in 2nd stage green shape(by weight) (by volume) 1st Stage (°C.) (% by volume)__________________________________________________________________________1 99.9/0.1 38/62 MC 800 202 99.0/1.0 20/80 ET 800 203 99.5/0.5 20/80 MC 800 204 99.6/0.4 28/72 ET 600 285 99.6/0.4 28/72 ET 600 286 99.7/0.3 35/65 MC 600 357 99.7/0.3 35/65 MC 550 358 99.8/0.2 42/58 ET 550 429 99.8/0.2 42/58 ET 600 4210 99.9/0.1 48/52 MC 600 4811 99.0/1.0 20/80 ET 800 2012 99.5/0.5 35/65 ET 600 3513 99.9/0.1 49/51 MC 600 4914 99.5/0.5 18/82 -- -- --15 99.5/0.5 51/49 -- -- --16 98.8/1.2 28/72 ET 600 28__________________________________________________________________________ Remarks: *ET means ethanol MC means methylene chloride.
TABLE 1-2______________________________________Effusion preventive Density Rate ofmaterial of alloy Contraction______________________________________1 BN 15.3 ± 0.2 0.82 ZrO.sub.2 17.2 ± 0.3 03 BN 17.2 ± 0.3 04 TiN 16.4 ± 0.3 05 Al.sub.2 O.sub.3 16.4 ± 0.3 06 BN 15.7 ± 0.2 0.57 BN 15.6 ± 0.2 0.58 TiN 14.9 ± 0.2 1.09 TiN 14.9 ± 0.2 1.010 AlN 14.3 ± 0.2 1.811 BN 9.9 ± 0.2 012 TiN 9.8 ± 0.2 0.213 AlN 9.6 ± 0.2 1.514 -- -- --15 -- -- --16 Al.sub.2 O.sub.3 6.4 ± 0.3 0______________________________________
In the above Tables 1--1 and 1-2, Sample Nos. 1 to 10 are present invention using W-Ni powder. Sample Nos. 11 to 113 are present invention using Mo-Ni powder. Sample Nos. 14, the mold was completely filled with the admixture so that a shape of required density could not be obtained. In sample 15, the green shape foamed during the debinderization so that a required porous green shape could not be obtained.
As shown in Tables 1--1 and 1-2, the densities of alloys of the metal cases in accordance with the present invention were almost equal to theoretical values. By this, it became clear that copper had been almost completely infiltrated into porosities of the green shape. In addition, no defect was found in cross sections of the metal cases.
Sample No. 10 had the largest contraction rate of 1.8 percent. The contraction occurred during the infiltration and the rate of the contraction was determined by the rate of porosities of the porous green shape. If the rate of porosities of the porous green shape was equal to or less than 30 percent by volume, the contraction hardly occurred. If the rate of porosities of the porous green shape excessed 30 percent by volume, the contraction occurred corresponding to the rate of porosities. However, according to the present invention, the contraction rate was at most 2 percent. In addition, this small contraction had no effect on the characteristics of the alloy and on accuracy of the size.
Thermal conductivities and thermal expansion coefficients of the alloys of the above metal cases were shown in the following Table 2:
TABLE 2______________________________________ Thermal expansion Thermal coefficient conductivitySample (×10.sup.-6 /°C.) (cal/cm · sec. · °C.)______________________________________1 8.6 0.512 6.5 0.393 6.5 0.424 7.2 0.455 7.2 0.456 8.3 0.487 8.3 0.488 9.1 0.559 9.1 0.5510 9.7 0.6311 8.0 0.3812 9.0 0.4913 10.0 0.5716 7.2 0.30______________________________________
The thermal conductivities and the thermal expansion coefficients of the alloys shown in Table 2 are suitable for metal casings for semiconductor devices.
Accuracy of dimensions of the metal cases of Sample 6 of Tables 1 and 2 and ones manufactured by a conventional method disclosed in International Patent Publication WO89/02803 having the same copper composition (Comparative Example 1) are shown in the following Tables 3-1 and 3-2.
TABLE 3-1__________________________________________________________________________ Base member DiameterRequired Length Width Thickness of holes Warpingvalue 32 ± 0.15 12.7 ± 0.1 1.0 ± 0.05 2.64 ± 0.05 0.015 Max__________________________________________________________________________Sample6-1 31.96 12.71 1.01 2.64 0.0056-2 31.96 12.72 1.01 2.63 0.0036-3 32.01 12.69 1.02 2.66 0.0056-4 32.05 12.70 0.99 2.65 0.0016-5 32.02 12.68 0.98 2.62 0.0036-6 32.03 12.68 1.00 2.65 0.0056-7 31.98 12.70 1.00 2.66 0.0046-8 31.99 12.73 1.02 2.64 0.0046-9 32.00 12.71 0.98 2.62 0.003 6-10 32.01 12.70 1.00 2.64 0.002Average 32.001 12.702 1.001 2.641 0.004R 0.090 0.050 0.040 0.040 0.004δ 0.028 0.015 0.014 0.014 0.001ComparativeExample 1Average 32.010 12.69 1.00 2.65 0.012R 0.12 0.08 0.05 0.05 0.08δ 0.049 0.034 0.026 0.025 0.030ComparativeExample 2Average 0.032R 0.017δ 0.048__________________________________________________________________________
TABLE 3-2______________________________________ Enclosure memberRequired Length Width Thicknessvalue 20.80 ± 0.15 12.7 ± 0.1 8.0 ± 0.1______________________________________Sample6-1 20.80 12.71 8.036-2 20.79 12.72 8.026-3 20.76 12.69 7.996-4 20.83 12.70 8.016-5 20.85 12.68 7.976-6 20.81 12.68 8.016-7 20.82 12.70 8.006-8 20.84 12.73 7.966-9 20.81 12.71 7.99 6-10 20.80 12.70 8.02Average 20.811 12.702 8.000R 0.090 0.050 0.070δ 0.025 0.015 0.021ComparativeExample 1Average 20.81 12.69 7.99R 0.11 0.08 0.04δ 0.043 0.034 0.026______________________________________ Remarks: Comparative Example 2 was manufactured by a conventional method disclosed in Japanese Patent Application Laidopen No. 5921032, in which base member were machined from coppertungsten alloy and enclosure members of a ironnickel-cobalt alloy were brazed on the base members. R: range δ: standard deviation
Then, ceramic members 30 of terminals and frame members 5 were brazed so that metal case assemblies shown in FIG. 1B were prepared by using the metal cases according to the present invention, and the metal cases of the Comparative example 1 and 2. Each of the metal case assemblies was nickel plated to a deposit thickness of 1.5 μm and further gold plated to a deposit thickness of 1.5 μm. Sapphire members were hermetically soldered to the openings 4 by using gold-tin solder.
Heat-resistance and gastightness after 100 heat cycles (-65° C.×10 min. ←→ +150° C.×10 min.) were respectively evaluated for each 200 metal cases. The heat-resistance was evaluated by observing surfaces of the metal cases by using a optical microscope at a magnification of ×20 so as to find blisters, stains and change in color after heating the metal cases to 450° C. for 5 minutes under the air.
Referring to FIG. 4, the gastightness test will be explained. The metal case assembly was disposed on a flange 41 through an O-ling 42 so as to be evacuated. Then, helium gas was jetted to the metal case so that leak rate of the helium gas was measured through the flange by helium detector. Metal cases having a leak rate of higher than 5×10 -8 atm.cm 3 /sec. were determined to be detective products. The results were shown in the following Table 4.
TABLE 4______________________________________ Comparative Comparative Invention Example 1 Example 2 (200 each) (200 each) (200 each)______________________________________Heat-resistance of 0 4 0deposit (number ofdefective products)(side surface ofEnclosure)Gastightness after heat 0 2 0cycles (number ofdefective products)Gastightness after 0 2 0thermal shock(number of defectiveproducts)______________________________________
As shown in Table 4, there were defective products in the samples of the comparative example 1. However, there were no defective products in samples according to the present invention. The metal cases according to the present invention had a leak rate of less than 1×10 -9 atm.cm 3 /sec. The poor gastightness of the samples of the comparative example 1 was considered to be caused by porosities of the metal case assemblies of the comparative example 1.
Laser diodes were mounted to the metal case assemblies and the metal case assemblies were fixed on heat spreaders 23 of copper by using bolts 24. The laser diodes were optically connected to power meters 25 by optical fibers 26 so that optical power was measured. The optical power of each was measured before (W 1 ) and after (W 2 ) tightening the bolts 24 so that a rate of power drop of (W 1 -W 2 )/W 1 was calculated. The results are shown in Table 5.
TABLE 5______________________________________ Comparative Comparative Invention Example 1 Example 2______________________________________Power drop rate less than 1% 1 to 7% 1 to 10%______________________________________
As shown in Table 5, the metal cases of comparative examples 1 and 2 had larger distortions and warpings than that of the present invention so that optical couplings deviated so as to lower optical power.
EMBODIMENT 2
Referring to FIGS. 2A and 2B, a second embodiment of the metal casing for a semiconductor device in accordance with the present invention will be explained. In FIG. 2A, there is shown a metal header for a laser diode for optical communication which is one embodiment of the metal casing in accordance with the present invention.
The metal header shown in FIG. 2A comprises a base member 10 formed of an alloy including copper, tungsten and nickel. The base member 10 comprises holes 8 for terminals and a depression 9 for semiconductor device such as a laser diode.
FIG. 2B shows the metal header of FIG. 2A to which some elements and parts are assembled. In FIG. 2B, terminals 3 are inserted into the holes 8 and hermetically fixed by sealing glass. A semiconductor device 7 is disposed in the depression 9.
The metal header is formed of an alloy including copper, nickel and tungsten or an alloy including copper, nickel and molybdenum or an alloy including copper, nickel, tungsten and molybdenum having high thermal conductivity and a thermal expansion coefficient similar to the ceramic and glass. The alloy has a content of 20 to 50 percent by volume of copper and equal to or less than 1 percent by weight of nickel and the remainder is tungsten and/or molybdenum. A ratio between tungsten and molybdenum can be arbitrarily selected.
According to the present invention, the metal header can be manufactured without costly and troublesome machinery. Namely, a net-shape metal header having the holes and depressions can be obtained.
The process for manufacturing the metal header in accordance with the present invention is identical with the process described in Embodiment 1, so that repetitive explanations are abbreviated in this Embodiment.
EMBODIMENT 3
Referring to FIGS. 3A and 3B, a third embodiment of the metal casing for a semiconductor device in accordance with the present invention will be explained. In FIG. 3A, there is shown a metal header for microwave devices which is one embodiment of the metal casing in accordance with the present invention.
The metal header shown in FIG. 3A comprises a base member 10 formed of an alloy including copper, tungsten and nickel. The base member 10 comprises holes 8 for terminals and depressions 9 for semiconductor devices such as microwave devices.
FIG. 2B shows the metal header of FIG. 2A to which some elements and parts are assembled. In FIG. 2B, terminals 3 are inserted into the holes 8 and hermetically fixed by sealing glass. Semiconductor devices 7 are disposed in the depressions 9. A frame 5 for a sealing cap (not shown) is disposed on an edge of the base member 10.
The metal header is formed of an alloy including copper, nickel and tungsten or an alloy including copper, nickel and molybdenum or an alloy including copper, nickel, tungsten and molybdenum having high thermal conductivity and a thermal expansion coefficient similar to the ceramic and glass. The alloy has a content of 20 to 50 percent by volume of copper and equal to or less than 1 percent by weight of nickel and the remainder is tungsten and/or molybdenum. A ratio between tungsten and molybdenum can be arbitrarily selected.
According to the present invention, the metal header can be manufactured without costly and troublesome machinery. Namely, a net-shape metal header having the holes and depressions can be obtained.
The process for manufacturing the metal header in accordance with the present invention is identical with the process described in Embodiment 1, so that repetitive explanations are abbreviated in this Embodiment.
The invention has thus been shown and described with reference to the specific embodiments. However, it should be noted that the present invention is in no way limited to the details of the illustrated structures but changes and modifications may be made within the scope of the appended claims. | A metal casing for a semiconductor device is manufactured by a powder metallurgy injection molding process which uses infiltration. The metal casing includes a base member and an enclosure member arranged on the base member. The base member and the enclosure member are formed of an alloy including 20 to 50 percent by volume of copper, equal to or less than 1 percent by weight of nickel and remainder of tungsten or molybdenum. The metal casing is manufactured as a net-shape product by a process which includes the steps of mixing tungsten powder and nickel powder having average particles sizes equal to or less than 40 μm so as to form mixed metal powder, kneading the mixed metal powder with an organic binder so as to form an admixture, injection molding said admixture so as to form a predetermined green shape, debinderizing said green shape, applying surface powder to at least one surface of the green shape so as to prevent effusion of copper during infiltration and infiltrating copper into the green shape so as to produce a net-shape product. | 7 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a composite radio apparatus including two radio systems, and more particularly to a composite radio apparatus for carrying out a diversity operation in the respective radio systems. Moreover, the invention relates to a diversity switching method in the composite radio apparatus.
[0002] In a radio communication, there has been employed a diversity technique in order to cope with fluctuation in the receiving signal power. According to the diversity technique, a plurality of antennas are connected to a radio apparatus such as a radio base station or a mobile terminal, so that it is switched into an antenna receiving a high receiving signal power depending on the fluctuation in the received power which is caused by fading to perform the communication, and the received radio wave signals are synthesized. In particular, there has been widely used an antenna switching type diversity receiving method which can be implemented with a simple circuit structure at a low cost.
[0003] [0003]FIG. 5 is a diagram showing the schematic structure of a radio apparatus capable of carrying out a diversity reception. In FIG. 5, an antenna changeover switch 52 serves to switch a first antenna 53 and a second antenna 54 and to connect them to the input/output section (not shown) of a radio system 51 . The antenna changeover switch 52 is switched in response to switching signals 55 a and 55 b sent from an antenna switching control circuit 55 . The control signal 55 a and the control signal 55 b have an inversion relationship and serve to connect the first antenna 53 and the radio system 51 , and the second antenna 54 and the radio system 51 separately. The reason why the separate control signals are sent is that it might be necessary to set a rise time and a fall time for a time sharing slot individually in respect of the characteristic of the radio system. In this respect, another antenna changeover switch, which will be described below, has the same possibility. Separate control signals are sent, respectively. The radio apparatus in FIG. 5 switches the antenna changeover switch 52 in response to the control signals 55 a and 55 b and always carries out a receipt while retrieving the first antenna 53 or the second antenna 54 which has a higher received signal level in the case in which the diversity operation is to be executed.
[0004] In a composite radio apparatus having two radio systems employing the diversity receiving method, the diversity operation can be carried out by using a common antenna.
[0005] [0005]FIG. 6 is a diagram showing the schematic structure of a composite radio apparatus having two radio systems capable of carrying out the diversity reception. The composite radio apparatus in FIG. 6 includes a first radio system 61 and a second radio system 62 which carry out different radio communications, and a first antenna 65 and a second antenna 66 are switched and connected to input-output sections (not shown) of the first radio system 61 and the second radio system 62 by means of a system changeover switch 63 and an antenna changeover switch 64 . The system changeover switch 63 is switched in response to control signals 1 a and 1 b sent from a system switching control circuit 67 and the antenna changeover switch 64 is switched in response to control signals 2 a and 2 b sent from an antenna switching control circuit 68 .
[0006] The control signal 1 a serves to select the first radio system 61 and the control signal 1 b serves to select the second radio system 62 . More specifically, the control signal 1 a is set to be H and the control signal 1 b is set to be L in the case that the first radio system 61 is to be selected, whereas the control signal 1 a is set to be L and the control signal 1 b is set to be H in the case in that the second radio system 62 is to be selected. Moreover, the control signal 2 a serves to select the first antenna 65 and the control signal 2 b serves to select the second antenna 66 . More specifically, the first antenna 65 is selected when the control signal 2 a is H and the control signal 2 b is L, whereas the second antenna 66 is selected when the control signal 2 a is L and the control signal 2 b is H.
[0007] Next, the operation of the composite ratio machine in FIG. 6 will be described. First of all, the system changeover switch 63 is switched to the radio system side to be used in response to the control signals 1 a and 1 b in order to select the ratio system for carrying out the diversity reception. In the case that the diversity operation is to be carried out in this state, the antenna changeover switch 64 is switched in response to the control signals 2 a and 2 b and a receipt is always performed while retrieving the first antenna 65 or the second antenna 66 which has a higher received signal level.
[0008] [0008]FIG. 7 is a diagram showing the state of the control signals 1 a , 1 b , 2 a and 2 b in the case in which the radio system is switched and the antenna is changed over in the composite radio apparatus of FIG. 6. FIG. 7 shows a time sharing operation in a transmitting slot T 1 and a receiving slot R 1 in the case in which the first radio system 61 is being operated, and the first antenna 65 is selected at time of a transmission and the second antenna 66 is selected at time of a receipt. More specifically, in the transmitting slot T 1 , the control signal 1 a is set to be H, the control signal 1 b is set to be L, the control signal 2 a is set to be H and the control signal 2 b is set to be L so that the first antenna 65 is selected. In the receiving slot R 1 , moreover, the control signal 1 a is set to be H, the control signal 1 b is set to be L, the control signal 2 a is set to be L and the control signal 2 b is set to be H so that the second antenna 66 is selected.
[0009] However, the conventional composite radio apparatus is provided with the antenna changeover switch 64 for switching the antenna for the diversity operation and the system changeover switch 63 for radio system switching, and a transmitted/received signal is sent through the two switches including the antenna changeover switch 64 and the system changeover switch 63 . Therefore, there is a problem in that a receiving sensitivity is deteriorated due to an increase in a loss corresponding to one switch and a transmitted output is reduced at time of a transmission.
[0010] Moreover, it is necessary to separately control the switching operations of the system changeover switch 63 and the antenna changeover switch 64 . For this reason, there is also a problem in that four control signals for the switching are required.
SUMMARY OF THE INVENTION
[0011] The invention has been made to solve the conventional problems and has an object to provide a composite radio apparatus comprising two radio systems and two antennas to be shared for the diversity operation of the two radio systems and capable of reducing a loss in the switching of the antenna and the radio system. Moreover, the invention has another object to provide a diversity switching method capable of reducing a loss in the switching of the antenna and the radio system in the composite radio apparatus.
[0012] The invention provides a composite radio apparatus having two radio systems, comprising two antennas to be shared for a diversity operation of the two radio systems, and two antenna changeover switches for switching the two antennas, wherein the two antenna changeover switches serve to directly connect the two antennas to respective input/output sections of the two radio systems.
[0013] According to the composite radio apparatus, one switch is passed in a path formed by the antenna and the respective radio systems. Therefore, it is possible to reduce a loss caused by the passage through two switches in the conventional art. Moreover, switching control can easily be carried out.
[0014] In the composite radio apparatus according to the invention, the two antenna changeover switches are operated such that one of the antenna changeover switches connects one of the two antennas to the input/output section of one of the two radio systems when the other antenna changeover switch connects the other antenna to the input/output section of the other radio system.
[0015] By the execution of such switching, when one of the antennas is connected to one of the radio systems and is thus used, the same antenna is not connected to the other radio system. Therefore, it is possible to prevent an influence such as a reduction in a transmitted signal from being caused by a fluctuation in a load impedance.
[0016] In the composite radio apparatus according to the invention, one of the antenna changeover switches serves to connect, by switching, the two antennas to either of the radio systems which is being operated.
[0017] By the execution of such switching, it is possible to easily carry out the switching control of the antenna corresponding to a control system which is being operated or is to be operated.
[0018] The composite radio apparatus according to the invention further comprises a matching circuit corresponding to the radio system between at least one of the antenna changeover switches and the input/output section of the radio system.
[0019] According to the composite radio apparatus, also in the case in which frequencies to be used for the two radio systems included in the composite radio apparatus are different from each other, it is possible to reduce a loss caused by the mismatching of an impedance through the connection switching.
[0020] The invention provides a diversity switching method in a composite radio apparatus comprising two radio systems and two antennas to be shared in a diversity operation of the two radio systems, wherein one of the two antennas is directly switched and connected to an input/output section of one of the radio systems which is carrying out the diversity operation and the other antenna is directly switched and connected to an input/output section of the other radio system.
[0021] According to the diversity switching method, it is possible to reduce a loss caused by the antenna switching through a simplified control method.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is a diagram showing the schematic structure of a composite radio apparatus according to a first embodiment of the invention;
[0023] [0023]FIG. 2 is a diagram showing the schematic structure of the composite radio apparatus according to the first embodiment of the invention;
[0024] [0024]FIG. 3 is a table showing the relationship between control signals corresponding to a radio system to be used and an antenna;
[0025] [0025]FIG. 4 is a diagram showing the state of the control signal in the composite radio apparatus according to the embodiment of the invention;
[0026] [0026]FIG. 5 is a diagram showing the schematic structure of a radio apparatus capable of carrying out a diversity reception;
[0027] [0027]FIG. 6 is a diagram showing the schematic structure of a conventional composite radio apparatus having two radio systems which can carry out the diversity reception; and
[0028] [0028]FIG. 7 is a diagram showing the state of a control signal in the conventional composite radio apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] An embodiment of the invention will be described below with reference to the drawings.
[0030] [0030]FIG. 1 is a diagram showing the schematic structure of a composite radio apparatus according to a first embodiment of the invention. The composite radio apparatus in FIG. 1 has a first radio system 11 and a second radio system 12 which carry out different radio communications, and a first antenna 15 and a second antenna 16 which are shared for the first radio system and the second radio system. The first antenna 15 and the second antenna 16 are directly switched and connected to an input/output section (not shown) of the first radio system by means of an antenna changeover switch 13 for the first radio system, and are directly switched and connected to the second radio system 12 by means of an antenna changeover switch 14 for the second radio system.
[0031] The antenna changeover switch 13 for the first radio system and the antenna changeover switch 14 for the second radio system are switched in response to a control signal 10 a of a first switching control circuit 17 and a control signal 10 b of a second switching control circuit 18 . The antenna changeover switch 13 for the first radio system connects the first antenna 15 to the first radio system 11 by switching when the control signal 10 a is H and the control signal 10 b is L, and connects the second antenna 16 to the first radio system 11 by switching when the control signal 10 a is L and the control signal 10 b is H. Moreover, the antenna changeover switch 14 for the second radio system connects the second antenna 16 to the second radio system 12 by switching when the control signal 10 a is H and the control signal 10 b is L, and connects the first antenna 16 to the second radio system 12 by switching when the control signal 10 a is L and the control signal 10 b is H.
[0032] The control signal 10 a and the control signal 10 b have an inversion relationship with each other when the switching control of the antenna changeover switch 13 for the first radio system and the antenna changeover switch 14 for the second radio system is carried out. Therefore, the first switching control circuit 17 and the second switching control circuit 18 may be collected into one switching control circuit and the control signals 10 a and 10 b having the inversion relationship with each other may be output.
[0033] [0033]FIG. 3 shows the relationship between the control signals corresponding to the antenna to be connected to the radio system which is used. As shown in FIG. 3, during the use of the first radio system 12 , the control signal 10 a is set to be H and the control signal 10 b is set to be L when the first antenna 15 is to be selected, and the control signal 10 a is set to be L and the control signal 10 b is set to be H when the second antenna 16 is to be selected. During the use of the second radio system, moreover, the control signal 10 a is set to be L and the control signal 10 b is set to be H when the first antenna 15 is to be selected, and the control signal 10 a is set to be H and the control signal 10 b is set to be L when the second antenna 16 is to be selected.
[0034] When one of the antennas is connected to one of the radio systems for use, a load impedance fluctuates so that a transmitted signal is reduced if the same antenna is connected to the other radio system. For example, in the case in which the control signal 10 a is set to be H, the control signal 10 b is set to be L and the first antenna 15 is connected to the first radio system during the use of the first radio system 12 , the above problem arises when the first antenna 15 is also connected to the second radio system. In the composite radio apparatus in FIG. 1, however, if the control signal 10 a is set to be H and the control signal 10 b is set to be L, the second antenna 16 is connected to the second radio system 12 and the first antenna 15 is disconnected from the second radio system 12 so that the above problem does not arise.
[0035] Next, the operation of the composite radio apparatus in FIG. 1 will be described by taking, as an example, a switching operation in transmitting and receiving timings in a radio system using a time sharing method. FIGS. 4A and 4B are diagrams showing the states of the control signals 10 a and 10 b in a transmitting slot T 1 and a receiving slot R 1 in the time sharing method. FIG. 4A shows a state obtained when the first radio system 11 is used and FIG. 4B shows a state obtained when the second radio system 12 is used, and both the drawings show the case in which the first antenna 15 is selected at time of a transmission and the second antenna 16 is selected at time of a receipt.
[0036] When the control signals 10 a and 10 b are brought into the state shown in FIGS. 4A and 4B, the radio system to be used and the first antenna are connected to each other in the transmitting slot T 1 and the radio system to be used and the second antenna are connected to each other in the receiving slot R 1 during both the use of the first radio system 11 and the use of the second radio system 12 .
[0037] In the composite radio apparatus shown in FIG. 1, in the case in which frequencies to be used by the two radio systems are different from each other, the mismatching of an impedance might be caused by the connection switching of the radio system through the antenna switching circuit, resulting in an increase in a loss.
[0038] [0038]FIG. 2 is a diagram showing the schematic structure of a composite radio apparatus according to a second embodiment of the invention, in which the mismatching of an impedance is not caused also when frequencies to be used by two radio systems included in the composite radio apparatus are different from each other. The composite radio apparatus of FIG. 2 is the same as the composite radio apparatus in FIG. 1 except that a first matching circuit 21 is provided between a first radio system 11 and an antenna changeover switch 13 for a first radio system and a second matching circuit 22 is provided between a second radio system 12 and an antenna changeover switch 14 for a second radio system.
[0039] The first matching circuit 21 serves to carry out frequency matching corresponding to a frequency to be used by the first radio system 11 and the second matching circuit 22 serves to carry out frequency matching corresponding to a frequency to be used by the second radio system 11 . By thus providing the matching circuits 21 and 22 corresponding to the frequencies to be used by the respective radio systems between the radio system and the antenna changeover switch, it is possible to reduce a loss caused by the mismatching of the impedance also when the frequencies to be used by the two radio systems are different from each other.
[0040] While the first matching circuit 21 and the second matching circuit 22 are provided in FIG. 2, only one of them may be provided. In that case, a first antenna 15 and a second antenna 16 are set to correspond to a frequency to be used by the radio system on the side where the matching circuit is not provided.
[0041] As described above, according to the invention, it is possible to provide a composite radio apparatus capable of reducing a loss in the switching of the antenna and the radio system. Moreover, it is possible to provide a diversity switching method capable of reducing a loss in the switching of the antenna and the radio system in the composite radio apparatus.
[0042] According to the invention, furthermore, the matching circuits corresponding to the frequencies to be used by the respective radio systems are provided between each of the radio systems and the antenna changeover switch. Also in the case in which the frequencies to be used by the two radio systems constituting the composite radio apparatus are different from each other, consequently, it is possible to reduce a loss caused by the mismatching of an impedance in a diversity operation sharing the antenna. | A composite radio apparatus having two radio systems, comprises two antennas to be shared for a diversity operation of the two radio systems, and two antenna changeover switches for switching the two antennas, wherein the two antenna changeover switches serve to directly connect the two antennas to respective input/output sections of the two radio systems. In the composite radio apparatus according to the invention, the two antenna changeover switches are operated such that one of the antenna changeover switches connects one of the two antennas to the input/output section of one of the two radio systems when the other antenna changeover switch connects the other antenna to the input/output section of the other radio system. | 7 |
[0001] This application claims the benefit of Taiwan application Serial No. 94101912, filed Jan. 21, 2005, the subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates in general to a computation apparatus and computation therefor, and more particularly to a computation apparatus and non-linear computations therefor.
[0004] 2. Description of the Related Art
[0005] Liquid crystal displays (LCDs) have been commonly used because of the merit of being thin, light, and having low radiation. Although the LCDs with higher resolutions and display frequencies are being developed, the displays suffer from a bottleneck in responding to voltages applied between liquid crystal layer of the displays. FIG. 1A illustrates this bottleneck in terms of a timing diagram of gray-levels of liquid crystal molecules (LC) when an input voltage is applied to the liquid crystal molecules. FIG. 1B shows a timing diagram of the input voltages. When an input voltage of V 1 is applied to the LC, the gray-level of the LC has a value of L 1 . When an input voltage of V 2 is applied to the LC, the gray-level of the LC has a value of L 2 .
[0006] The response of the LC does not keep pace with the change in the input voltage applied. Referring to FIGS. 1A and 1B , when the input voltage changes at time t 1 from V 1 to V 2 , the gray-level of the LC changes from L 1 to L 2 . Due to the characteristics of the LC, the transition of the gray-level from L 1 to L 2 occurs from time t 1 to t 3 , as indicated by a curve C 1 in FIG. 1A . From time t 4 to t 6 , the input voltage changes from V 2 to V 1 so that the gray-level of the LC decreases from L 2 to L 1 , as indicated by a curve C 3 in FIG. 1A . However, when the changes in the input voltage become more rapid, as in a display with higher display frequencies and resolutions, the response of the LC will be failed to keep pace with the changes due to the characteristics of the LCD, resulting in a residual effect in displaying frames on the LCD. In order to avoid the residual effect, a method of overdrive has been proposed. At time t 1 , an overdrive input voltage of V 2 ′, instead of the input voltage of V 2 , is initially employed for driving the LC so that the change of the gray-level from L 1 to L 2 takes a smaller period from time t 1 to t 2 , as indicated by a curve C 2 in FIG. 1A . When the gray-level reaches L 2 , the voltage applied to the LC is switched from the overdrive input voltage of V 2 to the input voltage of V 2 . Similarly, at time t 4 , an overdrive input voltage of V 1 ′, instead of the input voltage of V 1 , is initially employed for driving the LC so that the change of the gray-level from L 2 to L 1 takes a smaller period from time t 4 to t 5 , as indicated by a curve C 4 in FIG. 1A . When the gray-level reaches L 1 , the voltage applied to the LC is switched from the overdrive input voltage of V 1 ′ to the input voltage of V 1 .
[0007] When the overdrive voltages of V 1 ′ and V 2 are employed for driving the LC, the corresponding overdrive gray-level values can be recorded and associated with respective previous gray-level values and current gray-level values to establish an overdrive lookup table. In the lookup table, the previous gray-level values and the current gray-level values are regarded as two kinds of index values, denoted by PF and CF, respectively, and are associated with the corresponding overdrive gray-level values, denoted by OD. An overdrive gray-level value OD can then be determined according to the overdrive lookup table. For example, the previous gray-level index values PF and the current gray-level index values CF for 256 gray-levels result in an overdrive lookup table having 256 by 256 pieces of data for overdrive gray-level values OD. Since such a lookup table has a large amount of data, an overdrive lookup table of a reduced amount of data, for example, 17 by 17, is then derived to reduce the size of an overdrive data generator that includes the overdrive lookup table. FIG. 2 illustrates an overdrive lookup table of 17 by 17.
[0008] With a reduced-sized overdrive lookup table, interpolation is additionally required for determining overdrive gray-level values that cannot be directly obtained from the lookup table. FIGS. 3A, 3B , and 3 C show three cases that require interpolation. FIG. 3A shows a first case where the previous gray-level index values PF in the overdrive lookup table contain no item matching previous gray-level data PD. For example, the current gray-level data CD and previous gray-level data PD are 64 and 180 respectively. Since the previous gray-level index values PF has no value of 180, interpolation is required for determination of a corresponding overdrive gray-level value A 1 of the data CD and PD to drive the LC. FIG. 3B shows a second case where the current gray-level index values CF in the overdrive lookup table contain no item matching current gray-level data CD. For example, the current gray-level data CD and previous gray-level data PD are 70 and 176 respectively. Since the current gray-level index values CF has no value of 70, interpolation is required for determination of a corresponding overdrive gray-level value A 2 of the data CD and PD to drive the LC.
[0009] In the third case shown in FIG. 3C , both previous gray-level data PD and current gray-level data CD have no corresponding items found in the previous gray-level index values PF and the current gray-level index values CF in the overdrive lookup table. For example, the current gray-level data CD and previous gray-level data PD are 70 and 180 respectively. Since the current gray-level index values CF has no value of 70 and the previous gray-level index values PF has no value of 180, interpolation is required for determination of corresponding overdrive gray-level values A 1 and A 3 of the data PD and then a desired overdrive gray-level value A 4 according to the values A 1 and A 3 so as to drive the LC with the desired overdrive gray-level value A 4 .
[0010] FIG. 4 illustrates a conventional interpolator. The interpolator 400 includes a subtractor 401 , a subtractor 402 , a multiplier 403 , a shifter 404 , and an addition/subtraction device 405 . For the first or second case where the gray-level index values F contain no item matching gray-level data D, the subtractor 401 is applied with overdrive gray-level values OD 1 and OD 2 that respectively correspond to gray-level index values F 1 and F 2 which come closest to the gray-level data D. The subtractor 401 performs subtraction of the overdrive gray-level values OD 1 and OD 2 and outputs the difference Q 1 . The subtractor 402 receives the gray-level data D and the gray-level index value F 1 , performs subtraction of them, and outputs the difference Q 2 . The multiplier 403 receives the differences Q 1 and Q 2 and outputs the production Q 3 . The shifter 404 receives the production Q 3 , divides it by 16, and output a result Q 4 indicating the integer quotient of the division. The addition/subtraction device 405 receives the result Q 4 and the overdrive gray-level value OD 1 , and outputs an overdrive gray-level value On for driving the LC. For the third case, three times of similar interpolation are required. For the sake of brevity, the third case will not be described in detail. Finally, the interpolator 400 in FIG. 4 achieves a conventional interpolation that can be expressed by: On=OD 1 ±(OD 1 −OD 2 )*(D−F 1 )/(F 1 −F 2 ).
[0011] However, the conventional interpolation obtains the overdrive gray-level value On by linear computations. Such interpolation requires a number of multiplication and addition operations, and the multipliers, notably, are complicated, time-consuming, and large-sized computation devices so that it is difficult to meet the requirement of high computation performance and compact size in implementation. Besides, the results of linear interpolation may not be the closest overdrive gray-level values as determined by experiments.
SUMMARY OF THE INVENTION
[0012] It is therefore an object of the invention to provide an apparatus for overdrive computation and a method therefor.
[0013] The invention achieves the above-identified object by providing an overdrive computation apparatus for generating a desired overdrive gray-level value. The apparatus includes a first addition/subtraction device, a priority encoder, a computation device, and a second addition/subtraction device. The first addition/subtraction device receives a first overdrive gray-level value OD 1 and a second overdrive gray-level value OD 2 , and outputting a difference value indicating difference between the first overdrive gray-level value OD 1 and the second overdrive gray-level value OD 2 . The first overdrive gray-level value OD 1 is a corresponding value with respect to an ith first gray-level index value X(i) and a second gray-level index value Y 1 in an overdrive lookup table. The second overdrive gray-level value OD 2 is a corresponding value with respect to an (i+1)th first gray-level index value X(i+1) and the second gray-level index value Y 1 in the overdrive lookup table. The priority encoder determines a decision signal according to the difference value. The computation device receives first gray-level data, determines a first computation according to the decision signal, and performs the first computation on the first gray-level data to output operated gray-level data. The first gray-level data indicates a value lying between the ith first gray-level index value X(i) and the (i+1)th first gray-level index value X(i+1). The second addition/subtraction device receives the operated gray-level data and the first overdrive gray-level value OD 1 so as to produce the desired overdrive gray-level value.
[0014] The invention achieves another object by providing a computation apparatus including a determining device, a first computation device, and a second computation device. The determining device produces a first decision signal according to a difference between a first gray-level value and a second gray-level value. The first computation device, coupled to the determining device, performs a computation on a third gray-level value according to the decision signal to produce an operated third gray-level value. The second computation device, coupled to the first computation device, produces a desired gray-level value according to the first gray-level value and the operated third gray-level value.
[0015] The invention achieves another object by providing a method of generating a desired overdrive gray-level value. The method includes the following steps. First, a difference value between a first overdrive gray-level value OD 1 and a second overdrive gray-level value OD 2 is determined. The first overdrive gray-level value OD 1 is a corresponding value with respect to an ith first gray-level index value (gray-level index value) X(i) and a second gray-level index value Y 1 in an overdrive lookup table, and the second overdrive gray-level value OD 2 is a corresponding value with respect to an (i+1)th first gray-level index value X(i+1) and the second gray-level index value Y 1 in the overdrive lookup table. Next, a decision signal is generated according to the difference value. According to the decision signal, a first computation is determined and the first computation is performed on first gray-level data to output operated gray-level data, wherein the first gray-level data indicates a value lying between the ith first gray-level index value X(i) and the (i+1)th first gray-level index value X(i+1). Finally, the desired overdrive gray-level value is produced according to the operated gray-level data and the first overdrive gray-level value OD 1 .
[0016] The invention achieves another object by providing a computation method including the following steps. A first decision signal is produced according to a difference value between a first gray-level value and a second gray-level value. A computation is the performed on a third gray-level value according to the decision signal to produce an operated third gray-level value. Next, a desired gray-level value is produced according to the first gray-level value and the operated third gray-level value.
[0017] Other objects, features, and advantages of the invention will become apparent from the following detailed description of the preferred but non-limiting embodiments. The following description is made with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1A (PRIOR ART) illustrates a timing diagram of gray-levels of liquid crystal molecules.
[0019] FIG. 1B (PRIOR ART) illustrates a timing diagram of input voltages applied to the liquid crystal molecules with respect to FIG. 1A .
[0020] FIG. 2 (PRIOR ART) shows an overdrive lookup table of 17 by 17.
[0021] FIG. 3A (PRIOR ART) illustrates a first case where interpolation is required.
[0022] FIG. 3B (PRIOR ART) illustrates a second case where interpolation is required.
[0023] FIG. 3C (PRIOR ART) illustrates a third case where interpolation is required.
[0024] FIG. 4 (PRIOR ART) is a block diagram illustrating a conventional interpolator.
[0025] FIG. 5 shows an overdrive computation apparatus according to first to third embodiments of the invention in block diagram form.
[0026] FIG. 6 shows an overdrive computation apparatus according to a fourth embodiment of the invention in block diagram form.
DETAILED DESCRIPTION OF THE INVENTION
[0027] FIG. 5 shows an overdrive computation apparatus according to first to third embodiments of the invention in block diagram form. The overdrive computation apparatus 500 includes an addition/subtraction device 501 , a priority encoder 502 , a computation device 503 , and an addition/subtraction device 504 . The addition/subtraction device 501 is used for receiving overdrive gray-level value OD 1 and overdrive gray-level value OD 2 and outputting a difference value S 1 between the overdrive gray-level values OD 1 and OD 2 . The priority encoder 502 determines the magnitude of the difference value S 1 and outputting a decision signal S 2 . The computation device 503 receives a signal indicating gray-level data D, determines an computation according to the decision signal S 2 , performs the computation on the gray-level data D, and then outputs a signal indicating operated gray-level data D′. The addition/subtraction device 504 receives the operated gray-level data D′ and the overdrive gray-level value OD 1 , and outputs an overdrive gray-level value OD′.
[0028] For example, in the above-mentioned first case where the previous gray-level index values PF in an overdrive lookup table, such as the one shown in FIG. 2 , contain no item matching previous gray-level data PD, the previous gray-level index values PF 1 and PF 2 that come closest to the previous gray-level data PD are determined, where the value of the previous gray-level data PD lies between the previous gray-level index values PF 1 and PF 2 . The overdrive gray-level value OD 1 is a corresponding value of the current gray-level index value CF and the previous gray-level index value PF 1 while the overdrive gray-level value OD 2 is a corresponding value of the current gray-level index value CF and the previous gray-level index value PF 2 . In this case, the overdrive gray-level values OD 1 and OD 2 are recorded in the overdrive lookup table.
[0029] Similarly, in the above second case where the current gray-level index values CF in the overdrive lookup table contain no item matching current gray-level data CD, the current gray-level index values CF 1 and CF 2 that come closest to the current gray-level data CD are determined, where the value of the current gray-level data CD lies between the current gray-level index values CF 1 and CF 2 . The overdrive gray-level value OD 1 is a corresponding value with respect to the current gray-level index value CF 1 and the previous gray-level index value PF while the overdrive gray-level value OD 2 is a corresponding value with respect to the current gray-level index value CF 2 and the previous gray-level index value PF.
[0030] Next, in the above third case, both previous gray-level data PD and current gray-level data CD have no corresponding items found in the previous gray-level index values PF and the current gray-level index values CF in the overdrive lookup table. The overdrive gray-level values OD 1 and OD 2 cannot be determined by a lookup in the overdrive lookup table. In this case, a desired overdrive gray-level value OD′ can be found by first determining the overdrive gray-level values OD 1 and OD 2 in the way as in the first and the second cases. The desired overdrive gray-level value OD′ can then be determined according to the overdrive gray-level values OD 1 and OD 2 .
[0031] The following provides various embodiments according to the invention, which use different computations according to the magnitude of the difference value S 1 between the overdrive gray-level values OD 1 and OD 2 .
Embodiment One
[0032] In this embodiment, the difference value S 1 may lie in different interval, and the relationship between the interval where S 1 lies and the overdrive gray-level value OD′ is expressed by:
when S1>64 , OD′=OD 1±{ D[ 3:0]<<2};
when 64>S1>32 , OD′=OD 1±{ D[ 3:0]<<2};
when 32>S1>16 , OD′=OD 1±{ D[ 3:0]<<1};
when 16>S1>8 , OD′=OD 1±{ D[ 3:0]};
when 8>S1>0 , OD′=OD 1±{ D[ 3:0]>>1}; and
when S1=0, OD′=OD1,
where D[3: 0] indicates the last four least significant bits (LSBs) of the gray-level data D. During the computation for obtaining the operated gray-level data D′, D[3: 0] is shifted one or more bits to the left or right and then made to be positive or negative according to the interval where the difference value S 1 lies, and the computation of D[3: 0] is added to the overdrive gray-level value OD 1 . For instance, if gray-level data D is previous gray-level data indicating a value of 180. Correspondingly, previous gray-level index values PF 1 and PF 2 are 176 and 192, respectively, and the current gray-level data and the corresponding current gray-level index value CF are both 80. Therefore, the corresponding overdrive gray-level values OD 1 and OD 2 are 28 and 16 respectively. After that, the difference value S 1 between the corresponding overdrive gray-level values OD 1 and OD 2 is determined to be 12 and lies between 8 and 16, resulting in D′=D[3: 0]. The decimal number 180 is 10110100b in binary form. D[3: 0]=0100b=4 (in decimal) and OD′=OD 1 ±{D[3: 0]}=OD 1 ±4=28±4, where a determination has to be made as to whether a positive or negative sign is taken, according to the difference value S 1 . Since S 1 =+12 and OD′ needs to lie between 28 and 16, OD′=28−4=24. By contrast, the overdrive gray-level value is 25 according to the conventional overdrive computation.
[0033] If the gray-level data D is the current gray-level data having a value of 70, the corresponding current gray-level index values CF 1 and CF 2 are 64 and 80 respectively. If the previous gray-level data is 176, the corresponding previous gray-level index value is also 176. Thus, the overdrive gray-level values OD 1 and OD 2 are 24 and 48 respectively. The difference value S 1 is 24. The current gray-level data is 70 in decimal and is 01000110b in binary form such that {D[3: 0]<<1}=1100b=12, and OD′=OD 1 ±{D[3: 0]<<1}=OD 1 ±12=24±12. Since S 1 =−24 and OD′ needs to lie between 24 and 48, OD′=24+12=36.
Embodiment Two
[0034] This embodiment differs from the first one in operated gray-level data D′, wherein the operated gray-level data D′ and the overdrive gray-level value OD 1 are added to determine a desired overdrive gray-level value OD′. In the second embodiment, the relationship between the interval where S 1 lies and the overdrive gray-level value OD′ is expressed by:
when S1>64 , OD′=OD 1±{ D[ 3:0]<<2};
when 64>S1>32 , OD′=OD 1±{ D[ 3:0]<<1};
when 32>S1>16 , OD′=OD 1±{ D[ 3:0]};
when 16>S1>8 , OD′=OD 1±{ D[ 3:0]>>1};
when 8>S1>0 , OD′=OD 1±{ D[ 3:0]>>1}; and
when S1=0, OD′=OD1.
For instance, if gray-level data D is previous gray-level data indicating a value of 52. Correspondingly, previous gray-level index values PF 1 and PF 2 are 48 and 64, respectively, and both the current gray-level data and the corresponding current gray-level index value CF are 80. The corresponding overdrive gray-level values OD 1 and OD 2 are then 96 and 84 respectively. After that, the difference value S 1 between the corresponding overdrive gray-level values OD 1 and OD 2 is determined to be 12 and lies between 8 and 16, resulting in OD 1 =OD 1 ±{D[3: 0]>>1}. The binary form of decimal number 52 is 110100b. D[3: 0]=0100b=4 (in decimal) and {D[3: 0]>>1} indicates a value obtained by shifting D[3: 0] one bit to the right, that is, dividing D[3: 0] by 2, such that {D[3: 0]>>1}=010b=2 (in decimal); and OD′=OD 1 ±{D[3: 0]>>1}=OD 1 ±2=96±2. Next, a determination is made as to whether a positive or negative sign is taken in the above expression, according to the difference value S 1 . Since S 1 =+12 and OD′ needs to lie between 96 and 84, OD′=96−2=24.
[0035] If the gray-level data D is the current gray-level data having a value of 70, the corresponding current gray-level index values CF 1 and CF 2 are 64 and 80 respectively. The previous gray-level data is 48, the corresponding previous gray-level index value is also 48, and thus the overdrive gray-level values OD 1 and OD 2 are 72 and 96 respectively. The difference value S 1 is 24. The current gray-level data indicating 70 in decimal is 01000110b in binary form such that D[3: 0]=110b=6, and OD′=OD 1 ±{D[3: 0]}=OD 1 ±6=72±6. Since S 1 =−24 and OD′ needs to lie between 72 and 96, OD′=72+6=78.
Embodiment Three
[0036] In the third embodiment, the relationship between the interval where S 1 lies and the overdrive gray-level value OD′ is expressed by:
when S1>64 , OD′=OD 1±{ D[ 3:0]<<2};
when 64>S1>32 , OD′=OD 1±{( D[ 3:0]<<1)+( D[ 3:0]<<2)}/2;
when 32>S1>16 , OD′=OD 1±{ D[ 3:0]+( D[ 3:0]<<1)}/2;
when 16>S1>8 , OD′=OD 1±{( D[ 3:0]>>1)+ D[ 3:0]}/2;
when 8>S1>0 , OD′=OD 1±{ D[ 3:0]>>1}; and
when S1=0, OD′=OD1.
In this embodiment, operated gray-level data D′ obtained by using the computations disclosed in the first and the second embodiments are averaged and then the averaged data and overdrive gray-level value OD 1 are added together. The positive or negative sign in the expressions is determined in the way as in the above embodiments.
Embodiment Four
[0037] In the fourth embodiment, current gray-level data CD and previous gray-level data PD are first compared and the difference value S 1 is examined in magnitude so as to determine a computation for calculating the desired result. If PD<=CD, the relationship between the interval where S 1 lies and the overdrive gray-level value OD′ is expressed by:
when S1>64 , OD′=OD 1±{ D[ 3:0]<<2};
when 64>S1>32 , OD′=OD 1±{ D[ 3:0]<<1};
when 32>S1>16 , OD′=OD 1±{ D[ 3:0]};
when 16>S1>8 , OD′=OD 1±{ D[ 3:0]>>1};
when 8>S1>0 , OD′=OD 1±{ D[ 3:0]>>1}; and
when S1=0, OD′=OD1.
If PD>CD, the relationship between the interval where S 1 lies and the overdrive gray-level value OD′ is expressed by:
when S1>64 , OD′=OD 1±{ D[ 3:0]<<2};
when 64>S1>32 , OD′=OD 1±{ D[ 3:0]<<2};
when 32>S1>16 , OD′=OD 1±{ D[ 3:0]<<1};
when 16>S1>8 , OD′=OD 1±{ D[ 3:0]};
when 8>S1>0 , OD′=OD 1±{ D[ 3:0]>>1}; and
when S1=0, OD′=OD1.
[0038] If the previous gray-level data PD is 180, the corresponding previous gray-level index values PF 1 and PF 2 are 176 and 192 respectively. If the current gray-level data CD is 80, the corresponding current gray-level index value CF is also 80. The gray-level data D is equal to the previous gray-level data PD. Since PD is greater in value than CD, that is 180>80, the above-defined expressions with respect to the condition PD>CD are applicable in this case. The overdrive gray-level values OD 1 and OD 2 are 28 and 16 respectively, and the difference value S 1 is 12. Thus, OD′=OD 1 ±D[3: 0]=28±4=28−4=24, where the negative sign in this expression is determined according to the criteria in the first and the second embodiments.
[0039] If the current gray-level data CD indicates 70, the corresponding current gray-level index values CF 1 and CF 2 are 64 and 80 respectively. If the previous gray-level data PD indicates 48, the corresponding previous gray-level index value PF is also 48. The gray-level data D is equal to the current gray-level data CD in value. Since PD is smaller than CD in value, that is 48<70, the above-defined expressions with respect to the condition PD<=CD are applicable in this case. The overdrive gray-level values OD 1 and OD 2 are 72 and 96 respectively, and the difference value S 1 is 24. Therefore, OD′=OD 1 ±D[3: 0]=72±6=72+6=78, where the positive sign in this expression is determined according to the criteria in the first and the second embodiments.
[0040] If the current gray-level data CD indicates 70 and the previous gray-level data PD indicates 180, the corresponding current gray-level index values CF 1 and CF 2 are 64 and 80 respectively and the previous gray-level index values PF 1 and PF 2 are 176 and 192 respectively. In this case, three computation steps are needed to produce the desired result. As an example, two overdrive gray-level values OD′ are determined by performing two computation steps: (1) taking CD as 70 and PD as 176 and (2) taking CD as 70 and PD as 192, respectively. The desired overdrive gray-level value OD′ with respect to CD of 70 and PD of 180 is then determined in the third step according to the two determined overdrive gray-level values OD′ in the above two steps. Alternatively, two overdrive gray-level values OD′ can be determined by performing two computation steps: (1) taking PD as 180 and CD as 64 and (2) taking PD as 180 and CD as 80. Since the detailed computation is similar to the above embodiments and thus will not be described for the sake of brevity.
[0041] Referring to FIG. 6 , an overdrive computation apparatus is shown according to the fourth embodiment of the invention in block diagram form. In comparison with the apparatus 500 in FIG. 5 , the overdrive computation apparatus 600 in FIG. 6 further includes a comparator 601 . The apparatus 601 is so configured because the overdrive computation according to this embodiment requires comparing previous gray-level data PD and current gray-level data CD. The comparator 601 receives a signal indicating gray-level data D, such as current gray-level data CD, receives a signal indicating gray-level data D 1 , such as previous gray-level data PD, and then produces a decision signal S 3 according to the received data D and D 1 , for example the difference between the received data D and D 1 . According to the decision signals S 2 and S 3 , the computation device 503 determines a computation to be performed.
[0042] In the above embodiments of invention, the overdrive computation apparatus and the involved computation, which can be regarded as non-linear, are used for interpolation. In another embodiment, they can be used for implementation of extrapolation.
[0043] In the above embodiments, the overdrive computation apparatus and the involved computation achieve a simplified overdrive computation and a reduced chip area of circuitry implementing the computation apparatus, as compared with the conventional ones that rely on multipliers for interpolation. In comparison with the results obtained by experiments, the simplified computation produces desired results having less error than those obtained by the conventional interpolation. That is, the above embodiments according to invention can produce results for interpolation with better accuracy.
[0044] While the invention has been described by way of example and in terms of a preferred embodiment, it is to be understood that the invention is not limited thereto. On the contrary, it is intended to cover various modifications and similar arrangements and procedures, and the scope of the appended claims therefore should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements and procedures. | An apparatus for overdrive computation and method therefor. The overdrive computation apparatus is used for generating a desired overdrive gray-level value and includes first and second addition/subtraction devices, a priority encoder, and a computation device. The first addition/subtraction device outputs a difference value indicating difference between a first overdrive gray-level value OD 1 and a second overdrive gray-level value OD 2 . The priority encoder determines a decision signal according to the difference value. The computation device receives first gray-level data, determines a first computation according to the decision signal, and performs the first computation on the first gray-level data to output operated gray-level data. The first gray-level data indicates a value lying between the ith first gray-level index value X(i) and the (i+1)th first gray-level index value X(i+1). The second addition/subtraction device receives the operated gray-level data and the first overdrive gray-level value OD 1 to produce the desired overdrive gray-level value. | 6 |
This application is a division of application Ser. No. 08/735,134, filed on Oct. 22, 1996, the contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates in general to a process and apparatus designed to treat water degraded by acid mine drainage (AMD) and industrial or chemical manufacturing processes; and, more particularly, to a process and apparatus for carbon dioxide pretreatment and accelerated limestone dissolution for treatment of acidified water.
BACKGROUND OF THE INVENTION
Industrial, chemical and mining processes resulting in acid deposition have had a significant negative effect on aquatic resources in North America, including the loss of important commercial and recreational fisheries. Direct effects of acidification on fish include acute mortality, reproductive failure, altered growth rates, and chronic impairment to body organs and tissues. Negative indirect effects of acidification include fish habitat degradation, increase in concentrations of soluble toxic metals, such as aluminum, and changes in predator-prey relationships. Within the coal deposit regions of Appalachia and the Ohio River Basin, acid mine drainage (AMD) contributes significantly to acid deposition in surface waters. See Table 1 below.!
TABLE 1______________________________________Miles of streams degraded by AMD in theAppalachian coal region (Pennsylvania Department ofEnvironmental Protection (1995). State Miles______________________________________ Pennsylvania 2594 West Virginia 1900 Maryland 156 Ohio 852 Kentucky 1129 Virginia 101 Tennessee 698 Alabama 626______________________________________
In Pennsylvania alone, AMD has degraded 2,600 miles of streams resulting in an annual loss of revenues associated with sport fishing of 67 million dollars. Given the severity of the problem and associated environmental/economic ramifications, the National Biological Service (NBS) in February 1995 signed the statement of Mutual Intent for "Restoration and Protection of Streams and Watersheds Polluted by Acid Mine Drainage from Abandoned Coal Mines," put forth by the Office of Surface Mining and the Environmental Protection Agency. Work has been done to increase the understanding and application of the best technologies available for remediating and preventing mine drainage and to support the development of new technologies.
Acid mine drainage (AMD) results from the dissolution of pyrite and its subsequent oxidation to sulfuric acid:
FeS.sub.2 +H.sub.2 O+3.5O.sub.2 →FeSO.sub.4 +H.sub.2 SO.sub.4( 1)
Sulfuric acid dissolves aluminum, manganese, zinc, and copper from soil, and thus drainage is not only highly acidic but it may contain toxic metallic ions. Mitigation of AMD is typically achieved through direct addition of alkaline materials followed by clarification. High costs, however, limit widespread application of treatment. For example, with currently available technology, it has been estimated that 15 billion dollars will be required to correct AMD-related problems in Appalachia and 5 billion dollars in Pennsylvania. Alkaline materials used to treat acidified water include anhydrous ammonia, sodium hydroxide, sodium carbonate, calcium hydroxide, calcium oxide, and limestone. Limestone is a shaly or sandy sedimentary rock composed chiefly of calcium carbonate. Use of limestone (calcium carbonate) is desirable given its relatively low cost and widespread availability. Moreover, limestone is less caustic than alternative reagents; thus, use of limestone reduces the hazards of handling and application. Limestone dissolution also provides calcium ions needed to reduce the toxicity of certain dissolved metals. However, limestone use is restricted to sites with low acidities due to the slow dissolution (acid neutralizing) rates and problems associated with the development of a metal hydroxide coating of the limestone particles (armoring).
A variety of processes and apparatus designs using calcium carbonate have been developed in an attempt to treat effluent acidity.
In U.S. Pat. No. 4,272,498, Faatz discloses a non-mechanical method of converting coarsely ground limestone to a very fine powder. A slurry of this ground limestone is then contacted with carbon dioxide gas at high pressure to convert the solids in the slurry to an unstable form. The carbon dioxide pressure is instantaneously released to form a slurry of activated calcium carbonate particles substantially reduced in size. The activated calcium carbonate slurry is then used to scrub flue gases.
In U.S. Pat. No. 2,642,393, H. W. Gehm et al. discloses a neutralizing unit for a plant or system for the neutralization of acidic liquids. The arrangement effects an upflow of acid waste through a filter bed of a neutralizing agent of solid particles that are maintained in suspension and continually agitated. Air is used to affect a further suspension and agitation of the limestone particles, but does not chemically effect the reaction between the effluent and the limestone. There is no disclosure of carbon dioxide pretreatment of the effluent to increase limestone dissolution, pulsed bed technology which decrease the system's sensitivity to limestone armoring, or the recycling of CO 2 , gas.
In U.S. Pat. No. 1,742,110, C. R. Weihe discloses the use of a neutralizing agent to be maintained in contact with the running stream of waste water in such a way that the treating agent does not pass out with the waste water in the stream. The invention is particularly adapted for use in connection with neutralizing waste waters from mines, mills, and factories before it enters streams, lakes or rivers.
In U.S. Pat. No. 3,527,702, Holluta et al. disclosed a method of removing carbon dioxide from water using Portland cement clinkers or set hydraulic cements which consist of calcium oxide, silica and iron-aluminum oxides.
In U.S. Pat. No. 4,153,556, Riedinger discloses an apparatus for conditioning "aggressive" demineralized brackish water or sea water to remove CO 2 and raise the pH to about 8. A wide angle, low pressure (approximately 10-20 psi) spray nozzle is used to supply purified aggressive water to the system so that it can percolate up through the limestone bed and pass out through an outlet pipe to a final conditioned water storage tank.
In U.S. Pat. No. 5,158,835, Burke discloses blocks weighing about 35 lbs., formed of a homogenous mixture of about 75% gypsum and 25% lime. The blocks are strategically placed in surface water that is being damaged by acid rain and where by timed release of lime, the pH of the water is maintained at about 6.5.
In U.S. Pat. No. 5,484,535, Downs discloses a method for treating effluent seawater including aerating the effluent seawater in an aeration pond. The aerated effluent seawater is then channeled back to the fresh seawater source. Fresh limestone is added periodically to the bed and the size of the bed is varied depending on the amount of effluent seawater to be treated.
In U.S. Pat. No. 5,487,835, Shane discloses a method and apparatus for controlling the pH of a water stream using carbon dioxide. Carbon dioxide at a selected pressure and flow rate is mixed with the carrier water also at a selected pressure and flow rate. The carbon dioxide-carrier water mixture is injected into the water stream, which is at a lower pressure, allowing the carbon dioxide to come out of the solution, contact the water stream and correspondingly adjust the pH of the water stream.
In addition, a variety of apparatus designs have been used to dose AMD with calcium carbonate. These include a rotary drum, electric powered dosers, packed beds, and a diversion well. The diversion well has been applied with relatively low initial capital and maintenance costs at several Pennsylvania AMD sites. The diversion well is designed to establish a fluidized bed of crushed limestone 6-25 mm in diameter. Fluidization occurs within a cylindrical well that receives water through a centrally located down pipe discharging water at the bottom of the well. The diverted water flows upward through the limestone with sufficient force to agitate and fluidize the medium causing abrasion of the aggregate for enhanced dissolution. Although the device provides low total costs of treatment, treatment effect is severely limited by the use of relatively large aggregate diameters and high required hydraulic loading rates. The large aggregate diameters are used to circumvent problems such as a slow dissolution rate, associated with metal hydroxide coating of the limestone. This coating or armoring of the medium occurs rapidly when treating waters with high ferrous iron (Fe ++ ) concentrations.
Therefore, in spite of numerous attempts to restore water degraded by acid mine drainage and industrial chemical processes, there still remains a need for an improved process and apparatus using carbon dioxide pretreatment of the effluent to accelerate limestone dissolution with subsequent recycling of the CO 2 gas stripped or recovered from water exiting the apparatus.
SUMMARY OF THE INVENTION
The present invention is a method of using a intermittently fluidized (pulsed) limestone bed system incorporating carbon dioxide pretreatment to enhance restoration of acidified water from acid mine drainage and chemical industrial processes.
The method for reducing acidity in effluent discharge comprises charging the effluent with CO 2 , intermittently fluidizing and expanding at least one pulsed limestone bed with the charged effluent, treating the charged effluent with the limestone in the bed, displacing the limestone treated effluent from the bed with untreated charged effluent, stripping excess CO 2 from the effluent after treatment in the limestone bed, and discharging the limestone treated effluent. The method includes treating the CO 2 charged effluent in the limestone bed for preferably at least two minutes, more preferably about four to eight minutes. The charging of the untreated effluent is done in at least one stage. The stripping of CO 2 from the treated effluent is done in at least one stage. The stripped CO 2 can be recycled to the untreated effluent, and the treated effluent can be recycled to the untreated effluent or partially treated effluent. The step of intermittently fluidizing and expanding at least one pulsed limestone bed with charged effluent includes generally concurrently intermittently fluidizing and expanding at least one other pulsed limestone bed with charged effluent, whereby each limestone bed is expanded and fluidized alternately. The method further includes alternating between the limestone bed sets after preferably at least two minutes of treatment in one bed set, more preferably about four to eight minutes. The method includes introducing charged effluent at rates that exceed particle size dependent minimum fluidization velocities during expansion of the limestone beds. The method includes decreasing the limestone bed sensitivity to limestone armoring. The method includes raising the pH of the treated effluent to at least 5. Mineral acidities in excess of 1000 mg/l as CaCO 3 have been neutralized.
The apparatus for reducing the acidity in effluent discharges comprises means for charging the effluent with CO 2 , means for intermittently fluidizing and expanding at least one pulsed limestone bed with the charged effluent, means for treating the charged effluent in the limestone bed, means for displacing the limestone treated effluent from the bed with untreated charged effluent, means for stripping excess gas from the effluent after treatment in the bed, and means for discharging the limestone treated effluent. The apparatus includes means for treating the charged effluent with the limestone in the beds for preferably at least two minutes, more preferably about four to eight minutes. The apparatus includes means for generally concurrently intermittently fluidizing and expanding at least one other pulsed limestone bed with charged effluent, whereby each pulsed limestone bed is fluidized alternatively. The apparatus further includes means for alternating between the limestone beds after preferably at least two minutes of treatment, more preferably about 4 to 8 minutes. The apparatus also includes means for venting stripped CO 2 into the atmosphere, and means for recycling said treated effluent into said untreated effluent or partially treated effluent. The apparatus also includes means for charging said untreated effluent in at least one stage and stripping said CO 2 from said treated effluent in at least one stage. The apparatus also includes means for replacing the limestone in at least one bed.
It is an advantage of this method to accelerate limestone dissolution rates by increasing dissolved carbon dioxide concentrations and to decrease the treatment systems sensitivity to limestone armoring by intermittent fluidization of the limestone beds. Other advantages include the ability to enhance rates of biological productivity in acidified impaired waters, improve the efficiency and reduce the cost of limestone beds for the treatment of acid drainages, to increase the hardness and alkalinity of very soft waters, to make acid drainage suitable for development of aquaculture production, and to obtain the release of calcium ions from calcium carbonate to reduce the toxicity of certain dissolved metals.
The invention will be more fully understood from the following description of the invention and references to the illustration and appended claims hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, preferred embodiments of the invention are illustrated by way of example only, wherein:
FIG. 1 is a schematic of flows through a pulsed bed system incorporating carbon dioxide pretreatment for enhanced restoration of acid mine drainage.
FIG. 2 is a schematic of flows through a pulsed bed system incorporating carbon dioxide pretreatment using a three-stage absorber and a three-stage stripper with counter current gas and liquid flows.
FIG. 3 is a schematic of flows through a pulsed bed system incorporating carbon dioxide pretreatment using individual absorber and stripper stages paired and coupled with individual CO 2 rich and lean gas lines.
FIG. 4 is a schematic of flows through a pulsed bed system incorporating carbon dioxide pretreatment and recycle of effluent exiting the pulsed limestone beds.
FIG. 5 shows the major components of the test system incorporating carbon dioxide pretreatment, two pairs of limestone beds and recycle of pulsed limestone bed effluent. All motorized valves are controlled by a single time-based electronic controller.
FIG. 6 is a schematic of treatment and recharge cycle flows that occur concurrently within the test limestone dissolution system.
FIG. 7 is a graph showing the effect of carbon dioxide regulator pressure on the mass of limestone dissolved Δ acidity and effluent alkalinity! during treatment of water representing four levels of acidity.
FIG. 8 is a graph showing the effect of inlet acidity on the mass of limestone dissolved Δ acidity and effluent alkalinity! when operating at five different regulator pressures.
FIG. 9 is a graph showing the effect of carbon dioxide regulator pressure on effluent alkalinity during treatment of waters representing four levels of acidity.
FIG. 10 shows test water pH before and after treatment.
FIG. 11 shows the effect of treatment cycle duration on the mass of limestone dissolved Δ acidity and effluent alkalinity! when operating at three different regulator pressures and two inlet acidities.
FIG. 12 is a schematic of flows with side stream treatment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The rate of limestone dissolution is related to particle size, composition, turbulence, temperature, water chemistry, and the presence or absence of metal hydroxides or precipitates that tend to coat the stone. The rate of limestone (CaCO 3 ) dissolution is accelerated when inlet water acidity H + is high as shown in (2)
CaCO.sub.3 +H.sup.+ →Ca.sup.+2 +HCO.sub.3.sup.- (2)
and when aggregate size is small.
In equation form the dissolution rate is expressed as (3)
______________________________________ ##STR1## ##STR2##wherein:-dm/dt = Change in limestone mass with timeD = DifusivityΔr = Thickness of boundary layer ! = Ion concentrationk.sub.2 = Rate constant, reaction with carbon dioxidekW = Rate constant, reaction with waterkB = Rate constant, backward reaction ratem = Massp = Particle density______________________________________
Inspection of Eqn (3) reveals dissolution of calcium carbonate is accelerated at low inlet pH, high free carbon dioxide concentrations, and when aggregate size is small. Reducing particle size within a conventional diversion well, however, reduces significantly the flow required for fluidization, (Vmf). The correlation is provided by (4)
______________________________________ ##STR3## ##STR4##wherein:p = Particle densityP = Density of watervmf = Minimum fluidization velocityμ = ViscosityDeq = Equivalent diameterPp = Density of particle of mediag = Acceleration due to gravity______________________________________
Based on Eqn (4) reducing particle diameter from 1.5 mm to 0.7 mm, for example, decreases Vmf by about 70%. This response, in turn, limits the turbulence and interparticle collision forces needed to inhibit armoring. To circumvent the problems associated with small particle sizes, pulsed-bed technology is used in the present invention. Pulsed-beds are defined as intermittently fluidized limestone beds.
To accelerate limestone dissolution rates, commercial carbon dioxide gas is dissolved into the AMD prior to treatment (all or part as in the case of effluent recycle). The carbon dioxide is obtained from a commercial source, a carbon dioxide generator or is recycled from the pulsed bed effluent or a combination of more than one of the sources listed. Absorption of carbon dioxide will increase reaction rates through temporary development of high carbon dioxide concentrations and reduced pH (Eqns (3), (5) and (6)):
H.sub.2 0+CO.sub.2 H.sub.2 CO.sub.3 H.sup.+ +HCO.sub.3.sup.-(5)
CaCO.sub.3 +H.sub.2 O+CO.sub.2 →Ca.sup.2+ +2HCO.sub.3.sup.-(6)
The effect of free carbon dioxide on pH is described by the Henderson Hasselbalch equation (7).
______________________________________ ##STR5##wherein:pH = Negative log of hydrogen ion activitypK.sub.1 = Negative log of the disassociation constant______________________________________
With an inlet alkalinity of 0.5 mg/l, increasing the free carbon dioxide concentration from 5 to 50 mg/l lowers the pH from about 5.4 to 4.5 mg/l. This change in pH will increase reaction rates approximately 3.5 fold. This data shows that dissolved carbon dioxide is a performance control variable or accelerant of limestone dissolution, particularly when the mine drainage has moderate pH and acidity levels or when high levels of the reaction product (HCO 3 - ) are required for treatment. High levels of HCO 3 - allow for side-stream treatment and hence a reduction in reactor size given the ability of HCO 3 - to react with acids (8):
HCO.sub.3.sup.- +H.sup.+ CO.sub.2 +H.sub.2 O (8)
Carbon dioxide levels in water are increased through reaction as shown in Eqn (8) and through development of appropriate gas-liquid interfacial area and along with control of the dissolved gas deficit. The gas deficit represents the difference between the saturation concentration of CO 2 in the water (C*) and the ambient concentration. The C* of CO 2 is determined by its partial pressure in the gas phase, water temperature, and water composition as related by Henry's Law (9)
______________________________________ ##STR6##wherein:C* = Saturation concentration of a gas in waterB.sub.i = Bunsen solubility coefficientK.sub.i = Ratio of molecular weight to molecular volumeX.sub.i = Mole fraction of gas in the gas phaseTP = Total pressureVP = Water vapor pressure______________________________________
The CO 2 absorption and stripping equipment used in the process alters C* by changing system pressure and the mole fraction (X i ) of CO 2 in the gas phase. The apparatus allows for capture and reuse of carbon dioxide present in the systems effluent to minimize carbon dioxide requirements and maximize effluent pH (Eqn (7)).
In operation, a valve assembly intermittently directs water into a small particle size (range about 0.05 to about 25 mm Deq (equivalent diameter)) bed of limestone, so as to expand the bed and allow for bed turnover and contraction (setting). A particle size close to fine sand has been used with the following particle size distribution.
TABLE 2______________________________________RETAINED ON STANDARDUS SIEVE NO. PERCENTAGE PASSING______________________________________8 010 020 8.240 63.360 24.9100 2.6270 1.0______________________________________
During bed expansion, water is introduced at a hydraulic loading rate that provides upflow velocities in the limestone bed that exceed the minimum fluidization velocity (Vmf, Eqn (4)) by a factor greater than 1.0, providing for high levels of particle attrition and turbulence. Water flow is interrupted prior to the expansion of the bed into the effluent. Altering the extent of the settling period allows for control of retention time/treatment effect. Control of this type is needed when AMD composition and flow varies seasonally. It is intended that metal precipitates such as iron hydroxide that often form during treatment will be purged from the reactor by the movement of the AMD through the limestone bed.
As the acidity of AMD is reduced by exposure to limestone within a reactor, the rate of acid neutralization slows rapidly (Eqn (3)) making it difficult to achieve needed changes in water chemistry (pH, acidity, alkalinity). The method and apparatus of the present invention avoids this problem by incorporating a unique carbonation pretreatment step. Here, the transfer of carbon dioxide into the AMD prior to or during treatment increases the rate of limestone dissolution through temporary development of high free carbon dioxide concentrations and increased acidity (lowers pH). The high free carbon dioxide concentrations encourage the dissolution of limestone via the reaction given as (6) hereinabove, and the product of the reaction (HCO 3 - ) is then available for acid neutralization as shown above in Eqn (8). This neutralization can occur within the water treatment system or, in the case of side stream treatment, it can occur at the point where treated water is mixed with AMD.
The carbon dioxide pretreatment step accelerates gas absorption by exposing the AMD to a gas with a partial pressure of carbon dioxide that exceeds dissolved carbon dioxide tensions in the AMD, and by establishing gas-liquid interfacial area needed for gas transfer. For example, exposing water to carbon dioxide at a pressure of 100 psi (gage) can increase the carbon dioxide saturation concentration (C*, Eqn (9)) by a factor of about 22,000. It is understood that gas-liquid interfacial area can be created by a number of reactor types (e.g. U-tubes, spray columns, packed beds, gas spargers, surface agitators, perforated trays), stages, and that the gas-liquid contacting can take place at pressures above, at, or below local atmospheric pressures. Following treatment in the limestone bed, the apparatus allows for capture and reuse of carbon dioxide not utilized in the first pass through the system or that generated during acid neutralization (Eqn (8)) as shown in FIGS. 1-4, so as to minimize makeup gas requirements and maximize effluent pH. It is understood that the degree of recovery of the carbon dioxide from the AMD exiting the limestone beds can be varied from zero percent to rates approaching one hundred percent, depending on equipment design, operating costs and desired AMD treatment effects. An alternate unillustrated embodiment can have just one pulsed limestone bed.
In FIG. 1, a timer-relay valve assembly 6 directs carbon dioxide charged effluent into small particle size (0.2 mm) beds 1 and 2 of limestone intermittently so as to expand the beds and allow for bed turnover and contraction (settling). Using two beds with equal on-off periods of flow provides for an uninterrupted supply of treated water exiting the apparatus 10. During bed expansion, water is introduced at a rate that exceeds Vmf (Eqn(4)) by a factor greater than 1.0 to ensure high levels of particle attrition and turbulence. Water flow is interrupted prior to bed carry over in the effluent, although it is understood that limestone dust, fines and particles that have been reduced in size due to chemical reaction (dissolution) will be present in the limestone bed effluent, but at low concentrations. Altering the extent of the settling (contraction) period and the duration and rate of the fluidization period allows for control of retention time, hydraulic head requirement, the mass of limestone available for AMD treatment, and apparatus performance. Carbon dioxide from the stripper 7, and carbon dioxide from a liquid carbon dioxide storage tank 8 that provides carbon dioxide gas under pressure to the gas regulator 5, is in the two absorbers 3 and 4 dissolved in the inflowing AMD. After the AMD has passed through the pulsed bed reactors, it is directed through the carbon dioxide stripper 7 for removal of surplus carbon dioxide. A carrier gas or gas mixture such as air is used to pick up and carry away carbon dioxide stripped from the effluent. The carbon dioxide enriched gas is routed through a closed conduit 18 to preclude dilution of the carbon dioxide with the surrounding atmosphere. Upon entering the carbon dioxide absorber 3, the carbon dioxide concentration in the carrier gas is reduced as the carbon dioxide is transferred into the inflowing AMD. In the example, the carbon dioxide lean gas mixture exiting the absorber is routed through a second closed conduit 19 back to the carbon dioxide stripper 7 to pick up additional carbon dioxide. Gas flows between the absorber and stripper may be forced with a blower, compressor, or fan. It is well known in the art that gas absorber and stripper performance will be influenced by gas circulation rates, e.g. in packed-bed applications air flow rates used for carbon dioxide stripping are often 2-10 times the water inflow rate on a volumetric basis (m 3 /min). The gas absorber and strippers used are designed to isolate treatment system gases from the atmosphere so as to conserve carbon dioxide although it is understood that some venting may be required to control gas pressure or volume. Water exiting the stripper 7 is routed through a settling pond 10 to allow metal precipitates forming in the AMD during and after treatment to be separated from the water by gravitational forces before the AMD is discharged into receiving waters.
FIGS. 2 and 3 show examples of absorberstripper configurations that can be used in the AMD treatment process to improve the efficiency of the carbon dioxide pre and post treatment steps, i.e. staging of the gas transfer equipment and circulating gas in closed conduits to establish counter current gas-AMD flows (FIG. 2) or absorber-stripper pairs (FIG. 3). FIG. 4 gives the schematic of gas and liquid flows in the preferred embodiment of the treatment process. Here, AMD exiting the limestone beds 11 is routed back to the limestone bed influent line 12 through a pumped 14 water recycle line 13 to increase water retention time in the treatment system beds 1 and 2. An alternative location for picking up the AMD to be recycled includes the discharge of the carbon dioxide stripper 15. Alternative points for reintroducing the recycled AMD are marked 16 and 17. Water recycle rates can be varied to control water retention time or treatment effect. Introducing partially treated water into the limestone beds with the recycle system in operation can reduce the effective concentration of dissolved metals such as iron that the limestone is exposed to and hence, can reduce the potential for armoring of the limestone particles. With AMD recycle, closing valves marked 118 and 119 with a controller 20 allows for system operating pressures to exceed local barometric pressures when closed conduits are used to route liquid flows and when the limestone beds are constructed as pressure vessels. With this configuration, operating pressures within the recycle loop can reach carbon dioxide (make up) feed line 5 pressures. Feed line pressures are determined by liquid carbon dioxide tank pressure and pressure drop through the required pressure regulator, flow control valve and gas lines 5. Typically, pressure will be kept below about 300 psi(gage). Pressure within the recycle loop can also increase both with and without the use of make-up carbon dioxide 8 by the generation of carbon dioxide in the acid neutralization reaction (Eqn (8)). Operation of valves 118 and 119 with a timer control system 20 provides for batch treatment of the AMD. Associated interruption in system inflow 17 and outflow 10 can be avoided by incorporating a second pair of pulsed limestone beds. The two pairs of pulsed beds here would be plumbed so that while one pair is in the treatment mode (with recycle), the second pair of pulsed beds is in the mode that displaces treated AMD from the limestone beds by inflowing untreated AMD. Partial mixing of the untreated AMD with treated AMD in the plumbing just upstream of the limestone bed will, when bicarbonate is present in the treated AMD, result in elevated concentrations of carbon dioxide as shown in Eqn (8). It is understood that the two pairs of limestone beds would alternate between the treatment and displacement modes as directed by an appropriate timer control system. A treatment unit prototype incorporating this type of control/operating procedure is shown in FIG. 5, and a schematic of treatment and recharge flows are given in FIG. 6. The system was designed to handle AMD inflow rates of about 1.5 to about 3.5 gallons per minute using ground limestone with the particle size distribution given hereinbefore in Table 2.
The major components of the system include four substantially 10 cm diameter pressure vessels (limestone beds 1, 2, 3 and 4)) charged with granular limestone, a centrifugal pump 5, a packed tower carbonator 6, and a time-relay control system (not shown) used to direct the systems 3-way electric ball valves 7. Two of the four limestone beds (1 and 2 or 3 and 4) receive recycled water alternately from the carbonator 6, under pressure, to maintain high free carbon dioxide concentrations and to accelerate limestone dissolution. Pressure is provided by carbon dioxide entering the carbonator from a pressurized storage tank. System pressure is set by tank regulator pressure. Following treatment of at least two minutes, preferably about four to eight, both limestone beds receiving recycled AMD are isolated from the carbonator by the control system, then vented to the atmosphere, allowing degassing to occur as the treated water is displaced from the limestone beds by incoming AMD allowed at this time to pass through appropriate influent check valve (FIG. 5 (8)). When operating the test apparatus, the carbon dioxide stripping component was tested intermittently by sparging air in effluent AMD samples, thus allowing the effect of carbon dioxide stripping effects on effluent AMD chemistry to be identified (i.e., pH and acidity). Concurrently, the limestone beds in the vented or recharge mode (FIG. 6) are coupled with the carbonator, pressurized, and alternately expanded (fluidized) by recycle pump flow. This concurrent switch over occurs after at least two minutes, preferably four to eight, and a constant discharge from the treatment unit is then maintained. Check valves 9 in FIG. 5 prevent water in the recycle (treatment) loop from mixing with the water being displaced by inflowing AMD.
Performance of the test apparatus shown in FIG. 5 was evaluated using all combinations of the following design variables:
influent acidity: 9; 200; 555 and 1025 mg/l as CaCO 3 ; and
carbon dioxide supply tank regulator pressure (system operating pressure): 0; 10; 30; 60 and 100 psig.
Each unique set of operating conditions was replicated once providing a total of 40 observations. The system was also operated using two different treatment cycles (4 min. and 8 min.) at each of three operating pressures (0, 30 and 100 psig) and two influent acidities 9 mg/l and 1,000 mg/l!. In all tests, bed expansion and contraction periods for individual columns were equal (1 min), and AMD was simulated by adding sulfuric acid to well water with the following characteristics:
1. pH 6.7
2. acidity 9 mg/l
3. alkalinity 30 mg/l
4. water temperature 9°-10° C.
During tests, bed depth (limestone) after settling was kept at about 60 cm. Performance was assessed by measuring changes in variables 1-4 above across the system during treatment both with and without air stripping of dissolved carbon dioxide. Acidity and alkalinity were measured by titration using standard methods American Public Health Association, American Waterworks, Associated Water Pollution Control Federation (APHA), 1985!. The pH was measured electrochemically. Least squares regression analysis was used to establish correlations among performance variables and operating conditions. During this series of tests, carbon dioxide stripped from the intermittently obtained discharge samples was not recycled.
Laboratory tests demonstrated the ability of the new apparatus to accelerate limestone dissolution well beyond rates established with alternative equipment designs. Carbon dioxide pressure (X) and influent acidity effects on effluent alkalinity (Y 1 ) and the mass of limestone dissolved per liter treated (Y 2 ) are shown in FIGS. 7 through 9. The response of both variables to increases in regulator pressure in FIGS. 7 and 9 were fit with the model shown as equation (10)
Yi=a+bX.sup.0.5 (10)
In all cases, coefficients of determination (r 2 ) were high, ranging between 0.980 and 0.997, indicating a strong correlation between carbon dioxide regulator pressure and the rate of limestone dissolution. FIG. 9 shows AMD alkalinity following treatment was relatively insensitive to the acidity of the inflowing AMD. However, FIG. 8 shows the mass of limestone dissolved per liter (Y) increased directly with acidity (X) at each regulator pressure tested following the general linear model:
Y=a+bX (11)
FIG. 10 gives data for the test case where the influent acidity was held at 1024 mg/l, the hydraulic retention time (HRT) was 5.1 min (4 min. cycle) and the carbon dioxide regulator pressure was 100 psi(gage). Note that the pH of the AMD inflow was about 2.1 and this rose during treatment to about 5.6. Stripping the free carbon dioxide from the effluent reduced the acidity from 2147 mg/l to less than 100 mg/l, which allowed the pH to rise to about 8.3. This data demonstrates the importance of stripping carbon dioxide from the limestone column effluent. Note also that alkalinity rose from zero to about 1000 mg/l in the effluent. This concentration is about 25 to 50 times the concentration required to support freshwater fish populations and is about three times the concentration achieved with anoxic limestone drain systems that require HRT's of 15 to 24 hours.
FIG. 11 gives data from the test apparatus when operated with a hydraulic retention time of 5.1 and 10.2 min. (4 min. and 8 min. cycles) at each of two inlet acidities (9 and 100 mg/l) and three carbon dioxide regulator pressures (0, 30 and 100 psi(gage)). Increasing the retention time had little effect on the mass of limestone dissolved (mg/l) with an inflow acidity of 1000 mg/l but did improve dissolution rates with an influent acidity of 9 mg/l. Data in FIG. 11, along with data given in FIGS. 8 and 9, show the test apparatus was capable of eliminating the acidity of, and adding about 40 to 200 mg/l of alkalinity to, the simulated AMD without the need for make up carbon dioxide inflow (carbon dioxide regulator pressure=0).
EXAMPLE I
Given the encouraging results of the laboratory tests conducted with simulated AMD, a series of tests were undertaken to demonstrate the ability of the process to treat AMD in the field. Example 1 gives data for the test apparatus (FIG. 5) operated with a carbon dioxide regulator pressure of 20 psi(gage) and with a 4 min. treatment cycle at Antrim Mine, Antrim, Pa. These data demonstrate the ability of the apparatus to supertreat the AMD despite the presence of dissolved metals known to armor limestone in conventional treatment equipment, i.e., in this case less than 50% of the AMD must be run through the equipment with the product water then blended with untreated water. This capability helps keep capital costs low. SAMPLE:
______________________________________ Mix of 50% Untreated AMD Water and 50% Effluent FollowingRaw Influent CO.sub.2 Stripping______________________________________pH 3.18 7.61acidity 250 mg/l 10.1 mg/lalkalinity 0 137 mg/lIron 25.5 mg/l 0.69 mg/lManganese 21.9 mg/l 20.8 mg/lAluminum 17.4 mg/l 1.89 mg/l______________________________________
EXAMPLE II
Data given below are for a second test at Antrim mine using a test system like that shown in FIG. 1 and operated at atmospheric pressure, with no make up carbon dioxide flow--only carbon dioxide generated in the reaction shown in Eqn (8) was stripped and recycled. AMD inflow rates here were about 36 times that of earlier tests with the test apparatus shown in FIG. 5. Again, the process tested was effective in treating the AMD despite the presence of dissolved metals. SAMPLE:
______________________________________ Effluent FollowingInfluent CO.sub.2 Stripping______________________________________pH 3.10 6.40acidity 260 mg/l 42.7 mg/lalkalinity 0 mg/l 45.7 mg/l______________________________________
EXAMPLE III
Examples III and IV give data from tests with the apparatus shown in FIG. 5 and operated at the National Park Service's, Friendship Hill Historic Site, Point Marion, Pa. Here, the AMD inflow had acidities and dissolved metal concentrations that were about three times that of the Antrim Mine AMD. With a cycle duration of 4 min. and a carbon dioxide regulator pressure of 20 psi(gage), Table 3, the process tested was effective at increasing the pH by over 4 units, increasing the alkalinity from zero to 418 mg/l and provided for iron and aluminum removals with precipitation of over 98%. As at the Antrim site, this data demonstrates the ability of the process to supertreat AMD. When operated without make up carbon dioxide, the process was still effective in raising the pH and alkalinity of the AMD beyond minimum required changes (Table 4).
TABLE 3______________________________________EXAMPLE III Effluent FollowingInfluent CO.sub.2 Stripping______________________________________pH 2.39 6.82acidity 903 mg/l 0alkalinity 0 mg/l 418 mg/lIron 130 mg/l 0.16 mg/lManganese 9.3 mg/l 8.6 mg/lAluminum 59.2 mg/l 0.69 mg/l______________________________________
TABLE 4______________________________________EXAMPLE IVSAMPLE: Effluent FollowingInfluent Air Stripping______________________________________pH 2.57 7.34acidity 1050 mg/l 48 mg/lalkalinity 0 mg/l 148 mg/l______________________________________
As a result of the process of the present invention and the pulsed bed limestone water contactor that accelerates limestone dissolution rates through use of the carbon dioxide pretreatment step, acidities in excess of 1,000 mg/l were neutralized and unusually high levels of alkalinity were achieved during treatment. The ability of the method and apparatus to supertreat the acid mine drainage allows for side stream treatment in many cases.
FIG. 12 shows a schematic of flows with side stream treatment of acid mine drainage 111 absorbing CO 2 112, then flowing through a pulsed limestone bed treatment system 113 and the excess CO 2 being stripped 114 before the mine drainage is released. Side streaming eliminates the need to dam the entire flow and reduces significantly the size of the reactor and plumbing required for treatment. It reduces capital and site preparation costs.
The process and apparatus described above have met a long-felt need in the mining field where acid mine drainage (AMD) is a significant problem. The limestone aggregates and coarse limestone powders used in the pulsed bed apparatus of the invention have a significantly lower cost than other materials. The increased dissolution rates of limestone achieved in the pulsed limestone bed system significantly raises the pH of the effluent and can provide for high levels of HCO 3 - !. This is environmentally important because water with a low pH and poor buffering capacity prevents the reproduction of salmonids and acidification is associated with an increased concentration of toxic metals, often which induces stress, mortality, and threatens food safety of fish products. Buffering the water as was done here also improves the growth conditions for aquaculture, and it has implications for increasing the hardness and alkalinity of very soft water such as those present in waters of North Carolina.
Whereas particular embodiments of the present invention have been described above for purposes of the illustration, it will be evident to those skilled in the art that numerous variations of the details may be made without departing from the invention and defined in the appended Claims. | The method of reducing the acidity in effluent discharges comprises charging the effluent with carbon dioxide, intermittently fluidizing and expanding at least one pulsed limestone bed with the charged effluent, treating the charged effluent with the limestone in the bed, displacing the limestone treated effluent with untreated charged effluent, stripping excess carbon dioxide from the effluent after treatment in the limestone bed, and discharging the limestone treated effluent. | 2 |
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/033,832, Dec. 23, 1996.
The present invention is related to the following disclosures: U.S. Ser. No. 08/604,784, entitled "Method and Apparatus for Command and Control of Remote Systems Using Low Earth Orbit Communication Systems", filed Feb. 23, 1996; U.S. Ser. No. 08/390,461, entitled "Method and Apparatus for Using Satellites for Reverse Path Communication for Direct To Home Satellite Communication", filed Feb. 24, 1995, now U.S. Pat. No. 5,708,963 granted Jan. 13, 1998; and, U.S. Ser. No. 08/751,946 entitled "Method and Apparatus for Communicating Information Between a Headend and Subscriber Over a Wide Area Network", filed Nov. 19, 1996, now U.S. Pat. No. 5,896,382, granted Apr. 20, 1999. All of these disclosures are incorporated herein by reference for any necessary disclosure.
FIELD OF INVENTION
The invention generally relates to a control system for controlling when power consuming devices are started. More particularly, the present invention is directed to a scheme for communicating information such as utility scheduling tiers from a headend over a wide area network (WAN) to a gateway coupled to subscribers, and, in response, varying the start time for the power consuming devices.
BACKGROUND OF INVENTION
Utilities often have to cope with the problem of satisfying consumer demand for energy. Energy demands fluctuate widely between peak and off-peak periods. For example, energy demands peak during hot summer days when consumers require air conditioning. One of the ways utilities handle such situations is by employing load management systems. Information is communicated between subscribers and a headend to efficiently manage consumer energy demands.
Other energy services have been developed including utility-based applications such as water, gas, and electric meter readings. In these applications, the headend communicates with- a meter at a subscriber's premises. Often subscribers want to know what their energy cost and usage are at a particular time, for example during a billing period. An existing utility application allows the subscriber to request this information from the utility. The utility first obtains the information from the meter at the subscriber's premises, performs a calculation at the headend and transfers the desired information to the subscriber.
More and more applications have developed including those which extend beyond conventional utility applications. For example, home security and monitoring and the ability to program appliances are applications which can be implemented. These applications are distributed by different companies which use different protocols for both implementation of their services and for compatibility with the devices located on the subscriber premises.
Existing systems for communicating utility applications are closed or proprietary systems which require a specific type of native message compatible with devices located on the subscriber premises. For example, the applications are distributed over a wide area network that is specifically designed to handle the protocol for a particular vendor's application and the device located at the subscriber's premises.
Some signals received over the wide area networks referenced above are used to control the operation of various appliances. In most cases, these appliances consume electrical energy or fossil fuels. In the case of appliances run by electrical motors, utility companies vary the pricing of each unit of power throughout the day, week, month, or year to compensate for the load placed on their power distribution network. These pricing levels are known as price tiers. One outcome of power companies varying the price of electrical energy over time is a reduction in consumption during the high cost time intervals and a greater consumption during the lower cost time intervals. While the initiation of operation of an individual user's electrical appliances immediately after a change in a price tier do not appear to affect the individual user, the operation of many consumers in this manner can create a tremendous load on the power distribution network. For example, some electric motors require six times their normal operating currents during start up. When a number of users turn on, for example, their HVAC (heating, ventilation, and air conditioning) systems, the influx of current may be up to six times the normal load on the power grid. This initial influx can compromise the integrity of the power grid and, at when the power grid is fully loaded, result in a reduction or shut off in the power supplied to homes. These reductions and shut-offs of power are commonly known as brown-outs or black-outs. These events happen due to the reactions of reclosures.
Reclosures are circuit breakers located on utility poles. They guard against excessive current draws on power lines by tripping and resetting three times then by tripping without reset. For example, when a power line breaks (e.g., due to a falling tree), there is generally a current discharge from the power line to ground. The reclosure detects this abnormally high current and opens the current path. After a short interval, the reclosure resets and is tripped by the excessively high current flow. Finally, the reclosure reaches its preset number of retries and stays open. By this operation, the current flowing through the power line is stopped, protecting passersby and property from being caught in the path of the discharge of current. As the downed power line is only one element of a power grid interconnecting a variety of current paths, the power, which would have flowed through the downed power line, is rerouted through other utility lines. While the power is rerouted to compensate for the downed line, some homes near the downed power line may temporarily suffer a brownout or blackout until power is restored. This same brownout or blackout effect may also occur during the change in pricing tiers as mentioned above as reclosures may be repeatedly tripped by high current flows evident following price tier changes.
Accordingly, a need exists to minimize the stress of initial operation current fluxes on power grids.
SUMMARY OF THE INVENTION
The present invention overcomes the aforementioned problems by altering the operation of controlled end use devices by controlling the initial start times of devices at subscriber locations. The end use devices at each subscriber location receive an indication of a pricing tier change. In response, each end use device generates a random startup time offset and applies it to a time associated with the received pricing tier change. In an alternate embodiment, the gateway generates the random offset for the consumer's devices. Next, the modified times are compared to determine whether a preferred schedule indicates that the operation of controlled devices should change. If a change is needed, then the devices are controlled in accordance with the preferred schedule and pricing tier in effect. Accordingly, massive influx currents due to controlled device startups at consumers' locations can be significantly reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described in more detail with reference to preferred embodiments of the invention, given only by way of example, and illustrated in the accompanying drawings in which:
FIG. 1 illustrates several representative wide area networks for transporting information between a headend and subscribers according to the present invention.
FIG. 2 is an exemplary embodiment of a gateway according to the present invention.
FIG. 3 shows an illustrative downstream data packet according to the present invention.
FIG. 4 shows an illustrative upstream data packet according to the present invention.
FIG. 5 shows an example of the combination of influx currents on a power grid as contemplated by embodiments of the present invention.
FIG. 6 shows a flowchart as contemplated by embodiments of the present invention.
DETAILED DESCRIPTION
The present invention is discussed below with reference to a broadband communications network. However, the present invention may be extended to other types of communications networks and systems. Also, the present invention will primarily be described with reference to residential applications for purposes of illustration, although it should be understood that its applicability is widespread including commercial and industrial applications.
The present invention relates to a system architecture for providing a platform for communicating energy services (utility applications) and non-traditional services as part of an overall communications infrastructure. According to the invention, a native message, regardless of the source of the message's application, is divided into data packets that are encapsulated. The encapsulated data packets are transmitted through an open network from a headend to a gateway or from the gateway to the headend. The receiver of the encapsulated data reassembles the original native message from the encapsulated data packets.
An illustrative embodiment of the system is shown in FIG. 1. Applications platforms 10 provide utility applications to network controller 15 in the form of a native message payload and protocol. An applications platform includes its application and a protocol translator for utilization of the application. The native message payload generated by an applications platform is data for communication between one of the applications platforms 10 and the destination device, for example an in-home device such as a meter or appliance. Other data generated by the applications platforms 10 include a peripheral id (PID) which uniquely identifies the protocol and medium (local area network) for the in-home device, gateway peripheral processor data (GPPD) for communications with the medium for the in-home device, payload message length (len) which identifies the number of bytes in the native message payload, protocol translator id (PTID) which identifies the address of the originating applications platform at the headend, and a communications session identifier (SessionsID) for correlating an upstream response with a particular downstream request.
The system includes multiple applications platforms based on the number of applications. Typical applications include, but are not limited to, automatic meter reading for gas, water, and electric, load management, real time pricing for gas, water, and electric, outage detection, tamper detection (e.g., tampering with meters), remote service connect or disconnect, home security, customer messaging, and home automation. Utility application providers include, among others, Honeywell, General Electric, Schlumberger, American Innovations, and WE X. L.
The network controller 15 receives the native message payload and protocol from one of the applications platforms 10 in a data packet. Communications with the network controller 15 may be by TCP/IP (transaction communication protocol/Internet protocol) on Ethernet or other typical local area network forms. The hardware interface can vary as necessary. A routing look-up table assigns an address to each data packet. The network controller 15 forwards each data packet to an appropriate media access controller (MAC) based on the WAN form used to communicate with the gateway coupled to the subscribers. Thus, prior to sending the data packet to the MAC, the network controller 15 places the native message and protocol in a data packet with the MAC address.
The network controller 15 is a resident database that contains the control algorithms to route and store data for the applications. The network controller 15 configures the downstream flow of data in the system. In functioning as a database, the network controller 15 contains subscriber records and data in its files and provides other applications with data on request. In an exemplary embodiment of the present invention, the network controller 15 can accommodate 65,000 sites in broadband.
The system supports multiple WAN forms including, but not limited to, coaxial, fiber and hybrid fiber coaxial (HFC) broadband, RF, telephony, and satellite (e.g., low-earth orbit (LEO), little LEO (LLEO)). Exemplary WANs are shown in FIG. 1. Express reference is made to U.S. patent application Ser. No. 08/751,946, entitled "Method and Apparatus for Communicating Information Between a Headend and a Subscriber Over a Wide Area Network", filed Nov. 19, 1996, now U.S. Pat. No. 5,896,382, granted Apr. 20, 1999, whose disclosure is expressly incorporated herein by reference for any necessary disclosure.
When the data packet is to be sent by broadband, the broadband media access controller (BBMAC) 25 receives the data packet and removes the MAC address and encapsulates the data packet with header information and CRC error detection bits. The BBMAC 25 places the data packet into a network TDMA scheme using time slots for communication. The WAN architecture may be designed to support asynchronous transfer mode (ATM) transport with UDP/IP (user datagram protocol/Internet type, addressing on the cable system. TDMA addressing is preferred. The TDMA transport is used primarily, on a dynamically allocated basis, for routing message traffic and for file transport facilities. The BBMAC 25 operates in real time using an intelligent device such as a personal computer to transmit and receive real time data to and from a baseband modulator and demodulator in a modem 30. In an exemplary implementation, BBMAC 25 is a Windows NT Pentium running at 166 MHz with 120 M RAM.
The BBMAC 25 passes the slotted data packet in standard NRZ (UART) form at a rate of 115.5 kbps to digital modem 30. The modem 30 includes a broadband modulator and demodulator that physically interface the headend to the HFC network 35. The modem generates data communications (e.g., FSK, QPSK) based on signals provided at baseband in real time. The modulator portion of modem 30 receives the slotted data packet over a hardwired link such as an RS-422 connector. The data packet transmission rate is converted to 125 kbps by a microprocessor such as an 80C51XA by Philips Electronics. The 125 kbps data packet undergoes modulation (e.g., FSK) and is transmitted over the broadband HFC network 35 to gateway 40a.
The HFC network 35 is utility non-application specific, meaning no special modifications are required to provide utility applications. This is a feature common to all the WANs utilized. The typical architecture of an EFC network 35 includes a number of fiber nodes that receive and convert optical signals to electrical signals, and drive two-way signals onto the coaxial plant. In an illustrative embodiment, a fiber node can serve between 500 and 2000 homes. From the node, a coaxial distribution network carries signals to subscribers' homes. Along the distribution network, the side-of-the-home gateways 40a are connected for the final link to the utility application in-home devices such as an electric meter and home user interface. According to this exemplary embodiment, data may be transported at 125 kbps using FSK modulation. This approach permits apparent asynchronous communication, file transfer activities, Internet access and other modem functions, and shareable channel with other services in TDMA. In another broadband embodiment, data may be transported at T1 speed with a 1 MHz bandwidth in the forward and reverse directions (1.5 Mbps). QPSK modulation may be used for robust data communications and high bandwidth efficiency.
Other WANs can be used and their operation is described herein generally. When the data packet is sent by radio frequency (RF) such as at very high frequency (VHF) or via telephony, a VHF/telephony media access controller (VTMAC) 45 receives and transmits the data packet. Thereafter, if the data packet contains an unscheduled message, it is distributed by RF and sent to a radio tower 50 which broadcasts the information over the RF network to gateway 40b. Otherwise, the data packet is put onto the telephone network phone lines 55 and sent to gateway 40b. According to this exemplary configuration, the VTMAC 45 can control data transport so that unscheduled messages can be transported via the RF network while scheduled transactions and gateway return communications can be transported via the telephone network.
If the data packet is to be distributed via satellite, a little LEO (LLEO) media access controller (LLMAC) 60 receives and communicates the data packet over the phone lines 65 to a LLEO service provider 70 that broadcasts the information over a satellite network 75 to a gateway 40c. The return path for satellite-related communications is described in greater detail in U.S. Ser. No. 08/604,784, entitled "Method and Apparatus for Command and Control of Remote Systems Using Low Earth Orbit Communication System", filed May 10, 1996 and U.S. Ser. No. 08/390,461, entitled "Method and Apparatus for Using Satellites for Reverse Path Communication for Direct To Home Satellite Communication", filed Feb. 24, 1995, now U.S. Pat. No. 5,708,963, granted Jan. 13, 1998, whose disclosures are expressly incorporated herein by reference for any necessary disclosure.
The changes in pricing tiers are transmitted from the headends across the WANs to the gateways. In the broadband communication path 35, a signal indicating the change in pricing tier is transmitted concurrently with, or shortly before, the actual time of the change in pricing tier to gateway 40a. In comparison, in the narrowband communication paths (via radio tower 50, phone lines 55, or satellite 75), a signal indicating the schedule of changes in pricing tiers is transmitted to gateways 40b or 40c. Embodiments of the present invention contemplate the transmission of tier schedule information over broadband 35 and the transmission of a signal indicating the change in pricing tier (like that transmitted over WAN 35) via the narrowband communication paths (radio tower 50, phone lines 55, or satellite 75).
The power usage by each customer connected to gateways 40a, 40b, and 40c is transmitted back to the network controller (or a similar data collecting device) to collect power usage information for billing purposes. Each gateway 40a, 40b, and 40c is connected to the power meter of each customer. Accordingly, as each customer uses power, the meter readings are collected and transmitted upstream over various return paths. In the broadband approach of WAN 35, the meter reading is transmitted on a regular basis either automatically or upon polling from gateway 40a to the headend. In the narrowband approaches, the meter reading is stored in gateway 40b and 40c for a greater period of time and transmitted at a greater interval (for example, once every two weeks).
An illustrative gateway 40 is depicted in FIG. 2. The gateway 40 provides data communications from the WAN to a home LAN, and is designed to facilitate communication between the utility host (applications platforms) and residential devices such as an electric meter or home user interface. The gateway 40 can be designed to handle communications for a single homesite or multiple homesites and support installations at the homesite as well as pole top and other locations.
Encapsulated data packets are received over the WAN from the headend. The gateway 40 has one WAN interface 405 corresponding to the WAN (e.g., broadband, LLEO, RF, etc.) from which it communicates with the headend. The WAN interfaces are plug-in modules removable from the gateway. Thus, another complete physical and logical WAN interface can be implemented without the need to change any other parameters or devices in the gateway 40. Thus, if data transport is to take place over a different WAN network, the WAN interface 405 can imply be replaced.
In an exemplary broadband implementation of the gateway 40, the WAN interface 405 may include an FSK transceiver if the modulation technique at the headend is FSK. Also, the WAN interface 405 provides control for the TDMA transport scheme using a microprocessor. The microprocessor can receive messages, check CRC and address information, perform TDMA decoding, clocking, buss interface and memory management. The microprocessor will also manage the TDMA transmitter in response to the embedded clock signals in the downstream data packets. The microprocessor may be an 80C51XA made by Philips Electronics or in the Motorola 68000 family with internal ROM, RAM and EEROM.
According to another exemplary broadband implementation of the gateway 40, the WAN interface 405 may include a QPSK transceiver if the headend uses QPSK modulation. Some of the functions which may be embedded in this illustrative WAN interface include ATM filtering, IP filtering, TDMA control, CRC calculator, 68000 type or 80C51XA microcontroller, and buss controller and LAN interface drivers. External ROM may be used to support program control of the WAN communications interface. An external RAM can provide temporary storage of data. An external EEROM may be provided for permanent storage for MAC address and other permanent or semi-permanent data. The microcontroller manages slotted Aloha transmission and the TDMA transport scheme.
The WAN interface 405 demodulates the data packet and removes the header including routing and control information from the packet put on by the MAC. The WAN interface 405 sends the data over common bus 410 to an appropriate LAN interface 415, 420, 425 which translates and removes the protocol and recovers the native message when the gateway 40 is instructed to listen and pass the native message to the in-home device 430. The protocol removed includes PTID, PID, GPPD, and SessionID.
In the illustrative embodiment of FIG. 2, three LAN interfaces 415, 420 and 425 are provided. It is to be understood that any number of LAN interfaces may be provided. However, it is prudent to choose a relatively small number such as five because the size of the gateway increases as the number of LAN interfaces increases. Also, when a new application is implemented by a subscriber, the LAN interface corresponding to the new application simply needs to be added. The LAN interfaces can be plug-in cards, wherein replacement and addition of LAN interfaces is relatively easy. Exemplary LAN interfaces may include a LonWorksJ interface, CEBusJ interface, hardwired interface, RF interface, an RS-232 interface, and a broadband modem. LonWorksJ and CEBusJ are specific protocol designed for power line carrier communications.
The LonWorksJ interface is designed to provided Echelon power line carrier communications for the home LAN. The interface includes a microprocessor which is responsible for buss interface and protocol translations. The microprocessor may be a Neuron chip by Motorola. The Neuron chip receives standard LonWorksJ protocol to be inserted on the power lines. The data is routed to an Echelon PLT 20 communications device and inserted on the power wiring through a coupling network and external wiring. The Neuron chip handles data transport issues including collisions and delivers the requested data to the microprocessor when available. The microprocessor then presents data to the WAN interface 405 via the common bus 410 for communications to the MAC or other application as directed by routing (mapping) tables in the WAN interface 405. In some instances, gateway 40 may have intelligence such as in a narrowband implementation or in broadband if intelligent gateway and be able to directly rout information elsewhere, for example to a nearby load control device.
The CEBusJ interface provides CEBusJ power line carrier communications for the home LAN. The microprocessor may be in the 68000 family or a Philips 60C51XA and interface with a CEBusJ communications device which inserts the data on the power wiring through a coupling network and external wiring. The microprocessor handles data transport issues including collisions and delivers the requested data to the WAN interface 405 via the common bus 410 for communications to the MAC or other application as directed by routing (mapping) tables in the WAN interface 405.
The hardwired interface is provided for applications such as low cost scenarios. This interface provides for a pulse initiator and maintains an accumulator function with an EEROM type memory and long term battery support. The interface takes input from devices such as electric, gas, and water meters.
The RF interface provides wireless communications for devices in and around the home such as electric, gas, and water meters, and appliances.
An RS-232 interface can support services such as local narrowband nodes. The RS-232 interface may extract data files from a local host system on command. This permits the transfer of large data files.
A broadband modem may share the utility data communications channel for the purpose of Internet access and other computer type services. Rapid access to file servers providing access to a variety of services can be realized.
A native message is transmitted upstream from the in-home device 430 to the applications platforms 10 over the same mediums. The in-home device 430 passes the native message to its corresponding LAN interface (one of 415, 420, 425). The LAN interface adds the protocol to the native message and passes the data packet with the protocol and native message to the WAN interface 405 via the bus 410. The WAN interface 405 encapsulates the data packet by adding a header and transmits the information upstream from the gateway 40 over the appropriate WAN to the headend. For example, the gateway 40 can transmit the information over the HFC network 35 to the headend at a rate to 125 kbps. At the headend, the demodulator portion of broadband modem 30 demodulates the upstream data packet from a 125 kbps FSK modulated NRZ signal to a 115.2 kbps baseband NRZ signal.
The encapsulated data packet is then sent to the BBMAC 25 over an RS-422 data link. BBMAC 25 removes the header information leaving the protocol and native message. BBMAC 25 acknowledges receipt of upstream asynchronous messages prior to hand off to other applications to preserve data integrity. In the TDMA mode, BBMAC 25 checks for transport cell integrity by performing cyclic redundancy checking on the data and forwarding the data to the appropriate one of the applications platforms 10. To further enhance data integrity, BBMAC 25 sets up sessions between the applications platforms 10 and gateway 40. BBMAC 25 behaves as a bridging data router between the applications platforms 10 and the in-home devices coupled to the gateway 40. Communications to applications platforms 10 can be tightly linked to minimize real time delay for message transport while not slowing polled and asynchronous data transport. Returned power levels can be evaluated on every returned message and can be adjusted when outside predetermined boundaries.
The data packet passes through the network controller 15 and to the appropriate applications platform 10 where the protocol is removed and the native message from the in-home device 430 is recovered.
An illustrative TDMA transport scheme according to the present invention for use in a broadband network is controlled by BBMAC 25. The header information encapsulating the native message and protocol provides for the scheme. FIG. 3 shows the contents of an exemplary downstream data packet. Bytes 1-21 represent the header information added by BBMAC 25 to the protocol (bytes 22-30) and the native message (bytes 31-94) with bytes 95 and 96 providing the CRC error detection. FIG. 4 shows the contents of an illustrative upstream data packet. Bytes 1-13 represent the header information added by the LAN interface to the protocol (bytes 14-22) and the native message (bytes 23-86) with bytes 87 and 88 providing CRC error detection.
The TDMA scheme as illustrated in FIGS. 3 and 4 is described in greater detail in related U.S. Ser. No. 08/751,946, entitled "Method and Apparatus for Communicating Information Between a Headend and Subscriber Over a Wide Area Network", filed Nov. 19, 1996, now U.S. Pat. No. 5,896,382, granted Apr. 20, 1999, incorporated herein by reference for any necessary disclosure.
FIG. 5 shows the effect of the application of the present invention to the influx current as drawn by started devices. FIG. 5 shows, for example, four pricing tiers: Tier 1 501 (represented by pricing level 505) Tier 2 502, Tier 3 503, and Tier 4 504. It is readily understood that additional or fewer tiers may be used in accordance with the scope of the present invention. FIG. 5 shows the arrangements of pricing tiers during the course of a day. These tiers may relate to, for example, the costs of energy usage during the summer months. The tiers, in this example, may be associated with the following interpretations:
Tier 1 Normal Load on Power Grid;
Tier 2 Medium Load on Power Grid;
Tier 3 High Load on Power Grid; and,
Tier 4 Critical Load on Power Grid.
These different levels are associated with different prices to encourage the lower usage of power during the higher usage times.
To accommodate the different tiers, customers (through the use of adapted devices) may program their end use devices with their preferred usage schedules. These usage schedules balance the needs of the customer with the customer's reluctance to pay for the energy consumed at higher pricing tiers. Also, the schedule used for various end use devices may be different.
For example, in a customer's house with a thermostat and a pool pump, the customer has programmed each with a different operating schedule. As to the pool pump, the consumer has programmed it to run in all but the most costly pricing tier. As to the thermostat, the consumer has programmed it to keep the consumer's house at 75 degrees Fahrenheit with the following temperature additions:
add 0 degrees in tier 1,
add 2 degrees in tier 2,
add 5 degrees in tier 3, and
add 8 degrees in tier 4.
These programmed temperature additions reduce HVAC operation during the more costly pricing tiers and increase it during the less expensive pricing tiers. In particular, the consumer has opted to allow the gateway (40a, 40b, or 40c, depending on the WAN connected to the consumer) to control the operation of the consumer's thermostat and pool pump in accordance with the changes in pricing tiers. These devices, as well as other devices controlled by a schedule, also allow for the consumer's override of the preset schedule.
In both these devices, the influx in current peaks just after the electric motor in each is turned on. An example of the influx currents as related to changes in pricing tiers is shown in FIG. 5. The operation of device 1 506 is represented by line 507 (device 1 operates in all but tier 4). The operation of device 2 508 is represented by line 509 (device 2 operates in all but tiers 3 and 4). The operation of device 3 510 is represented by line 511 (device 3 operates in all but tiers 2-4). Finally, the operation of device 4 512 is represented by line 513 (device 4 operates during all tiers).
Reference elements 514 show the unit levels of current drawn by all devices. When all four devices 506, 508, 510, and 512 are operating, the current drawn is shown by level 515. When only three devices (506, 508, and 512) are operating, the current drawn is shown by level 516. When only two devices (506 and 512) are operating, the current drawn is shown by level 517. Finally, when only one device (512) is operating, the current drawn is shown by level 518. These current levels reflect the operation schedules of each of the devices 506, 508, 510, and 512.
As shown by schedules, 507, 509, and 511, devices are all scheduled to turn on at the same time when pricing tier 4 drops to pricing tier 3. These turn on points are shown by level shifts 507', 509' and 511'. As each electric motor draws up to six times its normal operating current, the combined current draw may be up to eighteen times the normal current draw for the combination. Here, this high current draw is indicated by spike 519. The peak of spike 519, in this example, may be up to 18 times the normal current draw for any signal device 506, 508, 510, or 512. The value 19 with three devices turning on is the sum of each current spike of devices 506, 508, and S10 plus the operating current (value of 1) of device 512.
As indicated above, the high current draw may result in the repeated tripping of reclosures in the power grid. As each reclosure trips, the devices creating the influx of current may not receive enough power to start up. Accordingly, each reclosure may be repeatedly asked for the same high amount of current to the point the reclosure locks itself open.
According to embodiments of the present invention, the turn-on time of each device is offset so as to shift the current draw for each device to minimize the current flux over time. In this example, a random time shift is added to the start time of each device. In this example, device 506 has a small offset, device 508 has a larger offset, and device 510 has an even larger offset. These offsets are shown by the distance between the level shifts 507', 509', and 511' and 507", 509" and 511", respectively. As the influx for each device is separated by random offsets, the current spike 519 does not appear. Rather, the increase in current drawn by the combination of devices is shown by sloping curve 520.
The random offsets may be generated by a number of different ways. Embodiments of the present invention contemplate a random number being generated in a micro controller. The random number is then multiplied by a time constant to derive a random offset. For instance, the random number is generated between 0 and 1. This value is then multiplied by a time constant of 10 minutes. Thus, the resulting time offset is a time value of between 0 and 10 minutes. The random number may be generated by a random number generator or a pseudo-random number generator with a starting seed.
Also, the location of the random number generator may vary per application. For example, a random number generator may be used in each device. Embodiments of the present invention contemplate the random number being generated in each device so that each device in a consumer's home may be subject to a different offset and lessen each consumers current influx spike. Additionally, embodiments of the present invention contemplate the random number being generated in at least one of the LAN cards 415, 420, or 425 (for example, in a Motorola micro controller HC11) in gateways 40a, 40b, and 40c so as to minimize the processing required in each end use device. By generating a common random offset for each consumer at gateways 40a, 40b, and 40c, the consumer's sensitivity to different end use devices starting at different times may be lessened. For example, by starting the HVAC unit and the pool pump at the same random offset may go unnoticed by a consumer. Otherwise, the consumer may question why both devices start at different times, while both are scheduled to start at the same time.
FIG. 6 shows a flowchart of the operation of the randomization of offset times according to embodiments of the present invention. At step 601, the gateway or end use device receives notification of a change in a pricing tier.
At step 602, it is determined whether the change was received before the end of a reset interval. The reset interval is a settable value of time. When the reset interval has lapsed without any change in the pricing tier, the random number used by the method is regenerated. For example, the reset interval can be set at six hours. This setting indicates that if no pricing tier change is received after six hours, then regenerate the random number. As a six hour delay before receiving a change in the pricing tier would most likely happen at night, one can use a value (such as six) to have the method reset each night.
Step 603 is implemented if no change in pricing tier was received before the end of the reset interval. Step 604 initializes the reset interval when either a pricing tier change was received or when the random offset is regenerated.
Step 605 sets a variable of a summed time (SUMMED TIME) to equal the random offset plus a time in which the pricing tier is supposed to change. The pricing tier information is transmitted to the gateway in at least one of two ways depending on the WAN used. In a broadband WAN, when each change in pricing tier is received, a time associated with the change (for example, "Change to Price Tier 4 at 12:00 PM") is recorded. In a narrow band WAN, a schedule of pricing tier changes is transmitted (for example, "Change to Price Tier 3 at 11:00 AM, Change to Price Tier 4 at 12:00 PM, Change to Price Tier 3 at 2:00 PM . . . "). The schedule is stored and the time associated with the next tier change is recorded.
Step 606 indicates that the summed time (SUMMED TIME) is stored in a register.
Step 607 indicates that the summed time (SUMMED TIME) is compared with the current time to see if they match. If the current time matches SUMMED TIME, meaning that the tier change occurs now, step 608 is implemented which changes the value of the stored tier. This value of the stored tier may be stored in the same register which stores the SUMMED TIME. Then, the method proceeds to step 609. Also, if the comparison of step 607 results in a different time, step 609 is implemented.
Step 609 operates the end use device in accordance with the stored tier currently in effect with a preferred usage schedule. An example of the preferred usage schedule of a thermostat is as follows.
______________________________________Time Requested Action______________________________________8:00 AM Set Temperature to 80 Degrees5:00 PM Set Temperature to 75 Degrees______________________________________
The preferred usage schedule is subject to the tier changes as follows:
add 0 degrees in tier 1,
add 2 degrees in tier 2,
add 5 degrees in tier 3, and
add 8 degrees in tier 4.
Accordingly, as the tiers change, the temperature to be maintained at the location of the thermostat varies as well. While this example is given with respect to a thermostat, the preferred usage schedule is readily applied to other end use devices as well.
Step 610 detects if there was a change in the pricing tier. If no change was received, then the method loops back to step 607. If a change in price tier was received, then the method steps back to step 601.
While particular embodiments of the present invention have been described and illustrated, it should be understood that the invention is not limited thereto since modifications may be made by persons skilled in the art. The present application contemplates any and all modifications that fall within the spirit and scope of the underlying invention disclosed and claimed herein. | A control system is disclosed which varies the operation of consumer's devices to minimize influx currents across a power grid. Power consuming devices are scheduled to operate in accordance with varying pricing tiers. As customers schedule the operation of various devices and appliances in accordance with pricing tiers, when the tiers change, the current drain on the power grid increases significantly. Even increasing the strain on the power grid is the fact that the startup current for electric motors is up to six times their normal operating current. When started, as electric motors place a heavy strain on a power grid, the power strain lead to the disruption of power to the very consumers requiring more power. The present invention randomizes the start up times of the controlled devices so as to minimize the strain of the power grid as each one comes on line. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] Applicant claims the priority date of U.S. Provisional Application 60/440,762, filed Jan. 17, 2003.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to jamb assemblies for double hung windows, and in particular, to a jamb assembly that provides a weather-seal for a double hung window and a visually pleasing finish.
[0003] Jambliners are used to mount window sashes in a double hung window configuration so that the window sashes may be moved up and down to be placed either in an open or a closed position. The jambliners have recesses in which hardware is placed to permit the windows to be moved in an up and down fashion.
[0004] In addition to providing a means for moving window sashes up and down, the jambliners also strive to provide a weather-seal between the window sash and the jambliner when the windows are in a closed position. Recesses are also provided to retain the weather-strip. When the windows are in a closed position, it is also desired to provide a finished look to the window. One problem with jambliners is that they are an integrally extruded piece typically extruded of polyvinylchloride (PVC) or other plastic which results in recesses running the length of the jambliner and being open to view when the windows are in a closed position. The portion of the recesses that are open to view are not associated with (hidden by) a window sash and are therefore open to view. The Hendrickson et al. U.S. Pat. No. 6,305,126 provides one solution to covering up those portions of the recesses that do not retain weather-stripping. The solution is another recess disposed between the recesses that retain the weather-stripping. This central or middle recess is used to insert a cover strip which then extends on an exterior surface of the jambliner to provide a visually pleasing finish.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention includes a window jamb assembly mountable in a jamb of a double hung window for cooperative engagement with upper and lower sash assemblies. The window jamb assembly includes a jambliner that has inner and outer sash hardware accepting recesses and first and second weather-strip retaining recesses disposed between the sash hardware accepting recesses. First and second weather-strips are retained by the first and second weather-strip retaining recesses and jambliner cover strips are disposed in a remainder of the weather-strip recesses that do not retain a weather-strip. The jambliner cover strips have a facade portion that provides a visually pleasing finish.
[0006] In addition, the present invention includes a weather-strip that provides a weather seal between two surfaces, one of the surfaces including a channel for retaining the weather-strip. The weather-strip includes a weather sealing portion having a forward edge for engaging the movable surface and a first leg for engaging one edge of the channel and a second leg for engaging another edge of the channel and a spring arm cooperating with at least one of the legs and having a distal free end for engaging a backwall of the channel. The spring arm exhibits a spring force to move the sealing portion to a weather sealing position with the movable surface. Since the weather-strip is not attached to the surface of the channel, it is free floating with respect to that surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of the jambliner assembly of the present invention.
[0008] FIG. 2 is a perspective sectional view of one embodiment of the jambliner of the present invention.
[0009] FIG. 3 is a sectional view of the embodiment of FIG. 2 .
[0010] FIG. 4 is a perspective sectional view of another embodiment of the present invention.
[0011] FIG. 5 is a sectional view of the embodiment of FIG. 4 .
[0012] FIG. 6 is a sectional view of an alternative embodiment of the present invention.
[0013] FIG. 7 is a sectional view of a free floating weather-strip of the present invention.
[0014] FIG. 8A is a sectional view of yet another alternative embodiment of the present invention.
[0015] FIG. 8B is a sectional view of a further alternative embodiment of the present invention.
DETAILED DESCRIPTION
[0016] The present invention includes a window jamb assembly generally indicated at 10 in FIG. 1 . The window jamb assembly is mountable in a jamb 12 of a double hung window 14 . The double hung window 14 has an upper portion 13 with an upper sash 16 and a lower portion 15 with a lower sash 18 . The upper and lower sashes 16 , 18 cooperate with the jamb assembly 10 . The jamb assembly 10 has a length and width selected to correspond to the window jamb 12 with which it is used.
[0017] The jamb assembly 10 includes a jambliner 20 , weather-strips 22 U and 22 L and jambliner covers 24 U and 24 L. The jambliner 20 is extruded typically of a plastic such as polyvinylchloride (PVC) and includes sash assembly recesses 26 and 28 and two weather-strip recesses 32 and 34 disposed between the sash assembly recesses 26 and 28 for retaining the weather-strips 22 U and 22 L and the jambliner covers 24 U and 24 L. The sash assembly recesses 26 and 28 and the weather-strip recesses 32 and 34 run the length of the jambliner.
[0018] The jambliner covers 24 U and 24 L engage the weather-strip recesses 32 and 34 in portions that are not occupied by the weather-strips 22 U and 22 L to provide aesthetically pleasing coverings over such portions of the recesses and adjacent areas of the jambliner. The cover strip 24 U and the weather-strip 22 U are associated with the upper portion 13 of the window while the cover 24 L and the weather-strip 22 L are associated with the lower portion 15 of the window 14 . Utilizing the construction of the present invention, the cover 24 U covers that portion of the weather-strip recess 34 that is in the upper portion of the window 14 and which is not occupied by the weather-strip 22 L which occupies the recess 34 that is in the lower portion 15 of the window 14 . Similarly the cover portion 24 L covers that portion of the weather-strip recess 32 in the lower portion 15 of the window 14 that is not occupied by the weather-strip 22 U which lies in the upper portion 13 of the window 14 .
[0019] It will be appreciated that the weather-strips 22 U and 22 L are of a length that is at least substantially equal to the length of the sash assembly with which such weather-strip is associated. Similarly, the covers 24 U and 24 L are of a length that is sufficient to cover the remaining portions of the weather-strip recesses that are not occupied by the weather-strips 22 U and 22 L. Alternatively, the weather-strips 22 U and 22 L may extend the entire length of the weather-strip recess.
[0020] As specifically illustrated in FIG. 1 , the weather-strips 22 U and 22 L are slightly longer than the respective sash assemblies with which such weather-strips are providing a weather seal. In the area that the weather-strips project beyond the respective sash assemblies, a weather seal 23 is affixed to the jambliner 20 to provide a weather seal between a lower portion of the upper sash assembly and an upper portion of the lower sash assembly when the double hung window is in a closed configuration. Alternatively, the weather-strips 22 U and 22 L may be less than the length of the sash with the weather seal extending between sash assembly recesses 26 and 28 and each weather-strip abutting against the weather seal. Such weather seals and the materials used are well known in the art.
[0021] The weather-strips 22 U and 22 L are typically the same in construction but could be different. For placement in either the upper portion 13 of the window 14 or the lower portion 15 of the window 14 , the weather-strips are turned 180°. Similarly the covers 24 U and 24 L are of the same construction and may be turned 180° to fit either in the upper portion 13 of the window 14 or the lower portion 15 of the window 14 . The weather-strip recesses interchangeably retain both the weather-strips 22 U and 22 L and the covers 24 U and 24 L to provide a flexible arrangement for sealing windows and jambliner covers over the unused portions of the weather-strip recesses. Such is accomplished using only the two weather-strip recesses disposed between the sash assembly recesses.
[0022] In reference to the embodiments described below, since the weather-strips and the jambliner covers are constructed the same, no distinction will be made as to whether weather-strips are upper or lower weather-strips or whether jambliner covers are upper or lower covers for purposes of ease of reference and only one reference character will be used for each of the weather-strips and each of the covers when referring to FIGS. 2 through 5 .
[0023] A first embodiment of the jamb assembly 10 is illustrated in FIGS. 2 and 3 . The sash assembly recesses of the jambliner 20 accept sash assembly interfacing hardware 30 (only one of which is shown). The sash assembly interfacing hardware 30 facilitates retention and translation of the upper and lower sash assemblies 16 and 18 relative to the window jamb 12 . The particular type of hardware used is unimportant to the present invention and is well known in the art.
[0024] The jambliner 20 further includes a chamber 36 disposed between the weather-strip recesses 32 and 34 that has an opening facing the window jamb 12 and a front wall 37 that hides from view the existence of the chamber 36 . The existence of the chamber 36 or its non-existence depends on the width of the jamb which the jambliner covers. It will be appreciated, for larger width jambs, the jambliner has to be wider, and the width of the chamber 36 is therefore increased.
[0025] The weather-strip 22 includes a sealing portion 40 and a pair of resilient legs 42 and 44 that extend into the weather-strip recess 32 . A foam block 46 is of a size and shape that fits between the resilient legs 42 and 44 and extends from a backwall 48 of the recess 32 to engage a backside 50 of the sealing portion 40 thereby providing a spring force in the direction indicated by arrow 51 . The spring force pushes the weather-strip 22 up against the window sash 16 to provide a weather seal. To retain the weather-strip within the recess 32 , the resilient legs 42 and 44 have shoulders 52 and 54 , that respectively engage shoulders 56 which are at a forward most position of the recess 32 . It will be appreciated that the shoulders 52 and 54 engage the shoulders 56 thereby retaining the weather-strip 22 in place when the sealing portion 40 is not in engagement with the sash 16 .
[0026] The resiliency of the legs 42 and 44 permits insertion of the legs into the recess 32 . The foam block 46 may be made of any suitable polymeric material such as polyurethane that is formed by processes well known to produce a resilient non-rigid foam. The sealing portion 40 is constructed of an exterior layer of polymeric material such as polyvinylchloride. The portion 40 has an interior 60 that may be filled with a resilient foam, or may be left empty. The weather-strip is typically extruded as one integral piece.
[0027] The jambliner cover 24 has a cover portion 62 that extends from the weather-strip 22 to an adjacent sash assembly recess as best illustrated in FIG. 3 . The cover portion 62 not only covers a portion of the weather-strip recess from view but also an area of the jambliner from the sash assembly recess up to an adjacent weather-strip. Essentially, the cover portion 62 is used to cover that portion of the recess 34 that is not engaging a weather-strip and those adjacent areas between the weather-strip and the sash assembly recess. A recess engaging plug 64 extends rearwardly from the cover portion 62 and preferably runs the length of the cover 24 . The plug 64 is insertable within the weather-strip recess 34 to retain the cover 24 in place. The jambliner cover 24 when positioned on an exterior side of the window 4 is intended to match the exterior trim of the window 14 . When the jambliner cover 24 is positioned on an interior side of the window 14 , the cover 24 may be made to match the interior trim of the window. The cover portion 62 may be made of actual wood, steel, aluminum, vinyl or any other material typically used for window trim. When the cover is not made of actual wood, the jambliner cover 24 is typically extruded as a single integral piece.
[0028] The above description with respect to the weather-strip in the recess 32 and the cover portion in the recess 34 is to be understood that each recess 32 or 34 is constructed exactly the same and that the shoulders 56 of the recess 32 are made to engage also the shoulders 66 of the plug portion 64 to provide interchangeability. Similarly, the shoulders 56 of the recess 34 are made to engage the shoulders 52 and 54 of the resilient legs 42 and 44 of the weather-strip 22 .
[0029] Another embodiment of the present invention is generally indicated at 100 in FIGS. 4 and 5 . A jambliner 102 includes similarly constructed sash assembly recesses 104 and 106 and similarly constructed weather-strip recesses 108 and 110 . The jambliner 102 does not include the chamber 36 as illustrated and described with respect to FIGS. 2 and 3 . Instead, the weather-strip recesses 108 and 110 share a common wall 112 . Each recess 108 and 110 includes shoulders 114 and slightly downwardly extending tabs 116 . A cover 24 having a cover portion 62 and plug 64 is of the same construction as described with reference to the cover of FIGS. 2 and 3 .
[0030] A weather-strip 122 having a sealing portion 124 is made of a polymer such as polyvinylchloride that when extruded in a layer having sufficient thickness has enough integrity to retain a rounded surface that engages the sash assembly while still being sufficiently resilient to form a weather seal with the sash assembly when pressed against it. The weather-strip 122 also has a first leg 126 having an end portion 128 with a hook-like configuration to engage one of the downwardly extending tabs 116 . The weather-strip's other leg 130 has a end portion 132 projecting toward the common wall 112 and which engages the shoulder 114 of the jambliner 102 .
[0031] On an opposite side of the leg portion 132 is attached a co-extruded plastic spring member 134 . The plastic spring member 134 is described in U.S. Pat. Nos. 5,265,308 and 5,772,190, both being hereby incorporated by reference. The plastic spring member 134 is comprised of a semi-circular tubularly configured hinge 136 to which is attached a leg portion 138 that engages a backwall 140 of the recess 108 to provide a spring force, as indicated by arrow 139 , in the direction of the sash assembly. The hinge 136 may be formed from any of a wide variety of resilient thermoplastic materials such as polyurethane or a polyester elastomer which resist creep while the leg portion is made of a relatively rigid plastic material such as PVC. The leg portions, the weather seal portions, the hinge and the weather-strip are typically co-extruded as one integral piece. Although a tubular hinge is shown, the hinge portion does not necessarily have to be tubular. The hinge may be co-extruded as a solid bead or other form attaching the leg portion 138 to the leg portion 132 .
[0032] The hinge may also be made of spring steel as indicated by reference character 160 in FIG. 6 . The spring steel member 160 is attached to end portion 162 of the leg 126 of the weather-strip 122 . Preferably, the spring steel member extends across recess 108 to leg portion 132 . An opposite end 164 of the spring steel member 160 engages the backwall 140 of the recess 108 thereby providing a spring force in the general direction of arrow 139 . Although a specific configuration of a spring is illustrated in FIG. 6 , other spring configurations which provide the spring force 139 are included within the present invention.
[0033] The weather-strip 122 is a free floating weather-strip. By free floating is meant that the weather-strip is detachable from the jambliner and when the sash assembly applies a force against the weather-strip, the shoulders of the channel and the legs of the weather strip become separated.
[0034] Alternatively, the weather-strip may also be used outside of a jamb assembly environment. As illustrated in FIG. 7 , a weather-strip 200 of the present invention acts as a weather seal that is movable laterally in a direction indicated by arrow 204 as contrasted with the vertical movement of a double-hung window as described previously. The weather-strip 200 has leg portions 206 and 208 positioned within a recess 210 formed by window frame member 212 and molding 214 . The molding 214 also acts as a stop for the sash 202 . The leg portions 206 and 208 are positioned within the recess 210 . The recess 210 is formed by recess 214 of the frame member 212 and recess 216 of the molding 214 . The molding 214 is then attached to the frame member and with corresponding recess 216 forms the recess 210 that captures the legs 206 and 208 therein.
[0035] A tubularly configured hinge 218 , as described with respect to FIG. 5 , is attached to the leg portion 206 . An arm portion 220 produced from a stiffer material is attached to the hinge at one end and engages a backwall 222 of the recess 210 thereby providing a spring force in a direction of arrow 224 . The spring force places the weather-strip 200 against a surface of the sash 202 to create a weather-seal.
[0036] As is apparent from the above description, the free floating weather-strip 122 may be used in a variety of different environments. For example, it may be used as a weather seal for casement windows, that is windows that pivot about a hinge from an open to a closed position. The weather-strip 122 may also be used as a weather-strip for a door, either a pivoting type door or a sliding door. Other examples of the free floating weather-strip of the present invention are indicated at 200 in FIG. 8a and 202 in FIG. 8b . Both embodiments of FIGS. 8a and 8b may be used in a variety of environments as discussed previously above to form a weather seal between two surfaces, one of which is moved to an open position.
[0037] Referring to FIG. 8 a , the weather-strip 200 has leg portions 204 and 206 positioned within recess 208 . The recess opening 210 is defined by shoulders 212 and 214 which retain the weather-strip within the recess by engaging the leg portions 204 and 206 . Providing a spring force in the direction of arrow 216 is hinge 218 which is attached to one of the leg portions 206 and has arm section 220 attached at one end that extends rearwardly to engage the backwall 222 of the recess 208 .
[0038] Similarly, the weather-strip 202 illustrated in FIG. 8 b is the same as discussed with reference to FIG. 5 , and like reference characters will be used to refer to like elements. The weather-strip 202 can also be used within a recess 230 that has no shoulders. A rail 232 having a slot 234 is inserted into the recess 230 . The rail 232 has edge portions 236 and 237 that define a slot 234 and acts as stops to retain the weather-strip 122 within the recess 230 . The weather-strip 122 is held within the recess by leg portions 128 and 132 engaging edge portions 236 and 237 .
[0039] The rail 232 may be made of any type of material and is typically made of extruded polyvinylchloride. The rail may be glued or fixed into the recess by fasteners.
[0040] Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. | The present invention includes a window jamb assembly mountable in a jamb of a double hung window for cooperative engagement with upper and lower sash assemblies. The window jamb assembly includes a jambliner that has inner and outer sash hardware accepting recesses and first and second weather-strip retaining recesses disposed between the sash hardware accepting recesses. First and second weather-strips are retained by the first and second weather-strip retaining recesses and cover strips are disposed in a remainder of the weather-strip recess that is not retaining a weather-strip. The cover strips have a facade portion that provides a visually pleasing finish. | 4 |
FIELD OF THE INVENTION
[0001] The invention relates generally to a diagnostic medical imaging apparatus that employs a near-infrared laser as a radiation source and particularly to a patient support structure having a tabletop with a breast positioning aperture to support a patient in a front-down prone position with her breast disposed vertically pendant in the aperture for scanning.
BACKGROUND OF THE INVENTION
[0002] In recent times, the use of light and more specifically laser light to noninvasively peer inside the body to reveal the interior structure has been investigated. This technique is called optical imaging. Optical imaging and spectroscopy are key components of optical tomography. Rapid progress over the past decade has brought optical computed tomography to the brink of clinical usefulness.
[0003] In optical tomography, the process of acquiring the data that will ultimately be used for image reconstruction is the first important step. Light photon propagation is not straight-line and techniques to produce cross-section images are mathematically intensive. To achieve adequate spatial resolution, multiple sensors are employed to measure photon flux density at small patches on the surface of the scanned object. The volume of an average female breast results in the requirement that data must be acquired from a large number of patches. The photon beam attenuation induced by breast tissue reduces the available photon flux to an extremely low level and requires sophisticated techniques to capture the low level signals.
[0004] U.S. Pat. No. 5,692,511 discloses such a laser imaging apparatus, This apparatus supports a patient in a face-down, prone position on a horizontal surface with a breast vertically pendant through an opening in a table surface. The patient's breast is pendant within a scanning chamber surrounded by an array of detectors, which revolve around the centerline of the scanning chamber. The array of detectors forms a portion of a circle and the scanning chamber and the opening or aperture in the tabletop are therefore circular. Provision is made to accommodate breasts of differing sizes via interchangeable breast centering rings, which provide circular openings or apertures of differing diameters, all centered on the centerline of the scanning chamber.
[0005] In such a computed-tomography geometry, it is required that the rotational centerline of the scanning mechanism pass through the object being scanned. Otherwise the laser beam does not impinge upon the object, and no optical transmission data can be obtained. While this constraint is easily met when the scanner is high in the breast, near the chest wall, the breast will likely move off the rotational centerline, as the scan progresses down the breast toward the nipple. Breasts are generally not conical in shape, typically being quite asymmetric from top to bottom, and somewhat asymmetric from left to right. Typically, even with a prone patient, the breast extends further above the nipple than below. The sagging caused by gravity is permanent, even in the prone position.
OBJECTS AND SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to provide a non-circular opening in the tabletop of the (prone) patient support structure such that more of the patient's breast will remain on the rotational centerline of the sensors and radiation beam.
[0007] It is another object of the present invention to provide a method for positioning a patient's breast vertically pendant below a tabletop and disposed within a scanning chamber below the tabletop having a scanning mechanism rotating about vertical axis of rotation such that the lowest portion of the breast intersects with the axis of rotation of the scanning mechanism.
[0008] It is still another object of the present invention to provide a scanning apparatus, comprising a support structure including a tabletop to support a female patient in front-down, prone position with an opening in which a breast of the patient is vertically pendant below the tabletop and a detector array that rotates around the breast about a vertical axis disposed asymmetrically through the opening such that the axis intersects a bottom portion of the pendant breast.
[0009] In summary, the present invention provides a patient support structure for a laser imaging apparatus, comprising a tabletop to support a female patient in front-down, prone position. The tabletop includes an opening adapted to permit a breast of the patient to be vertically pendant below the tabletop. The opening is non-symmetric with respect to an axis of rotation of a scanning mechanism disposed below the tabletop.
[0010] The present invention also provides a method for positioning a patient's breast vertically pendant below a tabletop and disposed within a scanning chamber below the tabletop having a scanning mechanism rotating about vertical axis of rotation. The method comprises positioning the breast within the scanning chamber such that its lowest portion intersects with the axis of rotation of the scanning mechanism.
[0011] The present invention further provides a scanning apparatus, comprising a support structure including a tabletop to support a female patient in front-down, prone position. The tabletop has an opening adapted to permit a breast of the patient to be vertically pendant below the tabletop. A detector array to image the internal structure of the breast is disposed below the tabletop and includes a laser beam directed toward the breast and a plurality of detectors disposed in an arc around the opening to detect the laser beam after passage through the breast. The detector array is rotatable about a vertical axis disposed asymmetrically through the opening such that the axis intersects a bottom portion of the pendant breast.
[0012] These and other objects of the present invention will become apparent from the following detailed description.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0013] [0013]FIG. 1 is a schematic side elevational view of a scanning apparatus with a planar detector array, showing a prone patient positioned for optical tomographic study, with one breast pendant through a scanning aperture and disposed within the scanning chamber.
[0014] [0014]FIG. 2 is a schematic top view of the scanning apparatus of FIG. 1, showing a circular scanning aperture.
[0015] [0015]FIG. 3 is a schematic top view of the scanning chamber of FIG. 1, showing the planar detector array, consisting of a plurality of detectors disposed around an object being scanned and a laser light source.
[0016] [0016]FIGS. 4A and 4B are schematic cross-sectional views through the planar detector array of FIG. 3, showing the laser light source and detectors and the breast pendant in the scanning chamber through a circular scanning aperture, with the scanning plane at two different positions on the breast.
[0017] [0017]FIG. 5 is a schematic top view of the scanning apparatus of FIG. 1, showing a non-circular scanning aperture superimposed over the circular scanning aperture of FIG. 2.
[0018] [0018]FIGS. 6A and 6B are schematic cross-sectional views through the planar detector array of FIG. 3, showing the laser light source and detectors and a breast pendant in the scanning chamber through the non-circular scanning aperture of FIG. 5, with the scanning plane at two different positions on the breast.
[0019] [0019]FIG. 7 shows a detailed view of the asymmetric and non-circular aperture of FIG. 5.
[0020] [0020]FIG. 8 is a schematic top view of the scanning apparatus of FIG. 1, showing a non-circular scanning aperture disposed in a removable centering disk.
[0021] [0021]FIG. 9 is schematic cross-sectional view along line 9 - 9 of FIG. 8.
[0022] [0022]FIG. 10 shows a plurality of centering disks, each one having a different sized scanning aperture.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Referring to FIG. 1, a scanning apparatus 2 , as described in U.S. Pat. Nos. 5,692,511 and 6,100,520, supports a prone patient 4 face down on a support structure 3 having an essentially flat tabletop 6 . The patient's breast 8 is pendant within a scanning chamber 10 , around which orbits a planar detector array 12 . The planar detector array 12 orbits typically 360° around the vertical axis of the scanning chamber 10 and increments vertically downward between orbits to image successive slice planes of the breast. This is repeated until all the slice planes of the breast have been scanned.
[0024] Referring to FIG. 2, a top view of the scanning apparatus 2 from FIG. 1 is shown. The patient 4 lies on the tabletop 6 with her breast through a circular scanning aperture 14 . The patient is shown positioned for a scan of her left breast and would move to her left for a scan of her right breast.
[0025] Referring to FIG. 3, a top view of the planar detector array 12 is shown. The laser source 16 impinges on the scanned breast 8 at point 18 . A plurality of detectors 20 defines an arc surrounding the breast. A collimator 22 defines each detector's field of view to a small area on the surface of the breast. Light enters the scanned object at point 18 and exits at every point on its circumference, such as at exit points 24 , 26 and 28 corresponding to three detectors. The entire mechanism rotates, as indicated by the curved arrow 32 .
[0026] Every detector 20 is collimated, aiming at the center of orbit rotation 30 and the laser source 16 also points toward the center of rotation. The detectors 20 are spaced at equal angular increments around the center of rotation. The orbit rotation is alternately 360° clockwise for one (horizontal) slice plane, then 360° counterclockwise for the next slice plane.
[0027] Referring to FIG. 4A, a vertical cross-section through the planar detector array of FIG. 3 is shown. The planar detector array 12 is shown as imaging one slice, though any number of slices can be imaged simultaneously as disclosed in U.S. Pat. No. 6,100,520. The patient's breast 8 is pendant within the scanning chamber 10 , with the rotational centerline 30 . The patient is supported by the tabletop 6 . The circular scanning aperture 14 in the tabletop 6 , defined by points 34 and 36 , is shown as symmetric about the rotational centerline 30 . The laser source 16 projects a coherent light beam 38 which impinges on the patient's breast 8 at point 40 . A detector assembly 41 (one of a plurality as shown in FIG. 3) receives the light emitted from the patient's breast at 42 . The detector assembly consists of the collimator 22 , shown as an opaque body 43 with a collimating channel 44 . The collimating channel can be round, square, hexagonal, triangular or any other cross-sectional shape. The collimator restricts the field of view of each detector assembly to a small, defined area on the surface of the scanned breast. At the rear of each collimating channel is a lens 46 , which focuses the light propagating down the collimating channel onto the photodetector 20 . The lenses are shown as plano-convex, but could be biconvex or could be eliminated if the photodetector's area were larger than the collimating channel's area. The photodetector is connected to a signal processing electronics board 32 , which would typically provide amplification and analog-to-digital conversion.
[0028] The laser source 16 could be a semiconductor diode laser, a solid-state laser or some other near-infrared light source. The photodetectors 20 could be photodiodes, avalanche photodiodes, phototransistors, photomultiplier tubes, microchannel plates or some other photosensitive device that converts incoming light photons to an electrical signal.
[0029] The detector assembly 41 is shown in FIG. 4A to be positioned at its highest point, nearest the patient's chest wall. The slice plane, defined by points 40 and 42 , is as high as possible, the nominal starting point of the scan. Referring to FIG. 4B, the same detector assembly 41 is shown later in the scan, having moved downward, away from the chest wall. The laser source 16 is fixed relative to the detector assembly 41 , such that it moves with the detector assembly during rotation around the breast and when it increments vertically. In other words, the laser source 16 or the laser beam 38 moves synchronously with the detector assembly 41 vertically and around the breast.
[0030] Because of the asymmetry of the breast, the laser beam 38 will miss the breast 8 entirely at some portion of the 360° orbit, as shown in FIG. 4B. The slice data is only valid if the laser beam 38 contacts the breast during the entire 360° orbit. At the level of the slice plane, defined by points 52 and 54 , the rotational centerline 30 of the scanning chamber 10 no longer passes through the breast 8 , which means that the laser beam 38 will not pass through the breast at some point in the rotation of the laser source 16 and the detector assembly 41 . The scan cannot continue any lower on the breast as a consequence, since the scan is programmed to shut down when the beam 38 impinges on the detector 20 without passing through the breast.
[0031] A top view of the scanning apparatus 2 is shown in FIG. 5 with an asymmetric non-circular scanning aperture 56 in the tabletop 6 . The aperture 56 is disposed non-symmetrically with respect to the axis of rotation 30 to provide more space on the side of the rotational centerline 30 toward the patient's head as compared to the circular aperture 14 (see FIG. 2). Part of the original circular aperture 14 is shown with a dashed line 58 .
[0032] The detector assembly 41 positioned at its highest point, nearest the patient's chest wall, is shown in FIG. 6A. The asymmetric scanning aperture 56 , defined by points 60 and 62 , allows more space above the rotational centerline 30 of the scanning chamber 10 for the breast 8 toward the patient's head. In FIG. 6B, the detector assembly 41 and the laser source 16 have moved downward and the rotational centerline 30 is still within the breast, which means that the slice data is valid. The laser beam 38 impinges the breast at points 64 and 66 , thereby still allowing the laser beam to penetrate the breast, as compared to FIG. 4B where the laser beam would not pass through the breast at some point in the orbit of the detector assembly. The asymmetric scanning aperture 56 permits the axis of rotation 30 to pass through the lowest portion 67 of the breast, thereby allowing the laser beam 38 not to miss the lower portion of the vertically pendant breast.
[0033] The preferred embodiment of the asymmetric scanning aperture 56 is shown in greater detail in FIG. 7. The scanning aperture 56 is defined with respect to the rotational centerline 30 . An inferior portion 68 is bounded on one side of an imaginary line 69 extending across the aperture and intersecting the axis of rotation 30 and a peripheral edge 71 of the aperture extending toward the patient's feet. The inferior portion has a radius 70 . A superior portion 72 is bounded by the opposite side of the imaginary line 69 and peripheral edge 73 extending from the imaginary line 69 toward the patient's head. The superior portion 72 has a radius 74 greater than the radius 70 . The dotted line 76 shows the continuation of the radius 70 to illustrate the additional space 76 provided by the superior portion 72 of the aperture as compared to the circular aperture 14 . The two radii are connected by tangents 78 to radius 70 with fillets 80 and 82 at the intersections of the tangents 78 with the radius 74 . The inferior portion 68 is seen to semi-circular, while the superior portion 72 includes a circular arc.
[0034] The scanning aperture 56 can be built into the tabletop 6 . However, it is preferable to implement the aperture 56 with a removable centering disk 84 which fits into a cooperating recess 86 in the tabletop 6 , as best shown in FIGS. 8 and 9. The tabletop 6 has an opening 88 which is smaller than the outside diameter of the disk 84 , thereby providing a flange portion 87 to support the disk. The disk 84 preferably has a circular outer shape. Since the disk 84 is removable, several disks may be provided, each disk having a different size aperture shape, so that the proper size aperture can be chosen that best fits a particular patient, as generally shown in FIG. 10.
[0035] Although a specific shape has been disclosed for the aperture, other shapes could be employed, such as ellipses, ovals, race-track shapes, etc and disposed asymmetrically with respect to the axis of rotation 30 . The peripheral edge portion 90 of the scanning aperture 56 can be made pliable to better accommodate the patient.
[0036] While this invention has been described as having preferred design, it is understood that it is capable of further modification, uses and/or adaptations following in general the principle of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains, and as may be applied to the essential features set forth, and fall within the scope of the invention or the limits of the appended claims. We claim: | A patient support structure for a laser imaging apparatus, comprises a tabletop to support a female patient in front-down, prone position. The tabletop includes an opening adapted to permit a breast of the patient to be vertically pendant below the tabletop. The opening is non-symmetric with respect to an axis of rotation of a scanning mechanism disposed below the tabletop. | 0 |
INTRODUCTION
This invention relates to a coupler and more particularly it relates to a protective device for a coupler such as used for coupling or connecting railroad cars.
Couplers can malfunction when splashed with molten metal such as encountered in steel plants, for instance. That is, when car couplers are accidently splashed with molten metal, the couplers can become inoperative as a result of metal freezing or solidifying thereon. As a result, the couplers are not free to move or function as designed when cars move around a curve, for example. The result of molten metal fusing on the coupler can result in damage to rails in addition to excessive wear of car wheels and wheel bearings. Furthermore, it will be understood that couplers frozen or welded together in this manner can greatly interfer with coupling and uncoupling cars. Such interference with coupling is best avoided since it can lead to personal injury because of the extra time spent coupling or uncoupling cars. To repair the damaged couplers by removing fused matal can require considerable grinding which at best is only a temporary solution which can be very expensive and time consuming. Thus, it will be seen that there is a great need for a device which will obviate these problems.
The present invention solves the aforegoing problems by providing a device which prevents materials such as molten metal from solidifying or freezing on the coupling members and ensures their continued operation without fear of binding.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a protective device for a coupler.
Another object of the invention is to provide a protective device which prevents molten metal and the like from depositing and solidifying on couplers such as used on railroad cars.
A further object of the invention is to provide a protective device for couplers such as used on railroad cars, the device while mounted on the coupling member permitting coupling or uncoupling cars.
Yet another object of the invention is to provide a protective device for couplers having a clamping means which releasably attaches to the coupler.
These and other objects will become apparent from the drawings, specification and claims appended hereto.
In accordance with the objects of the invention, there is provided a protective device for a coupler of the type such as used on railroad cars, the coupler having two members the ends of which have a generally C-shaped configuration and which engage each other for purposes of towing or moving cars, the protective device comprising a cover member designed to be placed over said coupler and adapted to prevent foreign materials from engaging the members of the coupler and impeding operation thereof. In addition, the protective device includes clamping means attached to the cover member, the clamping means designed to fixedly engage at least one of the members of the coupler for purposes of maintaining said cover member over the coupler. In a preferred embodiment, the clamping means is rotatably mounted on the cover member and releasably attaches or secures the cover on the coupler by spring action.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view schematically illustrating the protective device mounted on a coupler joining two railroad vehicles.
FIG. 2 is a top plan view schematically showing the protective device mounted on a coupler joining to vehicles.
FIG. 3 is a cross-section of the protective device through the line III--III of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is provided to illustrate the use of the present invention, a partial view of railroad cars 10 with wheels 12 located or positioned on rail 14. The cars are connected by a coupler 20, and protective device or shield referred to generally as 40 covers coupler 20. By reference to FIG. 2, it will be noted that coupler 20, typical of the type to which the present invention has application comprises two hooked or C-shaped members 22. The members are shown in meshed or coupled position exemplifying conditions when cars are connected. The members can have a portion 23 thereof, which can swivel or rotate about pin 25 for purposes of hitching or unhitching cars. Portion or section 23, of the coupling members, may be operated remotely by lever (not shown). Cover member 40 of the protective device is shown covering interfaces 24 of members 22. It will be understood, of course, that the coupler 20 as sketched in FIG. 2 is merely illustrative of coupling devices and the space shown between interfaces 24 of members 22 is merely shown for purposes of illustrating the invention and undoubtedly in some cases departures therefrom will be experienced without interfering with the application of the present invention. In any event, it will be noted from FIG. 2 that cover member 40 essentially protects interface 24 of each coupling member 22, preventing foreign materials, for example, molten metal from depositing or freezing in or bridging the space defined by interface 24 of each coupling member 22. It will be understood that while cover member 40 is shown as having a generally square configuration, other configurations which prevent materials from entering between interfaces 24 of the coupling members are contemplated with in the purview of the invention.
By reference to the Figures, it will be observed that means 60 is provided for clamping or maintaining cover member or protective shield 40 over the coupler and in protective relationship to the space defined by interface 24 of member 22. It will be understood that it is important that the cover member be maintained in a fixed position over the junction of coupler members 22. That is, it is important that cover member 40 be suitably mounted to prevent its sliding forwards or backwards on the coupler and exposing junction 26 between coupling members 22. Yet, it will be further understood that an important aspect of the invention is that the cover member may be mounted or removed easily and that it does not adversely interfer with coupling and uncoupling cars. Similarily, during coupling or uncoupling, it is important that the protective device be attached sufficiently securely so as to prevent its inadvertently falling from the coupler. Thus it can be seen that an important feature of the invention is providing a protective device which is attached or mounted on the coupling securely to prevent its sliding back and forth and yet it should not be so secure as to adversely or unduly delay or interfer with coupling or uncoupling cars.
In accordance with these features, in a preferred aspect of the invention, the protective device is secured to the coupler with clamping means 60 which releasably secures the device to the coupler and which can maintain it on the coupler even during coupling or uncoupling cars. Furthermore, in the preferred embodiment of the invention, the protective device may be quickly and easily mounted on or removed from the coupler without aid of tools.
Clamping device 60 as illustrated in FIGS. 2 and 3 comprises a rod section 62 mounted more or less substantially parallel to cover member 40 (FIG. 3), with rod section 62 extending across top 29 of coupler members 22. Rod section 62 can be rotatably mounted to the underside of cover member 60 by strap 64. It will be understood that rod section 62 may be mounted on the top side of the cover member; however, such arrangement is less preferred since molten metal solidifying thereon can interfer with its operation.
From FIG. 3 it will be seen that when the cover member is secured to the coupler, clamping device 60 also includes an arm 66 which extends generally downwardly from a plane substantially parallel to the plane of the shield. Arm 66 extends more or less down through the depth of coupling member 22. In the embodiment shown in FIG. 3, arm 66 is provided with a curved portion 68 which projects generally inwardly towards the other coupler member. Curved portion 68 is designed or adapted to grip or anchor itself in opening 89 on the underside of the coupler member.
Clamping device 60 as shown in FIG. 3, also includes a second arm 70 which extends generally downwardly from a plane substantially parallel to the plane of the cover member. Arm 70 also extends more or less downwardly through the depth of the coupler. In the embodiment shown, arm 70 has an elbow section 72 designed to engage underside 30 of the coupler member. In mounting the protective device on the coupler, elbow section 72 snaps on to a recessed area on underside 30. It should be noted that arms 66 and 70 of clamping device 60 are formed so as to provide spring action engagement of the protective device to the coupler. That is, arms 66 and 70 are formed so that they grip the coupler members with a determined amount of force. As noted earlier, the gripping force should be sufficient to prevent the protective device from sliding back and forth or otherwise moving on the coupler and leaving juncture 26 exposed to molten metal and the like. It will be noted that arm 70 is provided with a handle 74 for ease of disengagement of the clamping device.
From FIGS. 1 and 2 it will be noted that the clamping device is designed and attached to the cover member, so as to grip the coupler in a preferred orientation. That is, it will be observed particularly in FIG. 2 that rod section 62 of the clamping device is mounted at an angle in the range of about 15° to 30° as measured against a plane perpendicular with respect to the general direction of travel of the cars. With respect to FIG. 2, the angle is shown and referred to as angle X. A typical angle which is suitable for purposes of the present invention is in the range of 20° to 25°. Having rod sections mounted in this manner permits arms 66 and 70 to be positioned slightly into juncture 26 or space between the innerfaces 24 of coupler members 22. Having the clamping device mounted in this manner further provides additional assurance that the shield does not move back and forth on the coupler. It will be noted that rod section 62 may be mounted substantially perpendicular to the direction of travel with curved portion 88 and elbow section offset to form angles substantially as noted.
In the above, it was indicated that the clamping device may be rotatably attached or mounted on the cover member. Having the clamping device mounted in this manner serves to permit controlled movement of the cover member which may result, for example, from an uneven track. Additionally, having the clamping device rotatably mounted in this way makes for greater convenience during shipping or storing.
The cover member may be constructed from any suitable material depending largely on the elements it is likely to encounter. However, when protection is desired from molten metal and the likes, the cover member should be constructed from metal such as 16 guage mild steel, for example. Likewise, the clamping device may be fabricated from suitable steel rod or bar stock. As depicted, the clamping device may be mounted on the shield using a suitable metal strap which may be expeditiously joined to the shield by welding, for example.
While the invention has been described in terms of preferred embodiments, the claims appended hereto are intended to encompass other embodiments which fall within the spirit of the invention. | A protective device is provided for a coupler of the type such as used on railroad cars, the coupler having two members the ends of which have a generally C-shaped configuration and which engage each other for purposes of hitching or towing cars, the protective device comprising a cover member designed to be placed over the coupler and adapted to prevent foreign materials from engaging the members of the coupler and impeding operation thereof, and a clamping device attached to the cover, the clamping device designed to fixedly engage at least one of the members of the coupler for purposes of maintaining the cover member on the coupler. | 1 |
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates generally to spray nozzles and more particularly the spray nozzle used in the application of fluid agricultural chemicals such as fertilizers, herbicides, insecticides, fungicides and related materials to crops. Specifically, the present invention relates to removable flood tip nozzle arrangements for fluid spray applicators, which include a wide angle flat fan spray tip or nozzle fed through a flow regulating insert which may be removable and interchangeable with other inserts to modify performance, the nozzles are designed to spray straight downward at relatively high velocity and produce large droplets. The overall effect is one of high, localized flow with little drift.
II. Related Art
Most agricultural fluid spray application systems are designed to be pulled through fields mounted behind farm vehicles. These systems typically include one or more storage or supply vessels which serve as sources of material to be applied, some type of extended boom or other manifold system which carries a plurality of geometrically arranged spaced nozzles along its length together with connecting piping for carrying the material from the supply vessels or tanks to the manifold and so to the array of output nozzles. At least one pump is provided for forcing the material from the storage tanks under pressure through the piping to the nozzles for spray discharge. The pattern of the spaced nozzle arrangement is designed to perform uniform application to a fairly wide swath as the towing vehicle moves through the field.
Recent developments in crop spraying, on the one hand, have been directed to increasing productivity by increasing the capacity of sprayers and thereby reducing the time necessary for those conducting the spraying to accomplish coverage of a given area. This has led to the development of relatively high volume “flood” type spray nozzles particularly for large boom-type application devices. On the other hand, however, more and more attention is being paid to the effect that agricultural spraying has on the environment. One particular problem in this regard relates to overspraying or drift of airborne minute liquid spray droplets, which may be carried downwind unintentionally beyond the borders of the area intended to be covered.
Consequently, there exists a very real need to provide spray equipment that enables expeditious application of agriculture chemicals to a desired area but which, at the same time, minimizes overspray or drift beyond the bounds intended to be treated. Thus, there is also a need for a nozzle system that can be used to directly apply fluid material at high flow rates to enable coverage of relatively large areas in relatively short time spans which, also reduces or eliminates overspray drift of such materials.
SUMMARY OF THE INVENTION
The present invention overcomes many problems associated with overspray and drift in high volume, high pressure flood type agriculture spray nozzle devices by the provision of a spray nozzle system having a spray tip incorporating an elongated slot-shaped discharge opening that provides a relatively flat “fan” spray pattern that subtends a wide angle. The spray nozzle includes a cap body fixture formed integrally with or otherwise permanently fixed to the spray tip. The cap is further provided with a turn-lock type connection system for removably attaching and locking the cap to a conventional compatible hollow supply fitting having a tubular outlet opening on a boom manifold or other spray device that is, in turn, connected to a source of the material to be sprayed. Because the cap always locks in the same relative position, when the cap is in the locked position, the slot-shaped discharge opening in the spray tip is aligned in a corresponding predetermined orientation.
The cap and spray tip nozzle combination of the invention is further provided with a hollow tubular flow regulating nozzle insert device situated in line between the supply fitting inlet connection and the spray tip. The flow regulating insert includes a flow control or metering aspect that determines nozzle output. While it can be also an integral part of the system, preferably the regulating nozzle insert is a snap-fitting device which is removable and interchangeable with other metering inserts having different capacities to thereby offer a variety of flow rates at a given output pressure differential. The insert connects the spray tip to the outlet opening of the supply fitting at and a proximal end and it is sealed using an o-ring or other type liquid-tight gasket device. Preferably the flow regulating aspect of the nozzle insert device is an orifice integrally molded into the device.
Optionally, a cross-hair diffuser insert can be employed between the flow regulating nozzle insert and the spray tip to modify or improve stability and desired spray pattern. The diffuser may be snap or push fitted into the metering or regulating nozzle insert such that it can also be easily removed if desired. The diffuser may be oriented as desired relative to the main cap using a location key. In addition, a slot shroud may be utilized on the orifice tip to extend spray containment and reduce lateral spread or “thickness”.
The spray nozzle of the present invention is generally of a class intended to be mounted or aligned as one of a plurality of identical spray nozzles in spaced relation along a boom manifold such that wide lateral area may be simultaneously sprayed. Because the slot-shaped discharge opening in the spray tip produces a relatively flat fan-shaped spray pattern that subtends a wide angle, nominally greater than 90° and possibly 160°, the alignment of consecutive spray nozzles in a predetermined orientation that avoids interference between the sprays of the adjacent nozzles becomes important.
The spray nozzle system of the present invention can be manufactured out of any of many materials that would properly function in the role. Preferred materials include high impact plastic such as poly acetal resins. Spray tips may be molded integrally with the cap portion of the nozzle system or separately molded and fixed thereto during assembly. The slot-shaped discharge opening in the spray tip may also be provided after the tip has been molded with or assembled in the cap. The single piece system of course, assures the proper orientation of the slot-shaped discharge opening relative to the cap. Likewise, the flow-regulating insert may be molded as an integral part of the system but is preferably a removable snap-fitting separate piece. The attachment of the cap to the source of supply is normally a finger operated turn-lock type system which enables nozzles to be readily removed and reattached or replaced with other nozzles, as desired.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings wherein like numerals designate like parts throughout the same:
FIG. 1 is a top or front view of one embodiment of a wide-angle spray nozzle in accordance with present invention;
FIG. 2 is a side elevational view of the spray nozzle of FIG. 1 ;
FIG. 3 is a sectional view through the spray nozzle of FIGS. 1 and 2 ;
FIG. 4 is an exploded view of the spray nozzle of FIGS. 1–3 ;
FIG. 5 is a representation of an alternative embodiment of the spray nozzle of the invention with parts broken away;
FIG. 6 is a top or front view of an alternate embodiment of a wide-angle spray nozzle in accordance with the invention;
FIG. 7 is a side elevational view of the spray nozzle of FIG. 6 ;
FIG. 8 is a sectional view of the spray nozzle of FIGS. 6 and 7 along line A—A; and
FIG. 9 is an exploded perspective view of the embodiment of the spray nozzle of FIGS. 6–8 .
DETAILED DESCRIPTION
The present invention provides high-volume, low-pressure spray nozzle system that produces a high volume, large droplet low drift spray. The nozzle system includes a spray tip incorporating in the elongated shaped discharge opening that provides a spray pattern subtending a wide angle. The spray nozzle system includes a cap body that is fixed to or formed integrally with the spray tip. The cap and spray tip combination is further provided with an in-line flow regulating insert device which may be interchangeable with other such devices to modify the spray nozzle output. The cap fits a conventional accommodating supply fitting in a sprayer system connected to a source of spray material and is provided with a conventional rotating locking system which locks the spray tip in a predetermined orientation relative to the supply fitting.
The spray nozzle system of the invention may take any of several forms and those illustrated by the drawings and detailed description contained herein are provided as illustrations of the invention rather than with any intention to limit the scope of the invention in any manner.
Accordingly, FIGS. 1–4 illustrate one preferred embodiment of the spray nozzle system of the invention. As seen in the figures, the spray nozzle system, generally at 10 , includes a spray tip 12 having an elongated slot-shaped discharge opening 14 defining a fan-shaped flat spray pattern that subtends a wide angle. The spray tip 12 is carried in a cap body 16 permanently adhered in fixed relation thereto. The spray tip 12 may also be constructed or molded integrally with the cap body as a unitary structure. The cap body 16 includes reinforcing ribs as at 18 and a pair of opposed spiral grooves one of which is shown at 20 ( FIG. 3 ) which attach the spray nozzle system to a supply fitting at 22 ( FIG. 4 ) using a pair of corresponding fastening lugs 24 . A pair of wings 26 are provided on the cap body 16 as finger grips for rotating the cap body 16 to attach and detach the nozzle from the supply fitting 22 . The nozzle is keyed to the members 24 such that with the spiral grooves 20 it can be pushed and, in turn, locked to the supply fitting 22 readily by hand in a “bayonet” method of attachment. This enables easy attachment and removal of the spray nozzle system 10 while assuring that it locks in place in a specific orientation each time.
The slotted opening 14 is designed to be oriented at an offset angle 28 , which may between 5° and 15° and is typically about 5°–10° as illustrated in FIG. 1 at 28 . This avoids overlap and interference between adjacent nozzles on a boom, as will be described.
The spray nozzle system further includes a metering stem or flow regulating insert stem 30 having a first end 32 designed to be received in the supply fitting 22 and a second end 34 designed to be received in the spray tip/cap body system to supply spray material to the spray tip. The flow-regulating insert stem 30 , toward the end 34 , is provided with a raised ridge 36 designed to be snap fit into a corresponding recess 38 in the spray tip/cap structure. A shoulder 40 is also provided which is designed to abut a corresponding recess shoulder 42 in the spray tip/cap structure. The spray nozzle system connection to the fitting 22 is made liquid tight by the addition of an O-ring 44 designed to nest against the ridge 40 of the sealing it to the end of the fitting 22 at 46 when the nozzle system is assembled on to the fitting 22 .
The flow-regulating insert stem 30 is, of course, in the form of a hollow tubular member as is the fitting 22 so that flow can be maintained between the fitting 22 and the output slot-shaped discharge opening 14 . Within the structure of the flow regulating insert, there is provided a further flow-regulating device which may be in the form of an orifice meter as at 48 having an opening of a known diameter which produces a known output of spray at a given system operating pressure. The alternate embodiment illustrated at FIG. 5 illustrates the use of an insert 60 having an internal venturi-type metering system 62 instead of the orifice meter shown in the embodiment of FIGS. 1–4 . It will be recognized that any suitable type of liquid metering system can be utilized in the spray nozzle system of the invention.
FIGS. 6–9 illustrate an alternative preferred embodiment of the spray nozzle system of the invention which, although generally similar, differs in certain respects. The spray nozzle system of the alternate embodiment is shown generally at 100 and also includes a spray tip 102 having an elongated slot-shaped discharge opening 104 defining a fan-shaped flat spray pattern that subtends a wide angle. The tip also includes a slot shroud 106 which includes members that flank the discharge opening. The shroud further extends spray containment to enhance the nature of the fan-shaped flat spray pattern by further reducing its spread perpendicular to the slotted opening 104 or thickness.
As with the previous embodiment, the spray tip 102 is carried in a cap body 108 permanently adhered in fixed relation thereto and may also be constructed or molded integrally with the cap body as a unitary structure. The cap body 108 includes reinforcing ribs as at 110 and a pair of opposed spiral grooves, one of which is shown at 112 ( FIG. 8 ) which attach the spray nozzle system to a supply fitting as shown at 114 in FIG. 9 using a pair of corresponding fastening lugs 116 in a bayonet-type attachment. A pair of thumb wings 118 are provided on the cap body 108 as finger grips for rotating the cap body 108 to attach and detach the nozzle from the supply fitting 22 . The easy bayonet-type attachment is the same as that described above in relation to the embodiment of FIGS. 1–5 and locks the nozzle in place in a specific orientation each time. As was the case in the first-described embodiment, the slotted opening 104 is designed to be oriented at a similar offset angle illustrated at 120 in FIG. 6 .
This embodiment also includes a flow regulating insert stem 122 having a first end 124 designed to be received in the supply fitting 114 and a second end 126 designed to be received in the spray tip/cap body system to supply spray material to the spray tip. However, this embodiment contains an additional insert 128 in the form of a cross-hair diffuser insert including integral cross-hairs 130 . The cylindrical portion 132 of the diffuser 128 is designed to be removably push fitted into the end 126 of the metering or flow-regulating insert 122 and may be thereafter axially oriented relative to the main cap using a rotatable location key (not shown) in a well known manner. As was the case with insert 30 shown in FIG. 4 , a shoulder 134 is shown on member 122 which is designed to abut a corresponding recess shoulder 136 in the spray tip/cap structure. The spray nozzle system connection to the fitting 114 is made liquid tight by the addition of an O-ring 138 designed to nest against the ridge 134 of the insert stem 122 sealing it to the end of the fitting 114 at 140 when the nozzle system is assembled onto the fitting 114 .
In accordance with one aspect of the present invention the elongated slot-shaped discharge opening of the spray nozzle system of the present invention accords several distinct advantages. It has been found that the combination of the elongated slot-shaped discharge opening and the metering device combine to produce a spray that is characterized by droplets that are much larger than those typically associated with flood type nozzles of the system of the present invention is designed to replace. Thus, it has been found that with the spray nozzle system of the present invention that the spray tip achieves spray droplets of an average size greater than 600 microns compared with normal flood tip droplets size of about 300 microns.
The tip is also designed for high velocity spraying which, in conjunction with increased droplet size, greatly reduces spray drift. The elongated slot-shaped discharge opening 14 in the spray tip 12 , 102 is further designed to produce a wide-angle flat fan spray pattern which may subtend an angle greater than 90° and preferably subtends an angle of about 160°. This pattern may be further defined or sharpened by the use of the slot shroud 106 in conjunction with the spray tip and additional stability and pattern definition may be obtained by the addition of the cross-hair diffuser insert 128 . The offset angle between the elongated slot-shaped discharge opening and cap body of the spray nozzle system ensures that consecutive flow patterns generated by consecutive tips attached to an elongated boom manifold do not interfere with each other. The typical nozzle of the class of the present invention is capable of spraying approximately 2 gallons/minute at a pressure differential of 40 psi. Using interchangeable flow regulating inserts, however, enables one to change or replace the regulator as desired to modify the performance of the system including the flow rate and range of the fan spray, etc. It should be noted further that spray nozzle system of the present invention is designed to be interchangeable with existing nozzle cap body receiving fittings as depicted at 22 in FIG. 4 and 114 in FIG. 9 .
The metering stem or flow regulating insert stem 30 , 122 is rather elongated which facilitates removal for cleaning when necessary. In addition, the gradual radiused profile of the flow regulating insert reduces erosive wear on the insert during use. The spray pattern is further enhanced by the use of a large cross-sectional bore area between the metering orifice and the spray tip which slows liquid flow at higher pressures.
This invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself. | A spray nozzle system includes a spray tip having an elongated slot-shaped discharge opening for defining a flat fan spray pattern that subtends a wide angle, a cap body carrying the spray tip in fixed relation thereto and adapted to attach the spray tip to a supply fitting for tapping a supply of material to be sprayed in fixed aligned relation thereto and a flow regulating insert carried in the spray tip for connecting the spray tip to the supply of material to be sprayed and for controlling the amount of flow through the nozzle. | 1 |
This application is a continuation of application Ser. No. 07/471,007, filed Jan. 25, 1990, which is a continuation of Ser. No. 07/194,289 filed May 16, 1988, both now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of forming a polymeric matrix containing inorganic filler material comprising bringing together filler material, polymerisable material and a catalyst to effect polymerisation of the polymerisable material and forming said polymeric matrix. The invention includes a filled polymeric matrix formed by the method of the invention, and it extends to vitreous filler material for incorporation into a polymeric matrix.
2. Description of the Related Art
Many polymerisable materials are known, and their use in more and more varied fields is widespread. One considerable advantage of such materials is that they can be used in the fluid or even viscoelastic state so that they may be shaped by moulding extrusion, injection or otherwise at a controlled temperature. Many polymerisable materials which are heat-formable at moderate temperatures or formable at ambient temperatures by such techniques require the presence of a polymerisation catalyst to initiate the chain reaction which gives a useful hardened formed article. In order that the polymerisation reaction can proceed properly to yield a homogeneous polymeric mass, it is of course necessary that the catalyst should be well distributed in the polymerisable material.
It is also well known to incorporate filler material into a polymeric matrix. This may be done in order to modify the mechanical, electrical or thermal properties of the polymer, or simply in order to reduce the cost of articles formed from the polymer. It is well known for example to incorporate glass fibres, whether individual glass fibres or glass fibre matting (which may be woven or unwoven), into a polymeric matrix. A filler material which is finding increasing use is vitreous beads. The expression `vitreous` is used herein to denote glass and vitrocrystalline material which latter is a material produced by heat-treating a glass to introduce a crystalline phase therein. The use of hollow glass beads as filler in particular allows the manufacture of articles of low densities.
Difficulties are encountered in achieving a good distribution of filler and catalyst in the polymerisable material for the formation of a high quality polymeric matrix, especially when the polymerisation reaction is one which proceeds rather rapidly. As an example of the difficulties may be cited the case of painted road markings which incorporate glass bead filler material to render the paint retro-reflective so that the marking may be seen more easily at night. One known technique is illustrated in U.S. Pat. No. 2,897,732 and consists in spreading a paint which is polymerisable to form a polyestervinylidene copolymer, spraying a powder polymerisation catalyst onto the surface of the paint marking and then sprinkling glass beads over the paint so that at least some of them can sink into the marking before polymerisation is completed. This technique suffers from a number of disadvantages. Firstly, it requires a rather complicated apparatus having three separate material discharge heads. Secondly, the catalyst, which is the most expensive ingredient, can easily be blown away during discharge and wasted. Thirdly, the catalyst is essentially deposited on the surface of the paint marking, and this gives rise to differential polymerisation of the paint leading to cracking of the surface and a lack of catalyst in the depth of the paint. Fourthly, although rapid polymerisation of the paint is obviously desirable, the more rapidly such polymerisation takes place, the less easy it is to achieve the desired distribution of filler beads through the depth of the paint marking.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a method of forming a polymeric matrix containing filler material in which a good distribution of catalyst within the polymerisable material is facilitated, which allows a rapid catalytic action, and which allows a proportional reduction in the amount of catalyst required for effecting complete polymerisation of the polymerisable material to form the polymeric matrix.
According to the invention, there is provided a method of forming a polymeric matrix containing inorganic filler material comprising bringing together filler material, polymerisable material and a catalyst to effect polymerisation of the polymerisable material and form said polymeric matrix, characterised in that a catalyst is fixed to the surface of the filler material prior to its contact with the polymerisable material.
Such a method is very simple to perform. In comparison with mixing a catalyst and a polymerisable material, it is generally much easier to ensure that a filler material and a polymerisable material have a desired relative distribution. Since, according to the invention, the catalyst is fixed to the filler, a good relative distribution of the polymerisable material and the filler ensures a good distribution of the catalyst and the polymerisable material. As a result, the catalysed polymerisation can take place rapidly, efficiently and evenly through the polymerisable material/polymer matrix. Also, the amount of catalyst applied to the filler can easily be regulated so that the amount of catalyst wasted is very much reduced. It has been observed that it is sometimes possible to use less catalyst in the technique of this invention than when using filler and catalyst separately. It is rather surprising that the technique of the invention should give a more efficient catalytic action since it would be expected that the efficiency would be reduced by fixing the catalyst to a material other than that which is to be catalysed.
Advantageously, said catalyst is adsorbed in a layer of fixing agent adherent to the surface of the filler material. This allows the catalyst to be fixed to the filler in such a way that the filler can be stored and handled before contact with a polymerisable material without loss of the catalyst and without reducing the reactivity of the catalyst in relation to the polymerisable matrix material which is to be polymerised.
It has been found that a number of materials are capable of forming a firm chemical bond with the range of filler materials commonly used for filling polymeric matrices and can be used as fixing agent for the catalyst. It is preferred that an organo-metallic compound is caused to adhere to said filler material to act as fixing agent. Many such compounds can easily be caused to bond chemically to the inorganic filler materials, in a monomolecular or multimolecular layer, and they are capable of fixing catalyst to the filler. It is especially preferred that said organo-metallic compound is selected from the group consisting of: silanes, chromium complexes, titanium derivatives and polymers having a methoxysilyl group. Such compounds are especially effective as fixing agents and they also have the advantage that they can promote coupling between the filler material and many common polymeric materials, such as polyesters and polyacrylates. This promotes the production of composite materials having a high breaking strength under flexure. It also promotes a high resistance to stripping out of the filler material by abrasion which is especially important where the polymeric matrix is to be used as a road marking.
As examples of such materials may be mentioned the following: vinylsilanes (A151 from Union Carbide), methacryloxysilanes (A174 from Union Carbide), styrylsilanes, chromium complexes of the Werner type including complexes with fumaric acid (Volans* from du Pont), isopropyl titanates (TSM2-7, TSA2-11, TTM33, TTAC-39 from Kenrich), and special polymers with methoxysilyl groups (Polyvest 25* from Huls). ≠(* Trademark)
A coating of fixing agent may be applied to the filler material by various techniques such as immersion or other contact with a liquid reagent followed by drying, or by deposition from a vaporised reagent, for example, in the case of a particulate filler, in a fluidised bed. The formation of such a coating can be followed by impregnation of the coating with the catalyst, by contacting the coating with a liquid or dissolved catalyst. In some preferred embodiments of the invention, said filler material is contacted with a solution containing said catalyst and a fixing agent in order to fix said catalyst to the surface of the filler material, and the filler material is then dried. In this way, the fixing agent and catalyst are applied to the filler material in a single step, so the method is very simple and quick. In other preferred embodiments of the invention, said filler material is contacted with a suspension containing said catalyst and a fixing agent in order to fix said catalyst to the surface of the filler material. This is even simpler and quicker, since the drying step can sometimes thereby be eliminated. For example a silane fixing agent may be mixed with INTEROX BP-40-S (Trademark) from Peroxid-Chemie GmbH of Munich, which is a 40 % suspension in phthalate of dibenzoyl peroxide as catalyst.
Embodiments of the invention wherein said filler material is mixed with an unsaturated polyester to effect polymerisation thereof are preferred. The invention may be used for the production of articles of such materials, for example acrylic or urethane/acrylic resins, in the presence of a catalyst at ambient temperature, using an accelerator if desired. This method may be used for manufacturing articles from a unsaturated polyester dissolved in a copolymerisable monomer, for example oligourethane methacrylic resins in methyl methacrylate as solvent monomer, or polyester resins mixed with a vinyl, acrylic or allyl monomer.
There are various polymerisation catalysts which make it possible to harden polymerisable materials more quickly and/or at lower temperatures. The use of a peroxide as catalyst is often recommended especially for unsaturated polyester resins and copolymers thereof. The invention includes a method wherein a peroxide, for example benzoyl peroxide which is available as a powder which is easy to handle, is fixed to the surface of the filler material as said catalyst.
Various fillers commonly used for forming filled polymeric matrices may be used in the method of the invention. Among such fillers may be mentioned natural minerals such as mica and talc. In the most preferred embodiments of the invention, however, said filler material comprises vitreous material. The use of vitreous material has a number of advantages, in particular vitreous filler materials are inexpensive and widely available, and such material can also be made in a variety of shapes and sizes for conferring particularly desirable properties on the product of the method.
In some preferred embodiments of the invention, said filler material comprises glass fibres. Such fibres may be short individual fibres, or they may be long fibres constituting woven or non-woven matting.
In most preferred embodiments of the invention, said filler material comprises vitreous beads. Vitreous beads are particularly useful because their very high degree of spherical symmetry allows especially easy mixing into a fluid or viscoelastic polymerisable material so that the beads, and thus also the catalyst, are well distributed therein, and their use gives good flow properties in any moulding operation and allows a uniform distribution of stresses within the formed polymeric matrix.
If it is desired to manufacture an article of low density, then hollow vitreous beads may be used. However, if it is envisaged that good mechanical resistance in the product will be more important than low density, it is preferred that said vitreous beads comprise solid vitreous beads. For the best mechanical properties in the product it may be desirable to use vitrocrystalline beads rather than glass beads, despite their generally higher cost.
The size of the beads used as filler can have an important effect on the ease with which a filled polymeric matrix can be formed and/or on the eventual properties of that matrix. In the case of moulded plastics materials, it is generally desirable for the beads to have a median diameter of between 20 and 50 micrometers, for example about 44 micrometers. This is because of the effect the presence of the beads has on the flow properties of the polymerisable material during the moulding process. Beads to be used in paints, on the other hand, generally have a median diameter between 50 and 650 micrometers, because this is found to be advantageous for good reflective properties of the filled paint. References to the median bead diameter here and throughout this specification are references to the median diameter by number of beads, that is to say, as many beads have a diameter less than the median as have a diameter greater than the median. In preferred embodiments of the invention therefore, said vitreous beads are selected so that they have a median diameter between 20 and 650 micrometers inclusive.
It will be noted that the smaller the specific surface area of the beads is the smaller the area available for catalyst fixing. In the case of casting or moulding resins, where smaller beads are usually used it may be sufficient to select the size of the beads according to the quantity of catalyst to be supplied to the polymerisable material with which the beads are to be mixed. However, in the case of paints or other resins where beads are applied to the polymerisable material after same has been applied to a surface as a layer, it may be desirable to use relatively large beads, for example with a diameter of between 150 and 650 micrometers, so that the beads can more easily sink into the layer of polymerisable material and entrain the catalyst to the depths of the layer, even though such larger beads have a lower specific surface area, and therefore can carry relatively little catalyst.
Advantageously, at least some of the vitreous beads used have rough surfaces. Such surface roughening can be obtained by a mechanical frosting technique, but in view of the preferred size of the beads it is very much easier to frost them chemically. It is especially preferred, therefore, that at least some of said vitreous beads are treated with an etching medium prior to coating. Such etched beads will have surfaces which are rough and they therefore have greater specific surface areas than smooth beads of the same sizes. Such roughened beads are therefore capable of fixing more catalyst for the same median diameter, and the use of such an etching technique can result in a three-fold increase in the amount of catalyst which can be carried by the beads. This is particularly beneficial when working with rather large beads and/or when rapid polymerisation is required, and/or when it is desired to effect such polymerisation at low ambient temperatures: for example, when laying down pavement markings in winter. It may be noted that beads having roughened surfaces will partially lose the reflective properties for which they have primarily been used in pavement markings. This does not present any real disadvantage, because such beads can be mixed with non-etched catalyst-bearing beads to ensure the desired level of reflectivity from the marking, or with other non-etched beads as will be adverted to below. Indeed it can in some circumstances be a positive advantage, in that such etched beads can be used to replace fillers serving as white pigment such as chalk or titanium dioxide which may be rather more costly.
Such an etching technique is very simply carried out using an etching medium containing fluorine ions, for example, a solution of ammonium bifluoride. Such should only be used however for treating solid beads since hollow beads may have walls too thin to withstand the treatment.
We have referred to the possibility of mixing catalyst-bearing vitreous beads with other beads. In some preferred embodiments of the invention, vitreous beads are coated with a material which renders them both oleophobic and hydrophobic and are incorporated in said filler material together with catalyst-bearing vitreous beads. Such a mixture is particularly well suited for use in pavement marking because the catalyst-bearing beads can be sprinkled onto the wet paint in admixture with the oleophobic and hydrophobic beads using a simple apparatus comprising a paint spray gun and a single bead and catalyst discharge head. The catalyst-bearing beads will sink and mix within the layer of paint while the oleophobic and hydrophobic beads will remain exposed on top of the paint surface where they can reflect light until eroded by traffic movement, at which time the erosion will have exposed some of the catalyst-bearing beads so that they in turn can reflect light.
Advantageously, said catalyst-bearing beads are incorporated in said filler material in a proportion of between 70% and 90% by weight of the total filler. The adoption of this feature has been found particularly beneficial for the rapid formation of retro-reflective coats of polymerised paint.
Indeed, a method according to the invention is particularly suitable for the formation of pavement markings, and in the most preferred embodiments, polymerisable material is applied to a pavement and catalyst-bearing vitreous beads are applied to that polymerisable material to cause in situ polymerisation thereof and the formation of a pavement marking. The expression `pavement` is used herein in a broad sense, and includes: carriageways, footways, aircraft runways and taxiways, parking zones and other pavement areas. In one very simple and effective method of marking a pavement, a coat of polymerisable paint is deposited on the pavement, and then, while the paint is still wet, vitreous beads to whose surface is fixed a polymerisation catalyst for hardening the paint are sprayed onto the paint. The catalyst bearing beads may be the only beads used, or they may be mixed with other vitreous beads. This method makes it possible to form lines, patterns, letters or other symbols on for example concrete or tarmac surfaces, which markings may be perfectly clear and visible at night in the presence of light from vehicle headlamps. The markings can be applied in a very short time and thus with very little disruption of normal traffic flow. It has been found that by using such a method, savings can be made on the amount of catalyst which must be used as compared with a traditional pavement marking method in which a powder catalyst is applied to the surface of the paint. Moreover, such a method only requires a rather simple apparatus comprising a paint spray gun and a bead discharge device. Such an apparatus can be used for marking by means of a polymerisable paint as well as by means of traditional emulsion paints.
In other preferred embodiments of the invention, a polymerisable material is mixed with catalyst-bearing filler material and the mixture is shaped before hardening thereof by polymerisation. Such a method makes it possible to dose quite precisely the quantity of catalyst required to effect polymerisation of the polymerisable material.
In yet other preferred embodiments of the invention, woven or unwoven glass fibre catalyst-bearing matting is laid up and a polymerisable material is applied thereto. The glass fibre matting may be laid up in a mould or over a stretcher. This is a very simple way of forming a glass fibre reinforced polymeric article. It avoids wastage of the polymeric material due to premature curing of premixed polymerisable material and catalyst, and can ensure a good distribution of catalyst over the whole area of the glass fibre matting.
The invention includes a filled polymeric matrix formed by the method of the invention.
Vitreous filler material bearing a said catalyst is itself a new and useful product, and the present invention extends to vitreous filler material for incorporation into a polymeric matrix, characterised in that a polymerisation catalyst is fixed to the surface of such filler material.
Such a product is especially useful because it is very much easier to mix catalyst-bearing filler material into a polymerisable material with good distribution than it is to mix filler and separate catalyst into the polymerisable material. Thus it is easier to get a rapid and efficient polymerisation of the polymerisable material. The use of vitreous filler material has a number of advantages, in particular vitreous filler materials are inexpensive and widely available, and such material can also be made in a variety of shapes and sizes for conferring particularly desirable properties on filled polymeric material.
Advantageously, said catalyst is adsorbed in a layer of fixing agent adherent to the surface of the filler material. This allows the filler to be stored and handled before contact with a polymerisable material without loss of the catalyst and without reducing the reactivity of the catalyst in relation to the material which is to be polymerised.
As has been mentioned, a number of materials can be used as fixing agent for the catalyst. It is preferred that an organo-metallic compound is used as fixing agent. Many such compounds can easily be caused to bond chemically to the inorganic filler materials, in a monomolecular or multimolecular layer, and they are capable of fixing catalyst to the filler. It is especially preferred that said organo-metallic compound is selected from the group consisting of: silanes, chromium complexes, titanium derivatives and polymers having a methoxysilyl group. Such compounds are especially effective as fixing agents and they also have the advantage that they can promote coupling between the filler material and many common polymeric materials in view such as polyesters and polyacrylates.
There are various polymerisation catalysts which make it possible to harden polymerisable material more quickly and/or at lower temperatures. The use of a peroxide as catalyst is often recommended especially for unsaturated polyesters and copolymers thereof. The invention includes a said filler material wherein a peroxide, for example benzoyl peroxide which is available as a powder which is easy to handle, is fixed to the surface of the filler material as said catalyst.
In some preferred embodiments of the invention, said vitreous filler material comprises glass fibres. Such fibres may be short individual fibres, or they may be long fibres constituting woven or non-woven matting.
In most preferred embodiments of the invention, said filler material comprises vitreous beads. Vitreous beads are particularly useful because their very high degree of spherical symmetry allows especially easy mixing into a fluid or viscoelastic polymerisable material so that the beads and catalyst are well distributed therein, and their use gives good flow properties in any moulding operation and allows a uniform distribution of stresses within the formed polymeric matrix.
If it is desired to manufacture an article of low density, then hollow vitreous beads may be used. However, if it is envisaged that good mechanical resistance in the product will be more important than low density, it is preferred that said vitreous beads comprise solid vitreous beads. For the best mechanical properties in the product it may be desirable to use vitrocrystalline beads rather than glass beads, despite their generally higher cost.
The size of the beads used as filler can have an important effect on the ease with which a filled polymeric matrix can be formed and/or on the eventual properties of that matrix. In the case of moulded plastics materials, it is generally desirable for the beads to have a median diameter of between 20 and 50 micrometers, for example about 44 micrometers. This is because of the effect the presence of the beads has on the flow properties of the polymerisable material during the moulding process. Beads to be used in paints, on the other hand, generally have a median diameter between 50 and 650 micrometers, because this is found to be advantageous for good reflective properties of the filled paint. In preferred embodiments of the invention therefore, said vitreous beads have a median diameter between 20 and 650 micrometers inclusive.
Advantageously, at least some of said vitreous beads have a rough surface bearing said catalyst. Such rough beads will have greater specific surface areas than smooth beads of the same sizes. Such rough beads are therefore capable of fixing more catalyst for the same median diameter, and they can carry up to three times as much catalyst as smooth beads. This is particularly beneficial when working with rather large beads and/or when rapid polymerisation is required, and/or when it is desired to effect such polymerisation at low ambient temperatures. It may be noted that beads having roughened surfaces will partially lose the reflective properties for which they have primarily been used in pavement markings. This does not present any real disadvantage, because such beads can be mixed with smooth catalyst-bearing beads to ensure the desired level of reflectivity from the marking, or with other smooth beads as will be adverted to below. Indeed it can in some circumstances be a positive advantage, in that such rough beads can be used to replace fillers serving as white pigment such as chalk or titanium dioxide which may be rather more costly.
In some preferred embodiments of the invention, said filler material further comprises vitreous beads coated with a material which renders them both oleophobic and hydrophobic. Such a mixture is particularly well suited for use in pavement marking because the catalyst-bearing beads can be sprinkled onto the wet paint in admixture with the oleophobic and hydrophobic beads using a simple apparatus comprising a paint spray gun and a single bead and catalyst discharge head. The catalyst-bearing beads will sink and mix within the layer of paint while the oleophobic and hydrophobic beads will remain exposed on top of the paint surface where they can reflect light until eroded by traffic movement, at which time the erosion will have exposed some of the catalyst-bearing beads so that they in turn can reflect light.
Advantageously, said catalyst-bearing beads are incorporated in said filler material in a proportion of between 70% and 90% by weight of the total filler. The adoption of this feature has been found particularly beneficial for the rapid formation of retro-reflective coats of polymerised paint.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in more detail by means of the examples below.
EXAMPLE 1
Beads are manufactured for introductions into road marking paint. The beads have a diameter of between 150 and 250 micrometers and a median diameter (by number of particles) of 180 micrometers. The paint is an acrylic resin by Rohm, Plexilith SE 663 (Trademark).
Benzoyl peroxide is dissolved in toluene at the rate of 200 g/L solvent. After a few minutes, Union Carbide's silane A 174 is added (gamma-methacryloxypropyltrimethoxysilane). The solution containing the peroxide catalyst and the silane is poured over the beads while the mixture is kept continually moving. After 15 minutes' agitation, the beads are dried at ambient temperature for 24 hours. The beads carry 0.075 g silane per kilogram and 8 g peroxide per kilogram. This mixture is stored before being taken to the site of road marking.
The paint is sprayed onto the road, and onto the paint are sprayed beads prepared as indicated above at the rate of 1 part beads to 1 part paint (by weight). After 15 minutes, the paint is fully polymerised. The properties of retro-reflection of light exhibited by this paint are no different to those of a paint which is similar but into which the catalyst and bare glass beads have been introduced separately. If the technique according to the prior art is used, in the course of which the catalyst is supplied separately. 2 to 3 times more peroxide is needed to harden the paint in 15 minutes.
In a varient of the present example, 20% of the beads bearing the catalyst were replaced with beads treated by an agent which renders them hydrophobic and oleophobic such as a fluorocarbon agent of the type FC 129 by 3M. Hardening of the paint takes a few minutes longer, but the retro-reflective properties of the paint are improved on account of the presence of the hydrophobic and oleophobic beads at the surface of the hardened coat.
EXAMPLE 2
Example 1 was repeated, but using a mixture of beads of different particle sizes. There is used a mixture consisting of 1/3 solid glass beads with diameters between 40 and 80 micrometers, 1/3 beads with diameters between 75 and 150 micrometers, and 1/3 beads with diameters between 150 and 250 micrometers.
Different quantities of peroxide were deposited on the beads, and in instance the silane A 174 was replaced with an equivalent quantity of a bonding agent with a methoxysilyl group, Polyvest 25 (Trademark) by Huls.
Table 1 below gives the hardening time of the acrylic paint in the presence of this mixture of beads, for a beads-to-resin ratio of 1:1 by weight.
TABLE 1______________________________________Quantity of peroxide Polyvest 25 A 174 Hardeningg per kg beads g/kg g/kg time______________________________________4 -- 0.075 35 min8 -- 0.075 15 min8 0.075 -- 15 min______________________________________
EXAMPLE 3
Solid glass beads with a median diameter of 44 micrometers are treated with an aqueous solution of ammonium bifluoride. Beads having undergone this treatment have an opaque white apperance. Their surfaces are rough.
These beads are mixed with a solution of silane A 174 and benzoyl peroxide in toluene. Thus 2 g of silane and 8 g of peroxide per kilogram beads are deposited on the surface of the beads.
A methylacrylic resin of type MDR 824 by I.C.I. containing dimethyl-p-toluidine as accelerator is mixed with 1.25 kg beads per kilogram resin at 20° C. The filled resin is shaped by injection moulding. Hardening of the moulded article after 50 seconds at 70° C. is observed.
EXAMPLE 4
Glass beads of median diameter 44 micrometers are treated in a manner identical to those of example 3, with a glass etching agent and then with a mixture of silane and peroxide. In the present example, the peroxide with which the beads have been impregnated is methylethyl ketone peroxide.
100 parts by weight of these beads are mixed with 100 parts by weight of Epocryl 322 acrylic resin by Shell Chemical Co. and 0.4 parts by weight of cobalt naphthanate as accelerator (6% cobalt). The mixture is poured into a mould at 25° C. The gel time of the mixture is about 10 minutes, and hardening is attained after 20 minutes.
In a variant of this example, to the beads treated as above and bearing the polymerisation catalyst are added glass beads bearing a coating comprising a first substance which, if it were used alone, would render the beads hydrophobic while leaving them oleophilic and a second substance which, if it were used alone, would render the beads hydrophobic and oleophobic (these beads are treated in accordance with the method described in Belgian patent 904,453) so as to obtain good distribution of these beads in the resin and confer reflective properties on the latter. Said mixture is used to mould reflectors.
EXAMPLE 5
Solid glass beads with a median diameter of about 400 micrometers are treated with a mixture of Interox BP-40-S (Trademark) from Peroxide-Chemie GmbH and silane A174. Interox BP-40-S is a 40% suspension of dibenzoyl peroxide in phthalate. This mixture adheres well to the beads and there is no need for any positive drying of the beads after treatment. The phthalate plays the role of plasticiser in the resin. In this way, 0.3 g silane and 2.5 g catalyst per kilogram beads are fixed to the beads.
The treated beads are useful for incorporation in retro-reflective acrylic paints.
EXAMPLE 6
Chopped glass fibers are mixed with a solution of silane A 174 and benzoyl peroxide in toluene and dried. Thus 10 g of silane and about 100 g of peroxide per kilogram fibre are deposited on the surface of the fibres.
A methylacrylic resin of type MDR 806 by I.C.I. containing dimethyl-p-toluidine as accelerator is mixed with 0.20 kg fibre per kilogram resin. The filled resin is shaped by injection moulding. The gel time of the mixture at 20° C. is less than 10 minutes.
EXAMPLE 7
Solid glass beads with a median diameter of about 20 micrometers are mixed with vinyltriethoxysilane A151 (Union Carbide) and Interox BP-40-S (Trademark). This gave fixing to the beads of 0.5 g silane and 2 g of peroxide per kilogram beads. The beads are mixed with a liquid polyester resin, the mixture is immediately applied to a mat of woven glass fibres in a mould, and hardening is observed at ambient temperature.
In a variant, no beads are used. The catalyst is fixed to the surface of the glass fibres.
EXAMPLE 8
In a variant of example 3, the beads have a median diameter of about 40 micrometers and they are not etched. By mixing these beads with a solution of silane A 174 and benzoyl peroxide in toluene, 0.7 g of silane and 2 g of peroxide per kilogram beads are deposited on the surface of the beads.
In another variant, vitrocrystalline beads of the same granulometry are used.
EXAMPLE 9
Mica having a mean particle size of about 25 micrometers is used as filler. By mixing the mica with vinyltriethoxysilane A151 (Union Carbide) and Interox TBPB (Trademark) (t-butyl perbenzoate), 0.5 g of silane and 2.5 g of perbenzoate per kilogram mica are deposited on the surface of the mica. The catalyst-bearing mica is mixed with a polyester resin of the Bulk Moulding Compound type and moulded by injection. | Vitreous filler material for incorporation into a polymerizable matrix, including a filler material which is vitreous; a polymerization catalyst; and a fixing agent which is applied to at least a part of the surface of the filler material and which affixes the polymerization catalyst to the surface of the filler material. Fixing catalyst to the surface of the filler material prior to its being contacted with the polymerizable matrix material facilitates good distribution of the catalyst within the polymerizable matrix material, and advantageously allows rapid catalytic action and a reduction in the amount of catalyst required. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to exercising apparatus and more particularly to a compact, wall mounted exercising machine for accomplishing progressive resistance exercises.
2. Discussion of the Prior Art
The therapeutic value of progressive resistance exercises has long been recognized. Exercising muscles against progressively increasing weights not only results in added strength and endurance in the muscles, but also in the improvement of neuromuscular coordination and in a more efficient functioning of the cardiovascular and respiratory systems.
Traditionally apparatus such as dumbbells and barbells have been used for progressive exercises. The use of such apparatus, however, can be extremely dangerous when undertaken without proper training and supervision. When a large amount of weight is being lifted, barbells are particularly dangerous and present difficult balancing problems. If they are dropped, serious injury can result to the trainee or to those about him.
In the past, various types of progressive weight training machines have been suggested to overcome the drawbacks of barbells and dumbbells. However, to provide the required versitility and insure trainee safety such machines have typically been quite large and bulky and have required substantial amounts of floor space.
Among the most successful prior art devices known to applicant are those described in U.S. Pat. No. 3,971,555 and in U.S. Pat. No. Re. 28,066. Applicant is also familiar with U.S. Pat. Nos. 3,905,599 and 3,912,263. The aforementioned patents represent the most pertinent are known to applicant and serve to illustrate the novelty of the apparatus of the present invention.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved, wall mounted progressive resistance exercise machine which is simpler, less bulky, and less weighty than prior art machines making it ideally suited for use in homes, apartments and offices as well as in gymnasiums.
More particularly, it is an object of the invention to provide an exercise machine of the aforementioned character which includes a vertically reciprocative carriage biased against vertical upward movement by a plurality of weights disposed substantially below the carriage. The machine is of a unique design embodying a single central column which not only functions to guide vertical movement of the carriage, but also functions to guide vertical travel of the weights.
Another object of the invention is to provide a machine of the type described which uses a vertically movable direct connection between the carriage and the weights and in which said direct connection is receivable through and is positively guided by central apertures formed in the individual weights.
Still another object is to provide such a machine which embodies a minimum number of component parts, does not utilize ropes, cables, pulleys or the like and, therefore, is smoother, safter and more positive in operation.
A further object is to provide a machine of the type described in the proceeding paragraphs which includes a unique carriage reciprocation system comprising vertically spaced apart rollers adapted to rollably engage the front and rear surfaces of the single central column of the machine.
The superior engineering design and overall simplicity and compactness of the machine of the present invention permits it to be inexpensively manufactured, easily set up and operated in numerous locations, and to be safely used even by unskilled persons with a minimum of training.
In summary, these and other objects of the present invention are realized by an exercising apparatus comprising a vertically reciprocative carriage, having first and second vertically spaced apart bearing means; a substantially vertically disposed central guide column having first and second guide means for guiding said first and second bearing means of the carriage; body engaging means projecting laterally outward from the carriage for moving the carriage upwardly relative to the central guide column; and biasing means for biasing the carriage against upward movement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of the single column exercising apparatus of the invention.
FIG. 2 is a side elevational view partly broken away to show internal construction.
FIG. 3 is a cross-sectional view taken along lines 3--3 of FIG. 2 illustrating the construction of the body engaging means and its method of connection to the reciprocal carriage.
FIG. 4 is a view taken along lines 4--4 of FIG. 2 illustrating the unique construction of the central guide column, the selector bar and the apertured weights of the apparatus.
FIG. 5 is a fragmentary side elevational view showing another embodiment of the single column exercising apparatus of the invention.
FIG. 6 is a cross-sectional view taken along lines 6--6 of FIG. 5.
DESCRIPTION OF THE INVENTION
Referring to the drawings, and particularly FIGS. 1 through 3, one form of the single column exercising apparatus of the invention comprises a vertically reciprocative carriage 14, a substantially vertically disposed central guide column 16, body engaging means 18 projecting laterally outward from carriage 14 and biasing means in the form of a stack of weights 20 for biasing the carriage against upward movement by forces exerted on the body engaging means. As best seen in FIG. 2, the carriage 14 and one or more of the weights 22 of the weight stack 20 can be interconnected by a selector means shown here as comprising a substantially vertically disposed connecting column 24.
Turning to FIG. 4, it can be seen that each of the weights 22 which make up the weight stack is apertured to closely receive both central guide column 16 and connecting column 24. This unique construction has numerous advantages, one of which is the elimination of the requirement for separate guide means for guiding the vertical travel of the weights within the apparatus. As also shown in FIG. 4, a protective means in the form of a rigid vertically extending shield member 26 is connected to the lower front surfaces of guide column 16 to shield the trainee from the weight stack. This protective shield precludes injury to the trainee or others should the weights accidentally be dropped during the performance of an exercise.
Referring once again to FIGS. 1 and 2, brackets 27 and 29 are provided at the top and bottom of vertical column 16 to conveniently attach the apparatus to a wall or other vertical structural member. When the apparatus is installed in the manner shown in the drawings, brackets 27 and 29 securely position the central guide column 16 in a spaced apart relationship with respect to the wall or other vertical structure. Because of the unique single column design of the apparatus, a minimum amount of floor space and wall area is required to install the apparatus. This feature, along with the simplicity of the design and maximum weight savings attributable thereto, permits the apparatus to be conveniently installed and used in homes, offices or apartments, as well as in gymnasiums.
Turning now to FIG. 3, carriage 14 is seen to comprise a generally "U" shaped housing 28 adapted to carry first and second vertically spaced apart bearing or roller means. In the embodiment of the invention shown in the drawings, these latter means are provided in the form of upper and lower sets of wheel means 30 and 32 respectively (FIG. 2). Upper wheel means 30 include front and rear pairs of rollers 30a which are coaxially mounted on horizontally spaced apart axles 34 carried by housing 28. Similarly lower wheel means 32 include front and rear pairs of rollers 32a which are coaxially mounted on horizontally spaced apart axle members 36 carried by "U" shaped housing 28. Rollers 30a and 32a are of identical configuration, each having hub portions 33 and flange portions 34.
Central guide column 16 is provided first and second guide means for guiding said bearing or roller means of the carriage 14. In the embodiment of the invention shown in the drawings, central guide column 16 is substantially rectangular in cross-section and said first and second guide means comprise front and rear guide surfaces which are rollably engaged by the hub portions 33 of rollers 30a and 32a. Central guide column 16 is also provided with guide surfaces of each side thereof, adapted to be rollably engaged by flange portions 34 of rollers 30a and 32a.
As will be discussed in greater detail hereinafter, an important and highly novel feature of the invention resides in the fact that the single central column 16 not only functions to guide vertical travel of the carriage in the manner just described, but also functions to guide the vertical travel of the weights thereby eliminating the need for separate guide columns for the weights.
In the form of the invention shown in FIGS. 1 through 4, the body engaging means 18 comprises a lifting arm or handle bar structure 40 which can be removably connected to carriage 14 at vertically spaced apart locations. Referring to FIG. 1, lifting arm 40 includes a central portion 40a, a pair of flared out portions 40b and a pair of handle portions 40c. As shown in FIG. 3, extending rearwardly from central portion 40a, is a pair of transversely spaced apart arm members 42, each of which is provided with a keyhole shaped aperture 44 proximate its inboard end. Disposed intermediate arms 42 and extending rearwardly from central portion 40a of handle bar 40 is a stud 46 adapted to be closely received in vertically spaced apart apertures 48 provided in carriage 14 (FIG. 1).
The spacing between arms 42 is slightly wider than the width of housing 28 of carriage 14 so that the lifting arm can be positioned proximate carriage 14 with stud 46 protruding through a selected aperture 48. In this position apertures 44 formed in arms 42 will align with apertures 50 provided in housing 28 at a plurality of vertically spaced apart locations (FIG. 1). The lifting arm may be locked into position relative to the carriage by inserting a locking pin 52 through apertures 44 and apertures 50. A locking means in the form of a small protuberance 54 positioned intermediate the ends of locking pin 52 prevents accidental withdrawal of the pin.
As best seen by referring to FIGS. 2, 3 and 4, connecting column 24 is substantially "U" shaped in configuration, is closely receivable in apertures 55 formed in each weight 22 and is affixed at its upper end to the lower end of carriage 14. A plurality of vertically spaced apart keyhole shaped apertures 56 adapted to closely receive a second locking pin 58 are formed along the length of the connecting column. As indicated in FIG. 2, each of the weights 22 is also apertured to closely receive locking pin 58. Apertures 56 in column 24 are arranged to index with the apertures 60 in weights 22 when the connecting column is in its lowermost position. With this construction, pin 58 may be inserted into a selected aperture in column 24 and will extend through the weight aligned therewith. In this way, one or more weights may readily be interconnected with connecting column 24 so that as carriage 14 is raised through exertion of an upward force on handle bar 40, the weights in the weight stack above pin 58 will also move upwardly relative to central column 16. Pin 58 is also provided with a protuberance 59 located intermediate its ends to prevent accidental withdrawal of the pin.
An important and novel feature of the present invention comprises third guide means provided in guide column 16 for guiding the vertical travel of connector column 24. In the present form of the invention, the third guide means comprises a track 60 affixed to the rear surface of the guide column (FIGS. 3 and 4). Track 60 has a pair of vertically extending spaced apart channels 62 adapted to slidably receive inturned end portions 64 formed on the side walls of connector column 24. Although not shown in the drawings, other equivalent types of guide means such as cooperating rollers, slides and the like could, of course, also be used to operably interconnect column 24 and central guide column 16.
Turning now to FIGS. 5 and 6 there is illustrated an alternate embodiment of the exercising apparatus of the present invention. This embodiment is similar in most respects to the embodiment previously described herein save for the construction of the body engaging means and its method of attachment to the reciprocative carriage. In the drawings, like numbers are used to identify like parts. As was the case in the previously described embodiment, carriage 70 is generally "U" shaped in cross-section and is stradled by spaced apart arms 72 affixed to the handle bar, or lifting arm, 74 of the apparatus. As indicated in FIG. 5, the entire body engaging means including transversely spaced apart arms 72 lies in a single plane rather than being angularly inclined as was the case in the previously described embodiment. Additionally, in this form of the invention, the body engaging means is both vertically adjustable and pivotally movable relative to the carriage. Accordingly, the vertical starting height of the body engaging means can be adjusted relative to the carriage by vertical movement of arm 74, and also by pivoting the arm with respect to the carriage into different angular orientations. As best seen in FIG. 5, the carriage is provided with a plurality of spaced apart pairs of slots 75 formed in the rear edges of "U" shaped member 70. These slots are adapted to closely receive a transverse pin 76 which is fixedly positioned within apertures 77 formed proximate the inboard ends of arms 72 of the body engaging means (FIG. 6).
To position the body engaging means at a selected vertical height, pin 76 is first introduced into one of the pairs of slots 75 in member 70. To enable the lifting bar to be adjusted to a selected angle relative to the carriage, arms 72 have apertures 78 formed intermediate their ends which are adapted to closely receive a second locking pin 80 which may be inserted into the aperture and extend through one of several apertures 82 formed in the side walls of "U" shaped member 72. As illustrated in FIG. 5, apertures 82 are located along an arc of a circle so that as the body engaging means pivots about pin 76 the apertures in side arms 72 will align with a set of apertures 82 formed in the side wall of member 70.
OPERATION
In operating the apparatus of the invention, the trainee first adjusts the body engaging means relative to the carriage so that the handle bar grips are positioned at the correct vertical starting height for the particular exercise to be performed. Next, the trainee inserts selector pin 58 into the proper aperture in a given weight 50 to interconnect the desired number of weights with the connective column 24. He thereupon, by exerting upward pressure on the handles 40c raises the carriage 14, the connecting column 24 and the weights located above pin 58. This lifting force tends to apply an eccentric force to the carriage. However, due to the design of the bearing or roller means of the carriage and the cooperating guide means of the central guide column this tendency is effectively overcome so that the carriage travels in substantially a vertically straight line.
It is important to observe that as the carriage moves upwardly and downwardly, the central guide column not only constrains the path of travel of the carriage, but also of the connecting column 24 and the weights 22. The single central guide column construction of the apparatus is highly novel and provides a mode of operation which was heretofore unknown in exercise equipment. The unique configuration of the device minimizes the number of component parts required, markedly reduces the weight of the unit and ensures safe, positive, reliable and trouble free operation.
The invention and its attendant advantages will be understood from the foregoing description and it will be apparent that various changes may be made in the form, construction and arrangement of the parts of the invention without departing from the spirit and scope thereof or sacrificing its material advantages, the arrangement hereinbefore described being merely by way of example. We do not wish to be restricted to the specific forms shown or uses mentioned except as defined in the accompanying claims, wherein various portions have been separated for clarity of reading and not for emphasis. | A progressive resistance exercising machine having a single, substantially vertical guide column adapted to guide a vertically reciprocative carriage provided with a laterally outwardly extending lifting arm engageable by the trainee. The design of the highly compact machine is unique in that the guide column, as well as a weight selector bar which is connected to the carriage, extends through centrally disposed apertures formed in a plurality of weights positioned substantially directly below the carriage. When the selector bar is selectively interconnected with one or more weights in the weight stack, a lifting force exerted on the lifting arm will cause the carriage and the selector bar to move upwardly against the urging of the weights. As the carriage moves upwardly, the central guide column accomplishes the dual function of uniquely guiding the travel of the carriage as well as constraining the path of travel of the weights thereby eliminating the need for a separate guide for guiding the weights and the carriage. | 0 |
BACKGROUND TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. 119(e) on U.S. Provisional application No. 60/590,056 Entitled “ONE TOUCH, START OVER”, filed on Jul. 2 2004, by James R, Albrecht, et al.
FIELD OF THE INVENTION
[0002] This invention relates generally to interactive television systems providing DVD-like functionality, and more specifically, to a system which enables the instantaneous replay from the start of a partially elapsed program emanating from a conventional programming source using an convenient minimally interactive procedure.
BACKGROUND OF THE INVENTION
[0003] Historically, television programming sources provided multi-media entertainment to the consumer public over an aerial broadcast medium such that individual program offerings were supplied only at predetermined times as determined by the programming source. With this constraint, a consumer was essentially forced to modify his or her personal schedule in order to view the desired program at the prespecified time. The advent of video cassette recorders (VCRs), and other similar video recording devices such as digital versatile disks (DVDs), and TiVO™ brand digital video recording (DVR) equipment have alleviated this problem somewhat by allowing the user to record programs from a broadcast channel for personal viewing at a later time. Nevertheless, this flexibility requires that the user maintain a proactive knowledge base of future programming in order to avoid missing an interesting program altogether. The multi-media entertainment generally consists of video portion and an associated audio portion (hereinafter to be collectively termed video), which is typically delineated into multiple video programs, each spanning a predetermined amount of time.
[0004] Traditional television broadcast offerings consisted of relatively few choices in concurrent video programs from which a user simply chose between a very short list of program alternatives for view at any particular time. Nevertheless, television programming sources have since burgeoned into a rather large industry, wherein today's cable access television (CATV), and direct broadcast satellite (DBS) systems provide over a hundred channels, which are available for viewing at any given time. Given this rather large selection of viewing options, a phenomenon, commonly known as “channel surfing”, has developed whereby the user alternatively views each of the available channels at a somewhat rapid pace in order to find an interesting program. This makeshift mode of program selection does abate the necessity of maintaining an active knowledge of future programming, yet the initial portions of the video programs are almost always invariably missed due to the fact that the user is only able to obtain knowledge of the ongoing program after it has been playing for some predetermined amount of time.
[0005] Advances in video technology have provided for various types of video on demand (VoD) services, which have generally increased the level of interactivity that a user may have with their television viewing experience. Whereas viewing options historically available to the user only consisted of switching among the different channel offerings, VoD has provided such services as Pay-PerView™, wherein a user may order and view video programs from the CATV provider. Another service that has been proposed for use within a VoD environment is VCR-like functionality, wherein the user is allowed to interactively fast-forward, reverse, pause, or stop an ongoing video program. U.S. Pat. No. 6,609,253 to Swix, et al. describes one such device wherein a method is disclosed for managing potential bandwidth problems that are created while providing VCR-like functionality within a typical VoD system. U.S. Pat. No, 6,608,966 to Anderson, et al. describes a method of canceling selected frames from a conventional MPEG-2 video stream in order to enable fast-forward, and reverse functionality. The '966 and '253 devices, however, are defined for use only with stored video assets; rewinding to an earlier portion of an ongoing video program is not enabled using the teachings described therein.
[0006] U.S. Pat. No. 5,477,263 to O'Callaghan does describe a device which provides for rewind functionality to an ongoing program by the creation of duplicate copies of an ongoing program that are stored in a time-staggered fashion such that a user may interactively reverse, pause, or fast-forward through the video program via alternative access to either of these time-staggered video assets. However, no means are disclosed for quickly reverting back to the beginning of the ongoing program. Furthermore, it is contemplated that such a system that enables rewind to the start of a relatively long program would unduly tax the storage requirements of a typical VoD system as well unduly burden multi-media transport mediums such as currently implemented coaxial cable or hybrid fiber cable (HFC) distribution lines having only a finite amount of available bandwidth.
[0007] Typical users of consumer products will not make use of an available function of that product lithe use of that functionality requires a complicated sequence of steps or actions. That is, consumer acceptance is closely associated with simplicity of use. Rewind functionality provided by the '263 device is available for ongoing programming, however no means are disclosed for easily, and quickly finding the beginning of the ongoing program using a simple “start over” procedure, The act of rewinding a program while “channel surfing” is a burdensome task wherein the user is required to rewind the program in an iterative fashion until the starting location is found. It is projected that a typical “channel surfer”, who is characteristically known as a whimsical viewer, would forgo the use of such a device rather than go through the involved procedure of finding the actual beginning of any given program. Throughout the rest of this document, the term “start over” will be used to denote the action of returning the program to its starting location and subsequently beginning play therefrom.
[0008] Thus there has remained a long-felt, unsatisfied need for a system which implements “start over” functionality to an ongoing program of a conventional video distribution system, whereby play of an ongoing video program may be initiated from the start thereof utilizing a process that involves a minimally complicated sequence of commands.
SUMMARY OF THE INVENTION AND OBJECTIVES
[0009] The present invention provides a solution to these needs, as well as other needs, via a convenient video program start over system and method for a video entertainment distribution network whereby a user may interactively revert back to the beginning of an ongoing video program that is currently being broadcast over the video distribution network. With this system, a user who has inadvertently missed a portion of a currently broadcasted video program may interactively instruct the network to replay the entire program from the beginning thereof using a simple, minimally interactive procedure.
[0010] The present system is particularly suited for entertainment video distribution networks having a video data mass storage device that is adapted for the interactive storage and retrieval of selected streams of video data from a programming source. Such systems may include community access TV (CATV, also known as cable television), direct broadcast satellite (DBS) distribution networks having interactive television (ITV) capabilities, or may even be comprised of a system having an interactively controlled mass storage system located at the customer premises such as TiVO™ brand digital video recording (DVR) equipment. An interactive television (ITV) enabled network defined as pertaining to this disclosure, is the ability of a server device such as a head end to receive and process upstream requests from a distally located client device such as a conventional set top box (STB) and thus manipulate video data which is sent downstream to the STB corresponding to those requests. ITV functionality is typically provided in a video distribution network via a conventional type of system which is commonly referred to as a navigator. The navigator, among other services, provides a means of handling human interaction with the network in a preferably ergonomic manner, and processes requests from the user, then forwards these requests to the upstream server or head end. The navigator is preferably a microprocessor driven algorithm which is executed by a plurality of stored program instructions located either in the head end or STB.
[0011] The present invention provides a user interface which is simple and convenient, thereby enhancing the probability of acceptance by a user. The system preferably utilizes a process that involves a minimally complicated sequence of commands that are easily understood and remembered by virtually any user. The convenient, minimally interactive procedure may be defined as any user interactive set of user commands that involves a minimally complicated sequence of user operations to initiate the start over system. As it is well known that systems which require a multiple sequence of actions are not easily remembered, the start over system preferably provides an intuitive operation requiring preferably only one-step from a user terminal such as a television style remote in order to initiate the start over operation.
[0012] It is therefore an object of the present invention is to provide an convenient use video program start over system and method for a video entertainment distribution network that enables an associated video program that is currently playing on said network to be played from the beginning of said video program.
[0013] Another object of the present invention is to provide an convenient video program start over system and method for a video entertainment distribution network which is adapted for use in any type of network having interactive television (ITV) capabilities.
[0014] Another object of the present invention is to provide an convenient video program start over system and method for a video entertainment distribution network having a user interface which requires a minimal number of user steps in order to initiate the start over operation.
[0015] Another object of the present invention is to provide an convenient video program start over system and method for a video entertainment distribution network, wherein optional means are provided to allow a programming source to determine Which of its particular video programs are to be start over enabled.
[0016] These and other objects of the present invention will eco readily apparent to those familiar with current video distribution principles and will become apparent in the following portions of the specification, wherein the detailed description is for the purpose of fully disclosing preferred embodiments of the invention without placing limitations thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] For a further understanding of the nature and objects of the present invention, reference should be made to the following detailed description, taken in conjunction with the accompanying drawings, in which like elements are given the same or analogous reference numbers, and wherein:
[0018] FIG. 1 is a block diagram of some of the principle components of a typical video distribution system having interactive television capabilities.
[0019] FIG. 2 is a front elevational view of a conventional television that is currently showing a partially elapsed video program, wherein a graphical, start over icon is overlaid thereon.
[0020] FIG. 3 is a front elevational view of a conventional television that is currently showing a conventional electronic programming guide (EPG), wherein several partially elapsed video programs each have a graphical, start over icon overlaid thereon, thereby exhibiting that the start over system is available for use with that particular video program.
[0021] FIG. 4 is a front elevational view of a conventional television having a broadcast program shown thereon, wherein the star over icon exists as a portion of a detailed description overlay bar.
[0022] FIG. 5 is a front elevational view of a conventional television having a broadcast program currently being shown thereon, wherein a partial electronic programming guide has several start over icons embedded on several corresponding cells thereof.
[0023] FIG. 6 is a simplified example of the start over lookup table of the present invention.
[0024] FIG. 7A is a simplified example of the programming source start over enablement table of the present invention.
[0025] FIG. 7B is a simplified example of the program ID start over enablement table of the present invention.
[0026] FIG. 8 is a flow diagram of a method for providing the start over system on a typical video distribution system having interactive television capabilities.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Referring now to the drawings, FIG. 1 shows a generic diagrammatic view of a video entertainment distribution network system having interactive television (ITV) capabilities 10 . The system generally comprises a head end II which processes broadcast video programs and other programming services emanating from a plurality of programming sources 12 and forwards these video programs onward to a client device such as a typical set top box (STB). Each STB 13 is operable to control which programs are shown on their associated display such as a conventional television 14 , and outputs commonly used NTSC, PAL, or SECAM formatted signals to the television set. The distribution network 15 is typically comprised of a lattice of coaxial cable lines or hybrid-fiber-cable (HFC) for connectivity of the head end to the plurality of STBs in the network, and may also include a plurality of broadcast centers or nodes that each service a subset of STBs within a small demographic area. Although a conventional television was cited as a specific type of display, it is to be appreciated that the present system may be implemented with any display defining a consumer electronic display device such as a PDA, a cellular telephone, a television, a personal computer, a laptop computer, and the like.
[0028] It is noted that the network, as shown in FIG. 1 , shows a conventional video entertainment distribution network having a head end that distributes video information to a plurality of STBs. However, as is apparent to one skilled in the art, the head end and STBs interconnected to the distribution network may, in fact, be an internet server and a client such as a conventional personal computer respectively. That is, the start over system of the present invention may also be implemented on an interne network, or any other network having a head end (server) and STB (client) configuration.
[0029] User input is typically accomplished in an ITV enabled network system via a remote control device 17 , which transmits individual keystroke commands via infrared (IR), Radio Frequency (RF), or other aerially transmittable signals to the STB. However, it is to be appreciated that user input may also be accomplished via a personal computer or other similar type device having user input means, which is interconnected to the network. Upstream signaling of user requests are typically provided in a video distribution network via a conventional type of system commonly referred to as a navigator. The navigator, among other services, provides a means of handling human interaction with the network in a preferably ergonomic manner, and processes requests from the user to the upstream server or head end. The navigator is preferably a micro-processor driven algorithm which is executed by a plurality of stored program instructions located either in the head end or STB.
[0030] The head end 11 of a typical ITV enabled system also includes a video server 20 , which is capable of storing a plurality of video programs for view at a user specified time. The server 20 is operable to process multiple incoming requests from a plurality of users at the same time, and delegates the necessary bandwidth for a requested stored video program for transmission to the user, wherein such a service that is provided to the user is commonly referred to as Video-On-Demand (VoD). in order to facilitate storage requirements for such a system, a video storage device 21 is included therein, which may consist of one or an array of magnetic disks, optical disks, or servers based on RAM technology. Additionally, an video server manager 22 is also included that controls access to content stored in the video server 20 and has an associated program and database storage 23 , which houses user information, stored video programs, or other fields of information that are used by the ITV system.
[0031] Historically, the incoming video stream contained a plurality of concurrent programming sources which were frequency division multiplexed onto a coaxial or fiber optic cable within a video distribution network, each requiring approximately 6 to 8 MHz of bandwidth. However, newer technologies have enabled digitization of the video stream, wherein individual video programs transmitted through the distribution network may be encapsulated within formats such as MPEG, MPEG-2, IP over DOCSIS, and the like. The newer digitized video formats have been very conducive to enabling ITV functionality in that upstream signaling (e.g. information which is sent from the STB to the head end) is accomplished using in-band signaling. Conversely, the older frequency division multiplexed systems did not provide for 2-way signaling within the distribution infrastructure, thus full ITV functionality was not possible with these systems. Additionally, television entertainment distribution systems utilizing satellite transmissions, which are commonly referred to as direct broadcast satellite (DBS), may incorporate ITV capabilities via use of out-of-band signaling methods made possible through the public switched telephone network (PSTN), or other similar upstream signaling mechanism. Accordingly, it is to be appreciated that the principles and teachings of the present invention are applicable to any video distribution system having ITV capabilities including those which have been described hereinabove.
[0032] Each programming source is allocated within the network and made available to the end user as a selective entity that is designated as a channel. Thus, multiple programming sources that are made concurrently available to the user over the network, are selectively accessible by the user using the well known process of changing channels. When carried on in a relatively rapid manner, the aforedescribed phenomenon of “channel surfing” occurs. Typically, this occurs when the user is simply changing channels in hopes of finding something interesting to watch. Because content that is currently viewed during the channel surfing operation has already been in progress for some predetermined amount of time, a portion of that particular program has been missed by a user.
[0033] FIG. 2 shows a television 30 exhibiting a screen-shot 31 of a sample channel which has been recently accessed by a user, wherein the program has partially elapsed. A partially elapsed program is defined as a video program having a predetermined run time that has begun play over a specified channel without having fully elapsed through the entire run time thereof. A start over icon 32 incorporating an embodiment of the present invention is shown on the display screen of the television set, which prompts the user to press a particular key on the remote 17 if replay of the presently viewed video program from start is desired. The start over icon 32 is preferably a small, graphical image that overlaid or embedded in the existing moving video image, somewhere on the display so as not to severely impair viewing of the video image, yet sufficiently prominent to alert the user that the start over system is available for use. The start over icon is preferably a momentary button that is displayed on the screen for a predetermined period of time, defining an icon persistency time, following a switch to that particular channel. The icon persistency time is preferably set by a CATV provider to a range of approximately 5 to 20 seconds, wherein it is believed that this range of time offers optimal amount of time for a typical user to react to the start over system offering without encumbering the user's viewing experience. Following this time, the icon will be removed from the screen and the start over system will be disabled for that particular channel. Re-enablement of the start over system for that particular channel is then only accomplished by switching to a different channel and then switching back to the present channel. Thus, there are two principle conditions which must exist for the start over icon 32 to be shown on the television display. The start over icon will only be shown on the display if the particular program is a partially elapsed program.
[0034] The key on the remote 17 , which is used for actuation for the start over feature, may exist as a dedicated key whose only functionality is to actuate the start over feature. In this case, a relatively small icon representative indicia may be imprinted on the upper surface of the key in order to facilitate ease of recognition by the user. Alternatively, the key on the remote may exist as a defined key, wherein any key commonly implemented on a conventional remote may be designated for use with the start over feature. Examples of such a defined key may be any numeric key, or either of the “up”, “down”, “left”, or “right” keys disposed on the remote 17 . Nevertheless, it is to be appreciated by those skilled in the art any type of user input device may be implemented for initiating the start over feature, wherein several examples include a button mounted on the front panel of the STB, or even a key on the keyboard of a personal computer that is interconnected to the STB.
[0035] The overlaid graphical image is created by an on-screen display (OSD) generator algorithm, which exists as a portion of the controller of the present invention. The OSD generator is operable to display the graphical image on top of the resulting raster image of the video program that is displayed on the television. Alternatively, if the OSD portion of the controller is executed from the head end, the graphical image may be embedded in the raster image of the video program. An embedded graphical image is defined as an image that is superimposed on the raster image of the video program such that only one television signal is sent to the display device. Conversely, a overlaid graphical image is defined as an image which is forwarded to the display device independently of the raster image of the video program.
[0036] Optionally, another condition for display of the start over icon 32 is disclosed, wherein individual channels, or individual video programs may be start over enabled or disabled by the CATV provider or by the programming source, thereby defining a start over enablement feature. That is, an entire channel may be configured to allow the start over system on all of its programs, or conversely disallowed from the use thereof. Further, individual programs may be enabled/disabled from use of the start over system. For example, some programming sources may not wish to have their programs played at any time other than at the prescribed schedule. Given this case, the programming source would have means to disable the start over system using an in-band, downstream signaling technique (to be described later). Other examples include programming sources having a programming schedule made up of predominantly instantaneous news reporting, yet interspersed with special interest news clips having a predetermined run time. Whereas the start over feature would not make sense for use with the instantaneous news report content, special interest news clips having information that is conveyed to the user that is developed throughout the run-time thereof, directly lend themselves for use with the start over system.
[0037] One aspect of the optional start over enablement feature is that the CATV provider has an efficient means of managing the storage requirements for the start over system within a video distribution network having a video storage device of limited storage capacity. Because modern video distribution systems typically offer over several hundred channels, providing the start over system for all programming sources or channels would unduly tax the storage capacities of most commonly used disk arrays. The start over enablement feature supplies a solution to this need by allowing the CATV provider to choose all of the available channels, or only a subset of available channels to be provided with the start over system.
[0038] Optionally, the start over icon may also be provided in conjunction with a. conventional full screen electronic program guide (EPG) as shown in FIG. 3 . An exemplary EPG screen 35 is shown having a grid-like display of five rows depicting the programming schedules for five associated programming sources. Each row has a multiple of cells of varying length, wherein the first cell of the left-most column contains information regarding the name of the programming source. Successive cells indicate individual programs that are aligned vertically according to their respective time slots. As shown, graphical start over icons 36 are shown embedded or overlaid upon several of the program cells in which the start over feature is enabled. As is well known in the art, any number of operations may be supplied to the user order to enable operation of the start over feature from within an EPG screen; one exemplary method contemplates a dedicated button on the remote, which may be pressed if the user wishes to view the desired partially elapsed program from the beginning thereof Alternatively, the start over icon 38 may be presented to the user as an embedded or overlaid icon upon a conventional information bar 39 as shown in FIG. 4 . Yet another alternative contemplates a start over icon 48 , which is embedded or overlaid upon cells within a partial grid electronic program guide 47 as shown in FIG. 5 . As shown, an ongoing broadcast video program 37 is shown with a detailed description bar overlay 39 overlaying the bottom portion thereof Thus, the previous two examples show several means of providing interactive notification to the user that the start over feature is available for a particular program.
[0039] Currently, most digital cable distribution systems utilize MPEG-2 transport techniques to deliver digital video over hybrid fiber coaxial architectures. It is well known to those familiar with the art that there are several techniques that are available for delivering program and channel information to the receiving device in order for the receiving device to become aware of what channels currently exist on the network and what programs are associated with those channels. On the in-band path there are two primary protocols; first the Program Specific Information (PSI) data is used to define what services are contained within each multiplexed HFC cable. The PSI data contains several information tables that the receiving device will use to determine the appropriate PH) values in which to extract data for each program within the transport stream. These information tables are; Program Association Table (PAT) and Program Map Table (PMT) which are used to correlate specific program numbers within the transport stream to specific PIDs values, such as the video and audio PIDs for the desired video program. The second in-band protocol which is optionally used by cable systems is the Program and System Information Protocol (PSIP). PSIP information defines the programming within an aerial broadcast system and will be modified by CATV provider to reflect the new position of the program as it relates to the frequency distribution within the CATV provider's system as opposed to its original over-the-air location.
[0040] Several pieces of information are also distributed to the receiving device via the downstream out-of-band (OOB) path which is used by the receiving device to define the available channels on the network. The first OOB information is Service Information (SI) or Network Information Table (NIT) which provides the virtual channel map information to the receiving device. This table relates program channel numbers to specific distribution frequencies on the cable network. Secondly proprietary data is also delivered OOB to support Electronic Program Guides (EPG) that exists on receiving devices. This information enables the EPG to display an on screen guide that presents to the user all the programs currently available on the network as well as their associated virtual channel numbers. In some cases this proprietary program guide data is delivered via an in-band channel whereby the STB would tune to a specified in-band channel and extract the program data from the MPEG transport stream.
[0041] The channel and program data mentioned above is coordinated by the delivery network, as such, it is well known to the delivery network. In addition, as video programs are stored within the network to support the “minimally interactive” start over solution, it should be categorized in such a way as to be consistent with at least one component of the information that is delivered to the receiving device, such as Program Name. By utilizing at least one common element the receiving device can deliver upstream to the head end this common indicator so the head end understands exactly which program the receiving device wishes to start from the beginning.
[0042] As hereinbefore described, the head end is operable to receive programs from the various programming sources and transmit the plurality of program offerings to the plurality of users through the video distribution network. In accordance with the present invention, video programs are stored in the program storage as well as forwarded to clients in the network. This is accomplished by parsing the channel and program data of each incoming video stream of a programming source in order to determine the start of a new program. When a new program name has been detected, storage is allocated in the video storage device 21 via the video server 20 , and an entry is added to a lookup table 40 contained in the video server manager 22 . FIG. 6 shows a partial list of program names that are contained within the exemplary lookup table 40 . Coupled with each program name entry 41 are several other fields, such as the programming source channel 42 , and a currently accessed flag 43 .
[0043] Each entry will remain persistent in the lookup table as long the program is partially elapsed or the currently accessed flag 43 is true (e.g. logic “1”). The currently accessed flag is set to true whenever a client (user) in the network is currently accessing the video program that is stored on the storage device, thereby defining a stored video program; if not, the currently accessed flag is set to false (e.g. logic “0”). The system constantly monitors the PID fields of the incoming video streams of each programming channel to determine if the particular program is partially elapsed. Whenever both currently accessed flag, and the program name field of the particular programming source changes, the program name entry is removed from the lookup table and the stored video program removed from the video storage device.
[0044] Optionally, the start over system may also include provisions to allow the programming source and/or CATV provider to determine what video programs, if any, are to be start over enabled. That is, the system may be configured to allow only a subset of available programming sources or individual video programs to be enabled for use with the start over system. This utility is accomplished by providing a pair of optional start over enablement tables that preferably reside in the program and database storage 23 and are accessible by the video server manager 22 . Nevertheless, it is to be appreciated that the pair of tables may reside in any portion of the network such as in storage means within individual STBs 13 within the network 10 and controlled by the processing system therein.
[0045] A pictorial representation of the programming source start over enablement table and program name start over enablement table are shown in FIGS. 7 a and 7 b respectively. The entries within a programming source start over enablement table 45 may be updated by the CATV provider, and serve to limit the use of the start over system to those programming sources or channels that are included therein. The program name start over enablement table 46 contains a list of individual video programs for which the start over system is enabled; accordingly, only individual video programs contained therein are enabled for use by the start over system. The entries in the program name start over enablement table 46 are perennially persistent and is only updated/modified by the CATV provider or by the programming source. While control of either table by the CATV provider is accomplished via modification of the aforementioned tables maintained locally at the head end, control and manipulation of either table by the programming source must be accomplished via information sent within the data stream of the incoming video stream. Preferably, this information is sent from the programming source to the server using a field of the MPEG-2 packet. The user portion of the incoming video stream of the MPEG-2 packet contains a user bit, which when parsed, is operable by the start over system to add the associated program ID to the lookup table 40 . That is, if the user bit is set to “true”, start over functionality is allowed for that particular program source or channel and thus . added to the table. When the start over system obtains receipt of a new program name, either or preferably both of these tables ( 45 , and 46 ) are consulted to verify that both the programming source and program name allow start over functionality thereof If not, the video program is not stored in the video server 20 while passing through the head end 11 .
[0046] FIG. 8 shows a flow diagram of the steps involved in a method for realizing the start over system of the present invention. The method may be embodied as a program of instructions, defining a controller, that are executed by a micro-processor located in the STB (client) or head end (server). Alternatively, the steps of the program may be executed on the STB as well as the head end wherein the processing responsibilities are shared therebetween. The system initially causes the head end to monitor incoming video streams (step 100 ) in a polling fashion until a new program name has been recovered therefrom (step 101 ), In practice, the head end may receive numerous new program names within a relatively short time frame, and subsequently pass multiple recordation requests to the video server 20 . It is also important to note that the video server is simultaneously capable of recording a plurality of video programs as well as playing a plurality of video programs in a concurrent manner. When a new program name has been detected by the system, it may optionally be compared against a programming source start over enablement table 45 or a program name start over table 46 located within the video server manager 22 (step 102 ). Preferably, both types of tables are existent and the system compares both the program name and associated programming source or channel to insure that the particular video program is start over enabled. If either the program name or associated channel does not have an entry in its respective table ( 45 , and 46 ), processing of that particular program name has ceased and control reverts back to step 100 .
[0047] The system then instructs the video server 20 to begin recordation of the entire video program and updates the lookup table 40 with the new program name information (step 103 ). After some period of time, the user may become cognizant of the partially elapsed video program via either changing to that particular channel or by browsing through the EPG. If this is the case and the user wishes to view the the entire video program from start, the dedicated or embedded button on the remote control device 17 is actuated (step 104 ). Next, the STB 13 reverts to the ITV mode, wherein a dedicated connection is established with the head end in order to begin receipt of the stored video program from the video server 20 (step 105 ) using commonly known ITV techniques. Because the current status of the STB is in an ITV mode, features that are commonly associated with an ITV system may be utilized such as pause, fast-forward, fast-rewind, stop, and the like. The user then begins viewing the stored video program in the normal manner, albeit in a time delayed fashion from the original time slot alloted by the programming source (step 106 ). The user may view the entire program through to its completion or may optionally stop play thereof prematurely. If the user chooses to view the entire program, the system is blocked from inadvertent deletion of the stored video program from the video storage by the setting of the currently accessed flag 43 . However, when the user has completed view of the selected program, the system checks for other users that could also he watching the same program, and thus only resets the currently accessed flag to “false” if no remaining users are watching that particular time delayed video program (step 107 ).
[0048] If all remaining users have completed view of the stored video program, or no user within the network has requested view of the program from start, the system will still monitor the incoming video stream in a polling fashion until the broadcast video program has totally elapsed (step 108 ). This allows users a maximum window of opportunity for view of the program in its entirety, regardless of what portion of the program has been missed. Once the program has totally elapsed and no further users are accessing the stored version thereof, the system instructs the video server to delete the stored video program from video storage and removes the program name and associated information from the lookup table (step 109 ).
[0049] Alternatively the start over system may he enabled for use with video programs transmitted over other network mediums such as the internet. The present invention provides enhanced utility over presently known start over systems in that only one button is required to enact reversion to play of the program from the start thereof. Although well known video players exist for use with internet coupled devices such a personal computer, these video players require a multiple step procedure for enacting the start over mechanism. The present invention on the other hand, provides advantage by requiring only a I step procedure for enacting the start over feature on a partially elapsed video program. This one step procedure encounters the dedication of a key of the keyboard of the client device. Thus, the user may, if so desired, revert to the start of a partially elapsed video program by simply pressing one key on the client's keyboard.
[0050] An alternative embodiment of the present invention contemplates a VOD start over system which is operable on video programs that are accessed by the user in VOD mode. The VOD start over system is similar to the previous embodiment in that a storage device, is existent for the storage of said stored video programs, interactive control by the user is provided by an embedded or overlaid graphical icon, and an input means for input by the user, and a controller for causing reversion to the start of the video program upon request from the input means. The only difference being that a VOD video program is enabled for start over viewing in lieu of the broadcast video program of the previous embodiment. Thus, with the present arrangement, no requirements exist for the storage of incoming broadcast video programs onto the storage device; virtually all VOD video programs are already existent therein. Another key difference from the previous embodiment is that the stored video program is never deleted from the storage device. A user may thus begin view of a VOD program, and if so desired during the play thereof, revert back to play from the beginning of the program using only a defined or dedicated button on the remote control device.
[0051] Although the present invention has been disclosed with a certain degree of particularity, it should be recognized that various elements thereof may be altered by persons skilled in the art without departing from the spirit and scope of the invention. For example, it is well known that individual video program information may be derived from an accompanying EPG database. Thus, the system as in step 100 of FIG. 8 may utilize the start time of a video program as stored in the EPG to initiate recordation thereof to video storage. Consequently, the completion time of the video program may be obtained therefrom as well. Thus, 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 system and method are described herein for providing an convenient video program start over system and method for a video entertainment distribution network whereby a user may interactively revert back to the beginning of an ongoing video program that is currently broadcasted over the video distribution network. The novel system and method may be implemented on any video network having interactive television (ITV) capabilities, wherein user requests from a client are serviceable at an upstream head end, and video storage means exist for the purpose of storage of time based broadcast video programs. The system preferably utilizes a process that involves a minimally complicated sequence of commands that are easily understood and remembered by virtually any user, thereby enhancing the probability of consumer acceptance. The start over system and method may be embodied as a program of instructions, defining a controller, that are executed by a micro-processor located in the STB (client) or head end (server). Optional means are also provided for allowing only a subset of all available broadcast video programs that emanate from a plurality of programming sources to be used with the start over system. | 7 |
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government for governmental purposes without the payment of any royalty thereon.
BACKGROUND OF THE INVENTION
This invention relates to a reusable container assembly for housing and shipping an item or a multiplicity of items.
Shipping containers as such are old, many and varied, and very well known. However, it is fair and accurate to say that there is no container, or container assembly, in the prior art which provides versitility for packaging a wide range of items of significantly different sizes, shapes, weights, and the like.
I have invented such a container assembly; and, thereby, I have materially advanced the state-of-the-art.
SUMMARY OF THE INVENTION
This invention relates to a container assembly for housing and shipping an item, or a plurality of items, of significantly different sizes, shapes, weights, and the like.
The principal object of this invention, therefore, is to teach the structure of such a container assembly.
Another object of this invention is to provide a container assembly which is reusable.
Still another object of this invention is to permit the use of an external fiberboard container and, yet, to provide the desired degree of shipping protection.
Yet another object of this invention is to allow the use of an external plywood container and skids therein, with said skids being integrated with the basic container assembly, and usable in the integrated condition after removal of the enclosing plywood container.
These objects, and other equally important and related objects, of may invention will become readily apparent after a consideration of the description of my invention and reference to the Figures of the drawing.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view in perspective, of the constituent members of a preferred embodiment of my invention, less a container member thereof;
FIG. 2 is a top plan view, in simplified form, of the planar base member of the preferred embodiment, with (and internal of) a fiberboard shipping container member of the inventive assembly, with the container shown in phantom, in perspective, and partially fragmented;
FIG. 3 is a top plan view of the planar floor memeber of the preferred embodiment; and
FIG. 4 is a side elevation view, in perspective, of the preferred embodiment of my invention, with the container thereof in phantom, shown in use ready for shipping two items internal of the container, with the two items varying in size and weight, but nevertheless safely and effectively secured and supported, including shifting relative to each other.
DESCRIPTION OF THE PREFERRED EMBODIMENT
My inventive reusable container assembly comprises, in its most basic and fundamental aspects: (a) means for securing and supporting the item that is to be housed and shipped; and (b) means for housing the securing and supporting means, and the item.
With reference to FIG. 1, therein is shown a preferred embodiment 10 of my invention, less a container member thereof. The means 20 for securing and supporting the item(s), now shown, includes: a planar base component 21 of preselected configuration, having a plurality of slots (such as representative ones 22A, 22B, 23A, 23B, 24A, 24B, 25A, 25B, 26A, 26B, 27A and 27B) therein and therethrough, and also having a plurality of holes (such as representative ones 28A, 28B, 28C, 28D, 28E and 28F) similarly therein and therethrough; and, a plurality of removable straps (such as representative ones 29A, 29C, 29E and 29G) having respective individual fasteners (such as 29B for 29A, 29D for 29C, 29F for 29E, and 29H for 29G), with each strap passing through two different base slots (e.g., strap 29A passing through base slots 23A and 27B). The securing and supporting means also includes a suitably configurated and dimensioned container, not shown in FIG. 1, that is completely closeable. However, with reference to FIG. 2, therein are shown: a completely closeable container 30, in phantom, and its partially fragmented oppositely disposed pairs of top closure panels; and, internal of the container 30, the planar base member 21, with its representative slots 22A-27F, and its representative bolt holes 28A-28F.
With reference to both FIGS. 1 and 2, it is to be noted that planar base member 21 is, preferably and not by way of any limitation in the form of a rectangular solid having an upper surface 21A, a lower surface 21B, a first end 21C, a second end 21D, a first edge 21E, a second edge 21F, and a geometric center 21G, with the plurality of slots therein preferably comprising individual sets of two adjacent parallel slots, i.e., a first set 22A and 22B, a second set 25A and 25B, a third set 27A and 27B, a fourth set 26A and 26B, a fifith set 23A and 23B, and a sixth set 24A and 24B.
The first set of slots 22A and 22B is disposed perpendicularly to the first end 21C of the base 21, with each of these two adjacent parallel slots extending from geometric center 21G of the base 21.
The second set of slots 25A and 25B is disposed perpendicularly to the second end 21D of the base 21, with each of these two adjacent parallel slots extending from near the second end 21D of the base 21 toward the geometric center 21G of the base 21.
The third set of slots 27A and 27B, and a fourth set of slots 26A and 26B, are disposed, respectively, in a coverging slanted position from near the first edge 21E of the base 21 toward the geometric center 21G of the base 21.
The fifth set of slots 23A and 23B, and the sixth set of slots 24A and 24B, are disposed, respectively, in a converging slanted position from near the second edge 21F of the base 21 toward the geometric center 21G of the base.
It is to be noted: that base 21, with the straps and individual fasteners (such as representative strap 29A with fasteners 29B) passing through two different base slots, could be used per se to secure and support a light item to be shipped; and, that in that situation the base with the strps, the fasteners, and the secured and supported item could be placed internal of the container 30 and can be, in fact, safely and effectively housed and shipped.
As a related matter, it is preferred that the base 21 be made of plywood, and that the straps (such as 29A, 29C, 29E and 29G) be made of nylon webbing.
If in fact, the light item is to be housed and shipped using the base 22, the straps (such as 29A), and the external, completely closeable container, such as 30, then the container 30 may be made either of fiberboard or of plywood.
If, on the other hand, a heavy item (or a plurality of items which collectively are heavy) is to be housed and shipped, then the container assembly shown in FIG. 1 and 4 preferably should be used. That sturdier and stronger container comprises, as can be easily seen, more consituent members. Additionally, the container, FIG. 4, is made of plywood. In other words, a fiberboard container, such as 30 may be, is not used.
With reference to FIGS. 1, 2 and 3, the sturdier container assembly further includes: a plurality, preferably six, of bracing blocks, such as 41, 42, 43, 44, 45 and 46, with each bracing block removably attached to base 21 at two different slots (preferably a set), such as bracing block 41 to first set of slots 22A and 22B; a planar floor component 50, of preselected configuration similar to, and of larger dimensions than, the base 21, and with the floor 50 having a forward portion 51, an aft portion 52, a top surface 53, a bottom surface 54, and a plurality of floor holes, such as 55A, 55B, 55C, 55D, 55E and 55F, with the floor holes in vertical alignment with the base holes, and thereby forming a plurality of matched sets of vertically aligned, spaced-apart holes, consisting of one base hole and one floor hole, i.e., 28A and 55A, 28B and 55B, 28C and 55C, 28D and 55D, 28E and 55E, and 28F and 55F; a first header member 61 attached to the top surface 53 of the floor member 50 at the forward portion 51 thereof; a second header member 62 attached to the top surface 53 of the floor member 50 at the aft portion 52 thereof; a plurality of bolts, such as 71, 72, 73, 74, 75 and 76, one bolt for each one of the plurality of matched sets of holes formed by the base and the floor, e.g., bolt 71 for matched set of holes 28A and 55A, with each bolt passing through a different one of the plurality of matched sets of holes; a first plurality of cushioning members, such as 81 and 82, disposed between and abutting with, the lower surface 21B of the base 21 and the top surface 53 of the floor 50; a second plurality of cushioning members, such as 83, 84 and 85, FIG. 4, one such member for each of the plurality of bolts, such as 83 for bolt 71, 84 for bolt 76, and 85 for bolt 75, with each cushioning member encircling its respective bolt and simultaneously also disposed betweem and abutting with, the lower surface 21B of the base 21 and the top surface 53 of the floor 50; a plurality of relief springs, such as 71A, 72A, 73A, 74A, 75A and 76A, with one relief spring for each bolt, such as relief spring 71A for bolt 71, with each relief spring disposed on and encircling its respective bolt, and with each relief spring having two ends, with one end abutting the upper surface 21A of the base and with the other end restrained, with each spring thereby held captive; a plurality of skids, such as 91, 92 and 93, with each skid, such as 91, having a top surface, such as 91A and a bottom surface 91B, and with each skid attached by its top surface, such as 93A, to the bottom surface 54 of the floor 50; and, a plurality of rubbing strips, such as 94, 95, 96 and 97, with each having a top surface, such as 94A for 94, and with at least two of the rubbing strips, such as 94 and 97, attached by their respective top surfaces, such as 94A and 97A, to the bottom surface, such as 91B, of a different one of each of the skids, such as 91, of the plurality of skids.
Returning to FIGS. 1 and 2, the bracing blocks (i.e., first block 41, second block 42, third block 43, fourth block 44, fifth block 45, and sixth block 46) are disposed on the upper surface 21A of base member 21 and are, as previously stated, removably attached to any two different slots in the base. However, as a matter of preference the bracing blocks are suitably configurated and dimensioned, and are disposed so that each block is slideable in and along two adjacent parallel slots, as follows: the first bracing block 41 in and along first set of slots 22A and 22B; the second bracing block 42 in and along fifth set of slots 23A and 23B; the third bracing block 43 in and along sixth set of slots 24A and 24B; the fourth bracing block 44 in and along second set of slots 25A and 25B; the fifth bracing block 45 in and along fourth set of slots 26A and 26B; and, the sixth bracing block 46 in and along the third set of slots 27A and 27B.
Now, with reference to FIG. 4, therein is shown the preferred embodiment 10 of my inventive reusable container assembly, as structured for housing and shipping a heavy item, or a plurality of items which together form a heavy load and are of different sizes and dimensions. More specifically, different items 200 and 300 are shown strapped down with the use of straps 29A, 29C, 29E and 29G and fasteners thereof 29B, 29D, 29F and 29H, and braced by bracing blocks 41, 42 and 46 (for item 200) and 43, 44, and 45 (for item 300), with the blocks disposed in and along the approriate slots on the upper surface 21A of base 21 and toward the base geometric center 21G, so that the bracing blocks abut their respective items. Of course the blocks are removably attached to the base, and are also releasably locked in their respective desired positions, by suitable means, such as bolts and nuts (i.e., 41A and 41B for block 41; 42A and 42B for block 42; 46A and 46B for block 46; 43A and 43B for block 43; 44A and 44B for block 44; and, 45A and 45B for block 45).
Shown in phantom is reusable container 100 which is completely closeable; houses the securing and supporting means 20 of the preferred embodiment 10; houses the items 200 and 300 to be shipped; and preferably, is made of plywood.
It is here to be noted that: the bracing blocks, such as 41, are preferably made of wood; the floor 50 is preferably made of plywood; the header members, such as 61, are preferably made of wood; the cushioning members, both of the first and of the second plurality, such as 81 and 85, are preferably made of polyethylene; the skids, such as 91, are preferably made of wood; and, the rubbing strips, such as 97, are preferably made of wood.
MANNER OF OPERATION AND OF USE OF THE PREFERRED EMBODIMENT
The manner of cooperative association between the constituent members of the preferreed embodiment, and the manner of use of the preferred embodiment, can be very easily ascertained and understood from the foregoing description, coupled with reference to FIGS. 1-4, inclusive.
For those not in the art, the following short description will serve the purpose.
As a preliminary matter, it is to be understood that whenever the term "the item" is used, said term may be substituted therefor by the plural thereof, i.e., "the terms".
If the item to be housed and shipped is light in weight, it may be safely and effectively housed and shipped by using base 21 with the appropriate straps, such as 29A and 29B, through the suitable base slots, such as 27B and 23A for strap 29A and 27A and 23B for strap 29C, and completely closeable container 30, FIG. 2, without the need of using any of the other members of the preferred embodiment 10 of my invention. In such a situation, the item is strapped down on base 21 (and, thereby, is safely secured and supported for shipment) by use of the appropriate straps and fasteners thereof; the strapped down item, the base and the tightened straps are placed within the container; and, the container is then completely closed. Thereby, the item is housed and can be safely and effectively shipped. It is here reiterated that, depending upon the circumstances, the container 30 can be made either of fiberboard or of plywood.
On the other hand, if the item to be housed and shipped is heavy, then many of the componenet members of the preferred embodiment may, or should be used. In such a situation, such as is shown in FIG. 4, the procedure is typically and essentially as follows. The item to be housed and shipped is strapped down on base 21; the bracing blocks 41-46, as applicable, are moved within and along the appropriate base slots, such as 22A-27B, until the bracing blocks abut the item, and the releasable locking means, such as 41A-46B are positioned in the locked condition (i.e., the nuts and bolts are tightened); the integrated securing and supporting means 20, and the strapped down item, are placed within container 100; and, the container 100 is them completely closed. The container assembly 10, with the item therein, is now ready for shipment.
With reference to FIG. 4, the items 200 and 300 are secured by use of the straps and fasteners, and the bracing blocks, all of which also assist in supporting the items. The items are principally supported by the base, the floor, the cushioning members therebetween, and the bolts with their relief springs, which collectively urge the base downwardly, and assist in keeping it down. The items are also incidentally supported by the skids and their rubbing skids, the principal function of which is to permit easier handling (such as by forklift or by pushing) of the integrated securing and supporting means 20 (with the strapped down and braced item on it), after the opening and removal of the external container 100 at the place os destination of the shipped container assembly containing the payload.
CONCLUSION
It is clearly evident from the foregoing description, coupled with the Figures of the drawings, that all of the objects of my invention have been attained.
Additionally, while there have been shown and described the fundamental features of my invention, as applied to a particular and preferred embodiment, it is to be understood that various substitutions, additions, omissions, and the like, can be made by those of ordinary skill in the art without departing from the spirit of my invention. For example, my preferred embodiment can be adapted for use in the long range storage of items of various sizes and weights, in other than their normal positon and attitude (e.g., inverted or obliquely), simply by securing, supporting and housing the items in a multiplicity of units of my preferred embodiment, so that the units can then be stacked and stored in modular fashion. | A reusable shipping container assembly for securing, supporting, housing and shipping items. In a preferred embodiment, the container assembly includes: (a) members for securing and supporting the item, including: a slotted base upon which the item is placed; a plurality of removable straps, with fasteners, passing through any two of the slots, for strapping the item to the base; a plurality of bracing blocks, movable on the base and releasably lockable in the slots, to abut and brace the item; and a floor, removably positioned under, and also cushioned under, the base; and, (b) a completely closeable container for housing the item to be shipped, and the members of the assembly which secure and support the item to be shipped. This container assembly, unlike the prior art not only is reusable, but also permits the simultaneous housing and shipping, within the same container, or a multiplicity of items that vary in size, shape, and weight. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application is related to U.S. patent application Ser. No. 09/205,577, entitled SYSTEM AND METHOD FOR ESTABLISHING PROCESSOR REDUNCANCY, filed Dec. 4, 1998, which is assigned to Cisco Technology, and is herein incorporated by reference.
FIELD OF THE INVENTION
The present invention is related to network protocols. In particular, the present invention relates to a protocol for discovering relative states for processors.
BACKGROUND OF THE INVENTION
A network is a communication system that allows users to access resources on other computers and exchange messages with other users. A network is typically a data communication system that links two or more computers and peripheral devices. It allows users to share resources on their own systems with other network users and to access information on centrally located systems or systems that are located at remote offices. It may provide connections to the Internet or the networks of other organizations. The network typically includes a cable that attaches to network interface cards (NIC) in each of the devices within the network. Users may interact with network-enabled software applications to make a network request (such as to get a file or print on a network printer). The application may also communicate with the network software and network software then may interact with the network hardware to transmit information to other devices attached to the network.
A local area network (LAN) is a network that is located in a relatively small area, such as a department or building. A LAN typically includes a shared medium to which workstations attach and communicate with one another by using broadcast methods. With broadcasting, any device on the LAN can transmit a message that all other devices on the LAN can listen to. The device to which the message is addressed actually receives the message. Data is typically packaged into frames for transmission on the LAN.
FIG. 1 is a block diagram illustrating a network connection between a user 10 and a particular web page 20 . This Figure is an example which may be consistent with any type of network, including a LAN, a wide are network (WAN), or a combination of networks, such as the Internet.
When a user 10 connects to a particular destination, such as a requested web page 20 , the connection from the user 10 to the web page 20 is typically routed through several routers 12 A- 12 D. Routers are internetworking devices. They are typically used to connect similar and heterogeneous network segments into Internetworks. For example, two LANs may be connected across a dial-up, integrated services digital network (ISDN), or a leased line via routers. Routers may also be found throughout the Internet. End users may connect to a local Internet service provider (ISP) (not shown), which are typically connected via routers to regional ISPs, which are in turn typically connected via routers to national ISPs.
If a router, such as router 12 C, fails and is no longer able to route the desired connection, then the desired connection between the user 10 the desired web page 20 may be significantly delayed or unable to connect at all.
To avoid this problem, a solution has been implemented by router manufacturers, such as Cisco Systems, that include two processors, a primary processor and a secondary processor, such that the secondary processor may take over as the main processor if the primary processor has either a hardware or software failure. Accordingly, such a solution provides redundancy to avoid failure of the router.
Although this solution works well, it may be desirable for many companies to avoid buying a specialized router with built in redundancy and simply use their existing routers for the same purpose. The present invention addresses such a need.
SUMMARY OF THE INVENTION
According to an embodiment of the present invention, two routers coupled through a network, such as a local access network (LAN), may be used to serve the function of redundancy to avoid the failure of a connection. The LAN may be used as a backplane to substitute for a bus between two processors. According to an embodiment of the present invention, the two routers may send their medium access control (MAC) addresses to each other and compare these MAC addresses. The router associated with the MAC address that meets a predetermined criteria may be deemed as a primary router and the other router can be deemed as a secondary router. An example of meeting the predetermined criteria is the router associated with the lower MAC address. Once processor states, such as stand alone, primary, and secondary, are established for the two routers, the primary router may serve the function of a standard router, while the secondary router monitors the health of the primary router and becomes a primary router should the original primary router have a failure.
A method according to an embodiment of the present invention for determining a state of a processor is presented. The method comprises providing a first criteria and a second criteria, wherein the first criteria is associated with a first device and the second criteria is associated with a second device, and wherein the first device and second device are coupled to each other. the method also compares the first criteria and the second criteria; and determines a first state for the first device.
A system according to an embodiment of the present invention for determining a state of a processor is also presented. The system comprises a first device providing a first criteria. The system also includes a second device coupled with the first device, the second device providing a second criteria. A processor is coupled with the first device. The processor is configured to compare the first criteria and the second criteria; and the processor is also configured to determine a first state for the first device.
Another system according to an embodiment of the present invention for determining a state of a processor is presented. The system comprises a processor that is configured to provide a first criteria and receive a second criteria. The first criteria is associated with a first device and the second criteria is associated with a second device. The processor is also configured to compare the first criteria and the second criteria, and determine a first state for the first device. A memory is coupled to the processor for providing instructions to the processor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an example of a network connection between a user and a web page.
FIG. 2 is a block diagram of an example of a router suitable for implementing an embodiment of the present invention.
FIG. 3 is a block diagram of a system of routers suitable for implementing an embodiment of the present invention.
FIGS. 4A-4B are flow diagrams of a method according to an embodiment of the present invention for determining a primary and a secondary router.
FIG. 5 is an illustration of a packet frame which may be used in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is presented to enable one of ordinary skill in the art to make and to use the invention and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiments will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. Thus, the present invention is not intended to be limited to the embodiment shown but is to be accorded the widest scope consistent with the principles and features described herein.
FIG. 2 is a block diagram of an example of a router suitable for implementing an embodiment of the present invention. The router 150 is shown to include a master central processing unit (CPU) 166 , low and medium speed interfaces 158 , and high speed interfaces 162 . The CPU 166 , may be responsible for such router tasks as routing table computations and network management. It may include one or more microprocessor chips selected from complex instruction set computer (CISC) chips (such as the Motorola 68040 Microprocessor), reduced instructions set computer (RISC) chips, or other available chips. Non-volatile RAM and/or ROM may also form part of CPU 166 . However, there are many different ways in which memory can be coupled to the system.
The interfaces 158 and 162 are typically provided as interface cards. Generally, they control the sending and receipt of data packets over the network and sometimes support other peripherals used with the router 150 . Examples of interfaces that may be included in the low and medium interfaces 158 include a multiport communications interface 152 , a serial communications interface 154 , and a token ring interface 156 . Examples of interfaces that may be included in the high speed interfaces 162 include a fiber distributed data interface (FDDI) 164 and a multiport Ethernet interface 160 . Each of these interfaces (low/medium and high speed) may include (1) a plurality of ports appropriate for communication with the appropriate media, and (2) an independent processor such as the 2901 bit slice processor (available from Advanced Micro Devices Corporation of Santa Clara, Calif.), and in some instances (3) volatile RAM. The independent processors control such communication intensive tasks as packet switching and filtering, and media control and management. By providing separate processors for the communication intensive tasks, this architecture permits the master microprocessor 166 to efficiently perform routing computations, network diagnostics, security functions, etc.
The low and medium speed interfaces are shown to be coupled to the master CPU 166 through a data, control, and address bus 168 . High speed interfaces 162 are shown to be connected to the bus 168 through a fast data, control, and address bus 172 which is in turn connected to a bus controller 170 . The bus controller functions are provided by a processor such as a 2901 bit slice processor.
Although the system shown in FIG. 2 is an example of a router suitable for implementing an embodiment of the present invention, it is by no means the only router architecture on which the present invention can be implemented. For example, an architecture having a single processor that handles communications as well as routing computations, etc. would also be acceptable. Further, other types of interfaces and media could also be used with the router.
FIG. 3 is a block diagram of a system of routers suitable for implementing an embodiment of the present invention. In this example, a first router 150 A is coupled with a second router 150 B through a network connection, such as a local access network (LAN). In this system, router 150 A and router 150 B may provide redundancy by acting as a unit with the LAN backplane being used as a substitute bus. One of these routers 150 A, 150 B may be determined as a primary router while the remaining router is determined as a secondary router. The main function of the primary router is to act as a stand alone router, for example by routing connections to a requested destination. The main function of the secondary router is to monitor the health of the primary router until a failure is detected. The failure of the primary router may be either a software failure or a hardware failure. Once a failure of the primary router is detected, the secondary router takes over as the new primary router. Accordingly, redundancy is used to ensure reliability. For further details of processor redundancy, U.S. patent application Ser. No. 09/205,577 entitled SYSTEM AND METHOD FOR ESTABLISHING PROCESSOR REDUNDANCY, filed Dec. 4, 1998, which is herein incorporated by reference may be referred.
FIGS. 4A-4B are flow diagrams of a method according to an embodiment of the present invention for determining a primary and secondary router. Each router in the system of routers, such as the system shown in FIG. 3, preferably performs the method exemplified in FIGS. 4A-4B. A network device, such as a LAN device, is initialized, (step 300 ). An example of a LAN device is an Ethernet card. Initialization of a LAN device is well known in the art. The initialization of the LAN device may occur after the router hardware has been initialized.
It is then determined whether a discovery frame has already been received (step 302 ). The discovery frame would be a packet received from another router, such as router 150 B of FIG. 3 . Further details of the discovery frame will later be discussed in conjunction with FIG. 5 .
If there is no discovery frame that has already been received, the medium access control (MAC) address of this router (such as router 150 A of FIG. 3 which is performing the method exemplified in FIGS. 4A-4B) is then periodically sent to the other router (such as router 150 B which is also performing this method) (step 304 ). An example of the time period between the sending of the MAC address of this router is every one second. The MAC address may be sent via a discovery frame, which will later be discussed in conjunction with FIG. 5 .
It is then determined whether a predetermined time period has expired (step 305 ). The routers participating in the primary/secondary router system may be identified by being powered on within a predetermined time of each other. An example of the predetermined time is approximately 30 seconds. When a router is powered on, it may have a predetermined time period, such as approximately 30 seconds, during which the MAC address of this router is sent periodically. If the time period has expired, then this router acts as a stand alone router (step 307 ). Optionally, once the router acts as a stand alone router, it may listen for a discovery frame in case another router sends its MAC address over to this router.
The other router that is expected to send a MAC address to this router should be on the same local access network (LAN) segment with this router. A LAN segment may be a logical grouping where all frames sent in that LAN segment can be seen by any device on that segment.
A discovery frame is then received from the other router (step 306 ). The received discovery frame will include either a MAC address or an acknowledgement (ACK) from the other router indicating that this router's discovery frame has been received (step 306 ). Once a discovery frame has been received, this router stops sending its MAC address to the other router (stop periodically sending this router's discovery frame) (step 308 ). The MAC address of this router is then compared to the received MAC address of the other router (step 310 ).
If a discovery frame had already been received when the LAN device was initialized (step 302 ), then the MAC address of the this router is compared to the MAC address of the other router (step 310 ), without the need to initiate the sending and receiving the discovery frames (steps 304 - 308 ).
It is then determined whether this device's MAC address meets a predetermined criteria (Step 312 ). An example of meeting a predetermined criteria is if this device's MAC address is a lower number than the MAC address of the other router (step 312 ). If this device's MAC address meets the predetermined criteria, then this router is determined as the primary router and a state of this router is set as primary (step 314 ). If this device's MAC address does not meet the predetermined criteria (step 312 ), then this router is determined as a secondary router and the state of this router is set as secondary (step 316 ).
Examples of options for the state of this router include stand alone, primary, and secondary. Stand alone is a state indicating that the router is functioning without redundancy. Primary is a state indicating that the router acts as the primary router. Secondary is a state indicating that the router is acting as a secondary router and monitoring the health of a primary router.
Once the state of the router has been determined, it is then determined whether an acknowledgement (ACK) from the other router has been received (step 318 ). The acknowledgement from the other router would include the acknowledgement of having received this router's MAC address and this router's state. If an ACK from the other router has been received then this process is complete. If, however, an ACK has not been received from the other router, then an ACK is sent from this router to the other router indicating this router's MAC address and this router's state (step 320 ).
Each of the routers involved in this system, such as the system shown in FIG. 3, performs the method exemplified in FIGS. 4A-4B. Accordingly, each of the routers determine their state, with the result of one of the routers being a primary router and the remaining router being a secondary router.
FIG. 5 is an example of a discovery frame according to an embodiment of the present invention. The discovery frame 400 is shown to include a destination 402 , a source 404 , a type or length 406 and a discovery protocol 408 . The destination 402 may indicate the destination router to which the discovery frame is sent, such as router 150 B of FIG. 3 . An example of the size of the destination 402 is 48 bits. The source 404 may be the source router from which the discovery frame originates, such as router 150 A of FIG. 3 . An example of the size of the source 404 is 48 bits. The type or length 406 may indicate either the length of the frame 400 or the type of frame, for example a protocol number indicating that this is a discovery frame. An example of the size of the type or length is 16 bits. The discovery protocol 408 is shown to include a type, a length, an address of the next message, an address of where the data begins for this message, and the data of this message including the router state and the MAC address. Examples of the sizes of these fields in the discovery protocol 408 include 16 bits for type, 16 bits for length, 32 bits for the address of the next message, 32 bits for the address of where the data begins for this message, 32 bits for the router state, and 48 bits for the MAC address.
A method and system for determining relative states of processors in a system such as a system of routers has been disclosed. Software written according to the present invention may be stored in some form of computer-readable medium, such as memory or CD-ROM, or transmitted over a network, and executed by a processor.
Although the present invention has been described in accordance with the embodiment shown, one of ordinary skill in the art will readily recognize that there could be variations to the embodiment and these variations would be within the spirit and scope of the present invention. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims. | According to an embodiment of the present invention, two routers coupled through a network, such as a local access network (LAN), may be used to serve the function of redundancy to avoid the failure of a connection. The LAN may be used as a backplane to substitute for a bus between two processors. According to an embodiment of the present invention, the two routers may send their medium access control (MAC) addresses to each other and compare these MAC addresses. The router associated with the MAC address that meets a predetermined criteria may be deemed as a primary router and the other router can be deemed as a secondary router. An example of meeting the predetermined criteria is the router associated with the lower MAC address. Once processor states, such as stand alone, primary, and secondary, are established for the two routers, the primary router may serve the function of a standard router, while the secondary router monitors the health of the primary router and becomes a primary router should the original primary router have a failure. | 7 |
BACKGROUND
[0001] Most homes are protected from entry by a deadbolt lock system. In many cases unwanted persons (ex-roommate, or former boyfriend or girlfriend, refugees of a relationship gone bad, etc.) may retain or obtain a key to the deadbolt lock. It would be desirable to keep those persons from being able to unlock the deadbolt and entire the residence or premises protected by the deadbolt lock. Alternatively, these deadbolt locks can be “picked” or opened using a “Bump” key, which can be easily purchased online. Such unkeyed methods of entry would also permit an undesired entry almost any existing deadbolt system.
[0002] Although conventional devices in this field do exist, they are not universal in their applicability to all or substantially all, deadbolt locks, or these conventional approaches require disassembly and reassembly of the existing deadbolt system. Experience with these conventional devices has led the Applicant to determine that are predominantly of very poor construction.
[0003] Improvements to these conventional devices and approaches to preventing unwanted access through a door secured by a deadbolt lock are desirable.
[0004] The present application relates generally to a device that clamps onto the interior deadbolt door lock thumb twist knob, preventing unlocking of the deadbolt door lock even with a key or when the lock is being picked. While clamped onto the deadbolt knob, the device of the present disclosure may incorporate a metal hook type arm that extends around the lower door handle to completely prevent turning of the deadbolt lock mechanism.
[0005] This device may be comprised of an upper and lower clamp system that secures the deadbolt interior knob. The device may also have two small thin steel plates on the back side of the clamp that when in place such that the plates are positioned behind the deadbolt knob itself With the upper and lower portions secured about the deadbolt interior knob, the metal arm may then easily be adjusted to extend around the door handle. This arm may only need to be adjusted the first time it is used on a particular door, or if the device is moved to another door.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The accompanying drawing figures, which are incorporated in and constitute a part of the description, illustrate several aspects of the present disclosure and together with the description, serve to explain the principles of the present disclosure. A brief description of the figures is as follows:
[0007] FIG. 1 is a perspective view of a deadbolt security device according to the present disclosure positioned about an interior knob of a deadbolt lock mounted to a door.
[0008] FIG. 2 is a perspective view of the deadbolt security device of FIG. 1 .
[0009] FIG. 3 is a rear view of a clamping unit of the deadbolt security device of FIG. 2 .
[0010] FIG. 4 is a cross-sectional view of the clamping unit of the deadbolt security device of FIG. 2 , taken along line 4 - 4 in FIG. 1 .
DETAILED DESCRIPTION
[0011] Reference will now be made in detail to exemplary aspects of the present disclosure which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0012] Referring now to FIG. 1 , door 12 is shown with an interior deadbolt knob 20 which may be used to actuate the extension or refraction of a deadbolt 22 . When extended, deadbolt 22 may extend into an opening in a door jamb 14 which may prohibit door 12 from being opened. In addition to the deadbolt mechanism, door 12 may further include a door handle 16 and a releasable latch 18 to permit the conventional opening and closing of door 12 . Door handle 16 may or may not include a locking mechanism. Where it is felt that door handle 16 and latch 18 are not sufficient to provide security to door 12 , retractable deadbolt 22 actuated by interior deadbolt knob 20 may be added to the door.
[0013] To provide additional security to deadbolt 22 , and to prevent an unauthorized user with a key or an unauthorized user capable of opening deadbolt 22 without a key from passing through door 12 , a deadbolt security device 10 may positioned about an interior deadbolt knob 20 . Deadbolt security device 10 may include a clamping unit 32 comprising an upper clamping member 34 and a lower clamping member 36 . Upper clamping member 34 and lower clamping member 36 may each include a notch 38 configured to fit about and engage interior deadbolt knob 20 . When clamping unit 32 engages knob 20 , the knob and clamping unit may be locked together and unable to turn independently from each other.
[0014] A pair of slider rods 40 may extend between the upper and lower clamping units and permit the clamping members to be separated to permit removal of device 10 from door 12 or permit placement of device 10 onto door 12 . When the clamping unit 32 is placed about interior knob 20 , lower clamp member 36 may be slid along slider rods 40 closer to upper clamp member 34 until knob 20 is engaged within notches 38 . A ratchet or other releasable mechanism may be provided to permit lower clamp member 36 to be moved away from upper clamp member 34 to permit removal of device 10 from door 12 . Such a releasable mechanism may be released or actuated by a release button 42 .
[0015] Once the clamping unit 32 is positioned about and engaged with interior deadbolt knob 20 , it is desirable that unit 32 be prevented from rotating to prevent the retraction of deadbolt 22 . To accomplish this, a door handle hook arm 24 may be mounted to clamping unit 32 and may include a shaft 26 and a hook 28 at a distal end of shaft 26 . To prevent rotation of clamping unit 32 , hook 28 will preferably engage door handle 16 . Even if a person outside of door 12 has an appropriate key to actuate the deadbolt lock mechanism and retract deadbolt 22 , the engagement between hook 28 and door handle 16 will serve to prevent rotation of the deadbolt and opening of door 12 .
[0016] Shaft 26 may be slidably mounted to clamping unit 32 by a slidable position clamp 31 . Since the distance between interior deadbolt knob 20 and door handle 16 may vary depending on the size, shape and nature of use of door 12 , it is desirable that security device 10 be adaptable to such different degrees of separation. Further, since the orientation of interior deadbolt knob 20 may not be consistent from door to door, it is also desirable that clamp 31 permit rotation of shaft 26 with regard to clamping unit 32 so that shaft 26 may be extended toward and engage door handle 16 on a wide variety of doors. Clamp 31 may include a simple slot 31 a and a thumbscrew 30 that may be loosened to permit shaft 26 to be extended or shortened so that hook 28 is positioned to engage door handle 16 . Once hook 28 is in place, thumbscrew 30 may be tightened down to secure device 10 to the door and prevent rotation of knob 20 . It is anticipated that hook 28 may be coated by a protective material 29 to prevent scratching or marring of door 12 and/or door handle 16 . Such a material 29 is not required for the functioning of device 10 within the scope of the present disclosure but may improve operation of the device. Such a material 29 may also serve to increase friction between door handle 16 and device 10 to further engage the resistance to rotation of interior deadbolt knob 20 .
[0017] Referring now also to FIGS. 2 to 4 , clamping unit 32 may further include backing plates 44 adjacent notches 32 on one or both of upper clamp member 34 and lower clamp member 36 . Backing plates 44 will be positioned preferably against door 12 when clamping unit 32 is positioned about interior deadbolt knob 20 . Backing plates 44 may serve to prevent device 10 from being accidently or deliberately dislodged from door 12 when device 10 is being used to prevent actuation of interior deadbolt knob 20 . As shown in FIG. 4 , backing plates 44 extend behind interior deadbolt knob 20 when device 10 is positioned on door 12 .
[0018] As shown in FIGS. 3 and 4 , within lower clamp member 36 may be a releasable mechanism to permit or prevent the movement of lower clamp member 36 along slider rods 40 . Such a mechanism may include a pair of tabs 46 extending within a cavity include lower clamp member 36 between an interior end of button 42 and engaging slider rods 40 . A spring 50 may be included within lower clamp member 36 to bias button 42 and inboard ends of tabs 46 outward. Button 42 may include a retaining ring 43 to prevent spring 50 form forcing button 42 entirely out of lower clamp member 36 . An outboard end of each tab 46 may be positioned to engage one of the slider rods 40 . A fulcrum 48 may be provided within the cavity through which tabs 46 extend, with each fulcrum 48 positioned generally equidistant between button 42 and rods 40 .
[0019] With button 42 and the inboard ends of tabs 46 positioned where biased by spring 50 , engagement of the outboard ends of tabs 46 and slider rods 40 within lower clamp member 36 will preferably prevent movement of upper clamp member 34 and lower clamp member 36 away from each other. This will help secure deadbolt security device 10 to door 12 and prevent accidental or deliberate dislodging of the device. To release device 10 from door 12 , a user would press inward on button 42 to overcome the spring's bias outward and move button 42 into lower clamp member 36 . In this position, the engagement between tabs 36 and rods 40 would be released enough to permit movement of lower clamp member 36 along rods 40 either toward or away from upper clamp member 34 . Each slider rod 40 may include a stop ring 45 at a distal end to prevent removal of lower clamp member 36 from rods 40 .
[0020] Referring now to FIG. 1 , when device 10 is first positioned on door 12 , the upper and lower clamp members would be far enough apart to permit interior deadbolt knob 20 to be positioned past backing plates 44 and within notches 38 . Once knob 20 was in position between the upper and lower clamp members, button 42 may be depressed and lower clamp member 36 may be slid along slider rods 40 until knob 20 is closely engaged by notches 38 . When the notches a closely engaging knob 20 , button 42 may be released and spring 50 will urge the outboard ends of tabs 46 against road 40 and prevent further movement of the clamp members with respect to each other. Once clamping unit 32 is desirably positioned about knob 20 , shaft 26 may be rotated and moved within clamp 31 so that hook 38 will engage door handle 16 . When shaft 26 and hook 28 are positioned as desired to engage the door handle and prevent rotation of clamping unit 32 , thumbscrew 30 may be tightened up to lock hook 28 in place.
[0021] To remove security device 10 from door 12 , button 42 would be depressed so that lower clamp member 36 may be moved away from upper clamp member 34 sufficiently to disengage with knob 20 . If clamp 31 is mounted to lower clamp member 36 , such movement will also preferably disengage hook 28 from door handle 16 . Thus, removal of security device 10 may be accomplished simply by separating the clamp members along rods 40 . When repositioning device 10 to door 12 , the positioning of hook 28 and shaft 26 will preferably not be required, and hook 28 will be positioned to engage door handle 16 when the clamping members are again positioned closely about knob 20 .
[0022] The security device of the present disclosure differs from what currently exists in that this device is very sturdy and very easy to use. Device 10 requires no permanent installation on door 12 and further does not require disassembly and reassembly of the deadbolt mechanism to be used. Further, the security device of the present application is completely universal in nature, being adaptable for use with almost any common door, door handle and deadbolt knob configuration or positioning. Many people don't have the mechanical know how to install a conventional system that requires disassembly of the existing deadbolt system. Other conventional devices are known to break (due to poor construction) or even fall off the deadbolt interior knob.
[0023] Device 10 may be simply clamped onto inside deadbolt knob 20 on door 12 using minimal pressure. Once clamped, shaft 26 and hook 28 are simply adjusted in place also using minimal pressure. These functions may be accomplished by almost any person of any age with ease. When installed, security device 10 will render the deadbolt lock mechanism immobile. Push button 42 will permit the easy release of security device in mere seconds, also with minimal pressure.
[0024] Applicant anticipates that any number of suitable materials may be used to construct the security device according to the present disclosure and no limitation is intended within this disclosure with regard to the materials from which the device may be made.
[0025] While security device 10 has been described as including a pair of sliding rods 40 , it is anticipated that a security device having one rod or a plurality of rods may be configured according to the present application and it is not intended to limit the present disclosure to any particular number of rods. By the use of the word rod, Applicant is not intending to limit the present application to any particular size or shape of element(s) extending between the clamp members and permit movement of the clamp members with respect to each other. It is further anticipated that any number of releasable mechanisms may be used to fix one or both of the clamp members to the rod(s) extending between the clamp members. It is preferable that such mechanism be actuated without tools but beyond that it is not intended to limit the nature of the releasable mechanism.
[0026] While the invention has been described with reference to preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific embodiments set forth above. Thus, it is recognized that those skilled in the art will appreciate that certain substitutions, alterations, modifications, and omissions may be made without departing from the spirit or intent of the invention. Accordingly, the foregoing description is meant to be exemplary only, the invention is to be taken as including all reasonable equivalents to the subject matter of the invention, and should not limit the scope of the invention set forth in the following claims. | A deadbolt security device clamps onto an interior deadbolt knob and prevents unlocking of the deadbolt door lock even with a key. While clamped onto the deadbolt knob the device has a shaft and a hook that extends around a door handle of the door to completely preventing turning of the deadbolt lock mechanism. This device is comprised of upper and lower clamp members that are movable toward each other to tightly grip the deadbolt interior knob or away from each other to permit easy removal of the device from the door. | 4 |
BACKGROUND OF THE INVENTION
The invention relates to a cardiac pacemaker system of the type including a stimulation electrode adapted for being arranged in the heart; an output capacitor coupled to the stimulation electrode; a first circuit, coupled to the output capacitor, for generating a pulse following each stimulation pulse for at least one of reducing a residual charge of the output capacitor and eliminating an afterpotential following a stimulation pulse by the stimulation electrode; and a third circuit, for acquiring an evoked heart action from an electrical signal picked up by an electrode arranged in the heart.
For a long time, it has been a goal in the development of artificial cardiac pacemakers to verify the success of a heart stimulation through the measurement and evaluation of signals, which can be picked up in the heart on the basis of the evoked heart action via an electrode which is installed in the heart--and preferably the stimulation electrode itself.
The pickup of the electrical "response signal" of the heart after a stimulation is disturbed by the aftereffects of the stimulation pulse, which are caused by the polarization of the stimulated tissue, which can be reduced only when the recharging of the output (coupling) capacitor connected to the stimulation pulse is also eliminated.
This follows from the fact that the evoked potential, which indicates the success of the stimulation and is present at the heart approximately up to 300 ms after the stimulation, is superposed by an afterpotential in the order of magnitude of more than 10 mV. The afterpotential, which disturbs the effectiveness for recognition of the evoked potential, is caused by the effect of the stimulation electrode as an electrochemical electrode, from which results a saturation of the detection amplifier.
Apart from various circuits, with which attempts are made to eliminate the consequences of the afterpotential, an apparatus for the stimulation of the heart is known from EP-B1-0 000 989, wherein the disturbing afterpotential of the stimulation electrode is intended to be reduced in an accelerated manner by means of an additional, transistor-controlled resistor branch, which essentially short-circuits the Helmholtz capacity. The total time needed for the reduction of the disturbing afterpotential, however, is too long with customary electrodes to make possible an effective effectiveness recognition under all circumstances.
SUMMARY OF THE INVENTION
Starting from the drawbacks of the prior art, it is the object of the invention to provide a cardiac pacemaker system of the generic type mentioned in the introduction, in which an effective detection of evoked heart signals is possible in an effective manner, also under the different changing operating conditions of a cardiac pacemaker, which occur, for example, during the settling in of the electrode.
The above and other objects are accomplished in the context of a cardiac pacemaker system of the type first described above, wherein according to the invention the stimulation electrode includes a porous surface coating made of an inert material and having an active surface that is substantially larger than a surface of the basic geometric form of the stimulation electrode; and the pacemaker system includes circuit means for changing the time duration of the activation of the second circuit as a function of the acquisition of the evoked heart action, with the time duration of the activation of the second circuit being limited to no more than 70 ms.
The invention includes the finding that when an electrical voltage is applied to a pacemaker electrode, which is anchored in the heart, two layers of different charge carriers are formed, which, however, are separated by a monolayer of hydrogen molecules based on hydration effects. In its structure and electrical behavior, this so-called Helmholtz double layer corresponds to a plate capacitor. If, during the stimulation of the heart, a current flows via this Helmholtz capacity, a voltage is generated there which forms the afterpotential, with the voltage increasing as the Helmholtz capacity decreases. The afterpotential is additionally increased through further electrochemical reactions with charged reaction products taking place at the phase boundary. Apart from the increase of the Helmholtz capacity, a reduction of the stimulation pulse amplitude, above all, is important for reducing the afterpotential so that a definitive effectiveness recognition can be carried out with the same electrode. In addition, a reduction of the amplitude of the stimulation pulse contributes in an advantageous manner to increasing the service life of the pacemaker's current supply source.
The selection of the measures according to the invention can thus, on the one hand, reduce the stimulation pulse amplitude so that the afterpotential as a whole becomes lower. Moreover, the reduction of the afterpotential is accelerated so that the afterpotential is reducible in a defined manner within a predetermined period of time.
This reduction can take place by means of an active counterpulse or also through passive means at the output of the stimulation circuit, as is known from the prior art that was mentioned (autoshort).
According to advantageous modifications of the invention, it becomes possible through automatically operating circuit means to automatically determine the time duration of the blocking of the input amplifier for the evoked pulses and to adapt it to the implantation conditions or their temporal change. In this process, an increased stimulus energy is used, which, with certainty, leads to a stimulation.
Additionally, in an advantageous modification, a cardiac pacemaker system can be provided, which overall only has a low energy requirement because of the automatic adjustment of the stimulation amplitude.
It was recognized here that
while a stimulation pulse having an excessive amplitude leads with certainty to a stimulation of the myocardium, the service life of the pacemaker's current supply source, however, is considerably reduced because of the increased energy consumption so that an early reimplantation must be carried out,
a sufficiently reliable detection of evoked signals, based on a myocardium stimulation that has taken place, is possible only after a sufficient reduction of the afterpotential, which occurs due to the stimulation pulse, if stimulation and detection are carried out with the same electrode,
the afterpotential may, at most, reach such a value which can be reduced to a negligible level within a period of approximately 30 to 80 ms (autoshort), before an evoked potential has decayed and
the materials of the known electrodes and, in particular, titanium, vanadium, zircon and niobium tend to, at times, show extreme oxidation and that, in case of contact with aqueous electrolytes, this high oxidation tendency leads to the formation of a thin, insulating or semiconductive oxide layer at the electrode surface, with the oxide layer representing a capacity C ox connected in series with the Helmholtz capacity C H and thus leading to a slow reduction of the total capacity and therewith to the corresponding increase of the respectively required stimulation energy.
The pulse control of the control system according to the invention is configured both for the automatic determination of the width of the autoshort pulses, which is necessary for the detection of evoked potentials, and for maintaining a minimum amplitude of the stimulation pulses, which exceeds the stimulus threshold of the myocardium at the determined necessary width of the autoshort pulses, and it is provided with the electrical means necessary for this purpose. These essentially comprise a controllable autoshort pulse generator, a generator for the generation of amplitude-controlled stimulation pulses controlled by a gate circuit at a predetermined pulse repetition frequency and devices for the detection of the potentials evoked by the stimulation pulses as a function of the width of the autoshort pulses. The automatic setting of the autoshort time is among the most essential advantages of the pulse control.
The operation of the pulse control circuit represented here takes place in two different operating conditions, "alignment" and "continuous operation". According to the preferred embodiment of the invention, a pulse generator is provided for the generation of the autoshort pulses, in which a variation of the pulse width in the "alignment" operating condition is carried out in a scanning manner by a ramp generator. In this process, the stimulation pulses are kept constant with regard to their amplitude through a corresponding setting in the pulse amplitude control of the stimulation pulse generator, at a level which is above the stimulus threshold of the myocardium and at which an evoked potential is released with certainty. The correspondingly detected, pulse-shaped signals are fed to a memory after sufficient amplification.
The memory is configured in a matrix fashion or array fashion and is addressed by the above-mentioned ramp generator such that an allocation of the memory locations to the evoked signals takes place as a function of the respective autoshort pulses of a certain width.
An evaluation unit downstream of the matrix memory determines the most effective detection of the evoked potentials with respect to the pulse width of the autoshort pulses. This autoshort time is fixed in the generator for the autoshort pulses and sets as a self-adjusted value the width of the autoshort pulses for the "continuous operation" operating condition of the pulse control following the "alignment" operating condition. For the change-over of the operating conditions, a cyclical timer switch is provided by means of which the ramp generator, the generator for the autoshort pulses and the amplitude control stage of the stimulation pulses can be correspondingly switched on or off. During the "continuous operation" of the pulse control, a gate circuit, which is provided at the input of the amplitude control stage for the stimulation pulses, is activated by the timer switch and the detection pulses of the evoked potentials.
Each pulse that corresponds to a detected potential leads to a reduction of the amplitude of the stimulation pulses by a certain amount. If, after a number of stimulations, the stimulation pulse remains below the stimulus threshold, an evoked potential can no longer be picked up. A corresponding output signal at a gate circuit leads to an increase of the amplitude of the stimulation pulses in the downstream amplitude control stage to the value that was last applied successfully. This accomplishes that the stimulation pulse, which follows the missing detection of an evoked potential, leads with certainty to a renewed stimulation of the myocardium and that a "falling-out-of-step" of the synchronization of the total system is prevented.
It is evident that, instead of the stimulation amplitude, also the pulse width or another value that determines the stimulus energy can be changed.
It is also particularly advantageous if the afterpotential is compensated through an active counterpulse, because the electrode used in the cardiac pacemaker system according to the invention can also be operated anodically, without an oxide layer impairing the stimulation threshold.
According to an advantageous modification of the invention, the amplitude increase in case of a missing detection of an evoked potential is a multiple of the value of the amplitude decrease when a detection took place. This is accomplished in a simple manner by means of a divider circuit, which provides the output signals of the gate circuit for the amplitude reduction with this factor.
According to another advantageous embodiment of the invention, a change of the switching conditions of the timer switch takes place in time intervals of equal length, which cyclically repeat themselves, in order to regularly carry out a control of the selected autoshort time. It has proven advantageous to again carry out an "alignment" after a predetermined number of lowering cycles of the amplitude of the stimulation pulses until a potential detection first fails to appear so as to adjust the autoshort time, if necessary, to a possible change of the ability of the myocardium to be stimulated.
The function of the pulse control according to the invention is only guaranteed for autoshort times in the range of 50 ms if the constructive configuration of the stimulation electrode accomplishes that only a relatively low afterpotential is built up following the stimulation pulse.
According to the preferred embodiment of the invention, the stimulation electrode is provided with a porous surface coating made of an inert material, with the active surface of the coating being considerably larger than the surface that results from the geometric shape of the electrode. Because of the fractal spatial geometry, the active surface is so large that the energy required for the stimulation can be set to a minimum value. Thus, because of the electrodes' large relative surface, a successful stimulation with low energy is possible, in principle, for the conventional coated, porous electrodes. It was now recognized that the Helmholtz capacity is reduced due to the oxidation tendency, which leads to an increase in the electrode impedance. The reason why the influence, which is thus generated, on the electrode properties in the course of the implantation time is so serious is that the deterioration of the electrode properties has consequences which, in turn, contribute to the fact that the stimulation properties are also influenced adversely.
Thus, for a deteriorating electrode, a greater pulse energy is necessary so that, for the effectiveness recognition, a counterpulse with a greater energy requirement is also necessary which, in turn, again contributes to the deterioration of the electrode properties. Since the pulse energy and the counterpulses necessary for the effectiveness recognition are set to values that have to have validity over the total implantation time of the pacemaker, the deterioration of the operating conditions ultimately is essentially based on measures, which are actually intended to counteract the deteriorated operating conditions.
The long-term-stable, biocompatible surface coating of the stimulation electrode according to the invention is made of a material whose oxidation tendency is very low, with the coating being applied on the electrode using vacuum technology, preferably by using an inert material, namely a nitride, carbide, carbonitride or a pure element or certain alloys from the group gold, silver, platinum, iridium, titanium or carbon. Owing to the fractal spatial geometry of a surface layer applied in this manner, its active surface is very large so that the amount of energy needed for the stimulation can be kept extremely low.
The afterpotential of a stimulation electrode made of titanium, which is provided with a sputtered iridium nitride layer or titanium nitride layer by means of the reactive cathode sputtering, is smaller by up to six times (from approximately 600 mV to approximately 100 mV) than the afterpotential of a bare stimulation electrode made of titanium. Owing to this significant reduction of the afterpotential, the recognition of the intracardiac ECG is possible not only in the conventional manner by means of an amplifier and a triggering device, but an operative effectiveness recognition can be applied, which can do without counterpulse and autoshort times for the reduction of the afterpotential in the magnitude of 50 ms.
Advantageous modifications of the invention are described below in greater detail in conjunction with the accompanying Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the preferred embodiment of the invention.
FIG. 2 is an overview diagram containing the most important influencing quantities for the pulse control in a schematic representation.
FIG. 3 is an amplitude-time diagram, shown schematically, for the generated stimulation pulses and the detected evocation potentials.
FIG. 4 is an embodiment of a stimulation electrode represented schematically in side view.
FIG. 5 is an enlarged representation of detail A in FIG. 4 in a sectional view.
FIG. 6 is a diagram to compare the impedance of the embodiment of the electrode with the impedance of corresponding electrodes known from prior art having the same geometric dimensions.
FIG. 7 is a representation of the afterpotential as a function of the autoshort time in dependence of the surface configuration of the electrode.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The means for the pulse generation of the control system according to the invention are schematically illustrated in FIG. 1. The stimulation electrode, which is part of the control system, is connected to the output capacitor 1 and is not shown in the drawing.
The electrode is provided with a pulse generator 4 for stimulation pulses that are released in the direction 2 onto the stimulation electrode.
A time control stage 6 determines the point in time of the release of stimulation pulses and, in this case, corresponds to a fixed frequency pacemaker. The schematic circuit diagram is also usable for other pacemaker circuits, where merely additional control lines must be provided, through which, for example, in a demand pacemaker, stimulation is prevented through the release of stimulation pulses in case of signals stemming from heart actions that come in before the end of the so-called escape interval. With an amplitude control stage 5, the amplitude (or the energy) of the stimulation pulses can be raised ("+") or lowered ("-") via additional inputs.
In addition, a pulse generator 15 is provided for the generation of autoshort pulses via the final pulse generator stage 4. Via a galvanic connection or an active counterpulse, the potential of the inner connection of the capacitor 1 is returned in this process to the initial state prior to the last stimulation pulse so that, by way of the charge shift generated, the afterpotential at the electrode is counteracted. The time duration of the pulse for eliminating the aftereffects of the stimulation pulse can be set via a corresponding input of the pulse generator 15.
Via an amplifier 11, signals that are generated by the heart are picked up, with the amplifier being switched so as to be insensitive by switching means, that are not shown, when a stimulation pulse occurs. An evoked event is retained in a memory 12. In order to be able to optimize the time duration of the autoshort pulse, a signal indicating an evoked event is retained in allocation to the duration of the corresponding autoshort pulse.
The "alignment" operating mode is set by means of a control switch 17 while, otherwise, the circuit is in the "continuous operation" operating mode.
During the "alignment" operating condition, the optimum autoshort time is determined, which is then maintained in the "continuous operation" position. For this purpose, a pulse amplitude is predetermined by the timer switch 17 via the control line 24 in the amplitude control 5 at a constant frequency (time control 6), at which pulse amplitude an evoked potential at the myocardium is generated with certainty. Simultaneously, the timer switch 17 activates, via the control line 26, a ramp generator 16, which is connected to the pulse generator 15 via a change-over switch 14 to vary the width of the autoshort pulses in in a scanning manner. The AND gate 9 is blocked, also controlled by way of the timer switch 17 via the line 27 and a negator 10.
A picked up evoked potential or a corresponding signal 3 indicating this condition is fed to an amplifier 11 via the connecting line 32 and acquired in a matrix memory 12. The allocation of the individual memory locations takes place in dependence of the time function of the ramp generator 16 so that to each pulse width a signal can be allocated, which indicates the pickup of an evoked potential. An evaluation circuit 13 determines the most favorable autoshort time for the detection of the evoked potentials 3. In this process, a mean value of all pulse durations of the autoshort pulse, at which an evoked potential could be picked up, is selected so as to have a certain amount of certainty with respect to the change of the signal pickup conditions in the course of the operating time of the pacemaker.
Subsequently, the switch 17 is reset to the "continuous operation" operating condition, during which process the mean value of the autoshort time, at which an evoked potential could be picked up, is retained in the pulse generator 15 via the change-over switch 14 and the line 25, and the AND gate 9 is released via the negator 10. Afterwards, the stimulation amplitude is again lowered to its normal value.
It is now possible with the evoked potentials, which can be recognized reliably because of the alignment that was carried out, to set the stimulation energy (stimulation amplitude) during the operation with threshold control via an effectiveness recognition in such a way that the stimulation threshold is reliably exceeded without a premature exhaustion of the energy source occurring because of an excessive stimulation energy.
Each detection of an evoked potential 3 generates a pulse via the AND element 9 at the divider 7, which pulse decreases the amplitude of the next stimulation pulse 2 by a certain amount. This step-by-step amplitude reduction takes place until no evoked potential is detected at the predetermined autoshort time. The level change at the output of the AND gate 9 switches the negator 8 and then effects a raising of the stimulation amplitude up to a preceding value at which a stimulation took place reliably. Via the divider 7, an amplitude decrease only takes place at every nth (here 20. This value only represents an example, because, in practice, the stimulus threshold will stabilize in the long term so that divider ratios of several thousand will be practicable.) successful stimulation pulse--but a raising immediately following every failed stimulation. Thus, the stimulation pulses are always provided with a stimulus energy, in particular, amplitude, which is only slightly above the stimulus threshold, respectively leading to a heart stimulation with great certainty.
In order to acquire possible changes in the transmission ratios of the myocardium, it is of particular advantage after a "continuous operation" phase of the pulse control to again determine the autoshort time, which is optimal for the stimulation and detection of the heart activity, in a repetition of the "alignment." It has proven advantageous to carry out a further "alignment" for the amplitude of the stimulation pulses after a "continuous operation" with, for example, m-cycles. In addition, it is possible to adjust the change-over cycle of the switch 17 to the patient-specific conditions.
The schematically illustrated diagram of FIG. 2 shows, on the time axis, the possibility of picking up evoked potentials in the heart as a function of the variation of the autoshort time and of the stimulation amplitude.
Evoked signals can only be picked up if a stimulation pulse is effective, which means that the pulse has exceeded a predetermined threshold energy, as it is indicated by the horizontal line 21. In addition, the possibility of the pickup of evoked signals is further limited by the decay of the evoked potential, which is indicated by line 19 as limit for the decay of the stimulation effect (afterpotential). The line has a slight gradient, because, with a higher stimulation amplitude, the (disturbing) afterpotential also increases or the duration of its decay becomes longer. The point in time 20 forms that time mark after which an evoked potential has decayed to such a low level that its detection is no longer possible or the event of interest has passed. With the measures according to the invention, a time range for the measures to eliminate the afterpotential is set during an automatic adjustment of the duration of the autoshort time, this time range being within the effective range. Between the limit values generated by the lines 19 and 20, in particular, a mean value is set. The coating of the stimulation electrode according to the invention makes possible a lowering of the afterpotential, which disturbs the detection of the evoked potentials, at an autoshort time of 50 ms to a value of almost 0 mV (compare FIG. 7).
FIG. 3 shows the amplitude-time-diagram of the stimulation pulses 24 in relation to detectable evoked potentials 25 during the "continuous operation" operating condition of the pulse control. After each stimulation pulse 24, for which an evoked potential 25 is detected after the autoshort time T=t E -t S , a step-by-step amplitude reduction takes place via the pulse amplitude control (compare position 5 in FIG. 1). If the detection limit with the stimulus threshold 21 is reached or if a slight shortfall occurs, the resulting change in potential at the output of the gate circuit (comprising elements 7, 8, 9, 10 in FIG. 1) effects a renewed increase of the amplitude of the subsequent stimulation pulse 24. The amplitude jump occurs, in particular, to the amplitude value at which a successful stimulation has last taken place.
In order to keep the number of shortfalls of the stimulus threshold, at which effective stimulation does not occur, as low as possible, a lowering is only carried out at every nth stimulation pulse in advantageous embodiments of the invention, with a raising immediately following every threshold shortfall.
The stimulation electrode 100, illustrated in FIG. 4 in a schematic side view, is a unipolar nap electrode having a head that is provided with a cylinder-shaped basic body 126 made of titanium. The cylinder-shaped basic body 126 is provided with a surface coating 127 consisting of an inert material iridium nitride (IrN), which is applied to the cylinder-shaped basic body 126 of the titanium electrode by means of cathode sputtering. The electrode is provided with a coiled electrically conductive lead 131, which is provided with an electrically insulating sheathing 130 made of silicon. This silicon sheathing is shown to be transparent in the drawing. Formed to the silicon sheathing are flexible fastening elements 129 oriented rearward, which serve to anchor the electrode in the heart, with the surface of the basic body being kept in contact with the inner heart surface.
By means of a hollow-cylindrical shoulder 128, the basic body 126 is slid over the lead 131 and fastened there, with this shoulder being shown in sectional view in the drawing.
FIG. 5 is an enlarged view of a section (detail A in FIG. 4) of the active surface. As is evident from the illustration, the fractal spatial geometry (enlarged not to scale) of the coating 127, grown in the microscopic range in a stem-like manner, accomplishes an essential enlargement of the active surface. The surface enlargement achieved is in the range of more than 1000.
As can be seen from FIG. 6, which shows a comparison of the impedance curves of stimulation electrodes having different surface coatings, an electrode which is coated with iridium nitride has the lowest phase boundary impedance for picking up heart signals for which the low-frequency range is particularly important, especially in the region where the signals are weak, as compared to titanium or titanium nitride which are recognized state of the art electrode surface materials. The differences determined are particularly essential in their consequences for the reason that the amplitude of the picked up signal is related in a square function to the internal resistance of the signal source.
FIG. 7 illustrates the measurement results, which show the afterpotential generated by the stimulation as a function of the autoshort time T in dependence of the configuration of the stimulation electrode. Since the evoked potential indicating the success of a myocardium stimulation can be found in a time range of 50 to 300 ms after the stimulation, its detection can occur without disturbance with a titanium-nitride-coated stimulation electrode at autoshort times of 50 ms, whereas the evoked potential is "covered" by afterpotentials in the magnitude of 10 mV in uncoated platinum electrodes. This also makes the detection of the evoked potentials at a point in time after 50 ms considerably more difficult and is not possible with uncoated stimulation electrodes, since the amplitude of the evoked potential reduces itself very quickly after generation and drops below the level of the remaining afterpotential.
The invention is not limited in its implementation to the preferred embodiment described above. On the contrary, a number of variants are conceivable which utilize the described solution, also if the embodiments are, in principle, of a different type. | A cardiac pacemaker system is provided which includes a stimulation electrode adapted for being anchored in the heart. An output capacitor is coupled to the stimulation electrode. A first circuit coupled to the output capacitor generates stimulation pulses. A second circuit coupled to the output capacitor generates an autoshort pulse following each stimulation pulse to reduce a residual charge of the output capacitor for eliminating an after potential following a stimulation pulse by the stimulation electrode. A third circuit coupled to the output capacitor acquires an evoked pulse of the heart from an electrical signal picked up by the stimulation electrode. The stimulation electrode includes a porous surface coating made of an inert material and has an active surface that is substantially larger than a surface of the basic geometric form of the stimulation electrode. The second circuit includes circuit means for changing the time duration of the autoshort pulses as a function of the acquisition of the evoked pulses, with the time duration of the autoshort pulses being limited to 70 ms. | 0 |
FIELD OF INVENTION
The present disclosure relates to a cord reel assembly for supplying a retractable cord to electronic devices and the like. More specifically, the present disclosure includes a cord reel having a continuous cord with a retractable end with a jacket or similar covering to protect from wear and tear, a stationary end having a sheath and multiple connectors that can twist and untwist relative to the sheath, and a transition chamber to facilitate the meeting of the two ends, whereby the connectors in the stationary end twist and untwist in response to the extension and retraction of the retractable end.
BACKGROUND OF THE INVENTION
Retractable cord reels have been used in various applications to retractably store various types of cables. The cable held on the reel typically has a stationary end portion and a portion that may be extended from and retracted back into the reel. Conventionally, the reel comprises a spring-loaded spool on which the extendable portion of cable is wound. The extendable portion of the cable may be withdrawn from the reel, causing the spool to rotate against the force of the spring. Upon release of the cable, the spring causes the spool to rotate in the opposite direction thereby retracting the cable back onto the spool. A problem common to all prior art cord reels is providing a continuous electrical and data connection between the rotating extendable portion of the cable and the stationary end portion. Two basic types of cord reels have been developed to address this problem.
One type of reel utilizes rotating contacts, commonly placed between the rotating reel and a stationary housing. The stationary end portion of the cable is separate from the extendable portion. The stationary cable is connected to the contacts carried by the housing, and the extendable portion is connected to the contacts carried by the reel. When the reel rotates, substantially continuous contact is made between the rotating contacts. However there are numerous, well documented disadvantages of cord reels having moving contacts. Moving contacts have a propensity to spark, making such reels unsuitable for use in wet environments, hazardous environments and in medical applications, among others.
To overcome these problems, a second type of retractable cord reel has been developed that eliminates contacts. The reel comprises a spool on which the extendable portion of cord is held, an expansion chamber in which a fixed length of cable is spirally wound. The two cable portions are connected, typically in or adjacent the hub of the spool. As the spool rotates the spirally wound, fixed cable expands and contracts within the expansion chamber. An example of reels of this type is disclosed in U.S. Pat. No. 5,094,396 to Burke, the disclosures of which are hereby incorporated by reference.
Regardless of the success of this second kind of cord reel, it would be advantageous to have a cord reel assembly without any need for connections, which can be the subject of defects in soldering, potting chambers or similar connection points. In order to ensure a more durable and more reliable system for connecting to and supporting electronics connected to cord reels, it is necessary to provide a cord configuration to enable the connection of a continuous cord to such devices.
To date, however, there are no available products that permit a continuous cord to provide a cord reel with retractable and stationary ends.
What is needed is a cord reel assembly having retractable and stationary ends which employ a single, continuous cord so as to eliminate electrical and/or mechanical interconnection points in connecting to electronic devices.
DEFINITION OF TERMS
The following terms are used in the claims of the patent as filed and are intended to have their broadest plain and ordinary meaning consistent with the requirements of the law.
A “sheath” refers to a plastic and or metallic protective layer (made with, for example PTFE) which surrounds the plurality of connectors but which is capable of permitting helical or twisting movement of the connectors relative thereto.
Where alternative meanings are possible, the broadest meaning is intended. All words used in the claims set forth below are intended to be used in the normal, customary usage of grammar and the English language.
OBJECTS AND SUMMARY OF THE DISCLOSURE
The apparatus and method of the present disclosure generally includes a cable (e.g. electrical, data or mechanical) that is connected to a cord reel housing that includes a spool within the housing and capable of rotating relative to the housing. The spool and housing define a single storage chamber for holding a cord, and a transition chamber. The cord contained within the storage chamber is a single cord, and the single cord further traverses the interior of the housing, and terminates in retractable and stationary ends external to the housing. The retractable portion of the housing includes a jacket or covering for enclosing any connectors within the cord and for enabling the retraction and extension of the cord while affording a degree of protection from wear.
On the stationary end of the cord, the connectors have the jacket stripped away from the connectors, but as the connectors extend away from the housing on the stationary end, they are protected by a sheath of durable material. The connectors, however, may twist relative to the sheath so that when the spool is rotated and the cord is extended, the connectors in the stationary end of the cord will compensate by moving from a generally untwisted to a twisted configuration, thus permitting the connectors comprising the cord to compensate for the tension created by the extension of the retractable end of the cord. Thus, the assembly supports a single continuous cord comprised of multiple connectors which allows for one side to retract and extend while keeping the other end stationary.
The immediate application of the present invention will be seen in the context of retractable electric cords for supplying power and/or data to connected electronics, though those of skill will see that the present invention could be applied to non-electrical cord applications where supply of data and/or power through the cord is not needed (e.g., in wireless hub configuration or strictly mechanical application).
Thus can be seen that one object of the present invention is to provide a cord reel assembly having a single cord with one stationary end and one retractable end.
A further object of the present invention of the present invention is to provide a cord reel assembly with a cord having a single chamber that does not require any soldering or potting to connect cord segments.
Still another object of the present invention is to provide a cord with contiguous segments that allows one segment to extend or retract, while keeping the length of extension of the other segment constant.
Yet another object of the present invention is to provide a cord reel assembly that eliminates the need for axially displace chambers for storage of separate cord segments.
It should be noted that not every embodiment of the claimed invention will accomplish each of the objects of the invention set forth above. In addition, further objects of the invention will become apparent based on the summary of the invention, the detailed description of preferred embodiments, and as illustrated in the accompanying drawings. Such objects, features, and advantages of the present invention will become more apparent in light of the following detailed description various embodiments thereof, and as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a first example embodiment of cord reel assembly with a stationary end having a sheath for cover the plurality of connectors comprising the stationary segment of the cord in accord with a preferred embodiment of the present invention.
FIG. 2 shows an exposed side view of the cord reel in accord with another embodiment of the present invention.
FIG. 3 shows the detail of the twisted and untwisted arrangement of the connectors comprising the stationary end of the cord in response to the extension and retraction of the retractable end of the cord in accord with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Set forth below is a description of what is currently believed to be the preferred embodiment or best examples of the invention claimed. Future and present alternatives and modifications to this preferred embodiment are contemplated. Any alternatives or modifications which make insubstantial changes in function, in purpose, in structure or in result are intended to be covered by the claims in this patent.
FIGS. 1 and 2 show an example cord reel assembly 10 in accord with a first preferred embodiment of the present invention. Specifically, the assembly a housing 12 having a single storage chamber 14 and a transition chamber 16 . Inside the housing is a spool 20 rotates relative to the housing to facilitate retraction and extension of a cord 30 . As shown in FIGS. 2 and 3 , the cord 30 is a single cord traversing the interior of the housing 20 and terminating in retractable 40 and stationary 50 segments which end external to the housing. The cord 30 in this embodiment is an electrical cord which can supply power and/or data therethrough, although persons of skill in the art will recognize that the present disclosure can apply to mechanical (i.e., not electrical) tethering cords, too.
The retractable segment 40 is a typical cord configuration known to those of skill in the art, i.e., a number of connectors ( 52 , 54 , 56 , 58 ) surrounded optionally by a nylon jacket 42 or similar protective cover to provide durability against normal wear and tear of the cord during extension and retraction.
By contrast, the stationary segment 50 of the cord 30 extends from the transition chamber without any jacket (jacket 42 having been stripped away or otherwise not provided to the stationary segment 50 ). The stationary segment, however, has the same connectors ( 52 , 54 , 56 , 58 ) which are surrounded by a sheath ( 60 ), preferably made of a comparatively rigid, durable material such as PTFE, the sheath 60 preferably extending along the entire exposed length of the stationary segment 50 of the cord 30 , the sheath 60 being anchored to the housing 12 and a plurality of connectors (e.g., 54 , 56 ) twisted about one another, the plurality of connectors being capable of twisting and untwisting along the length of the cord from the transition chamber up to the stationary end relative to the sheath to support extension and retraction of the retractable end of the cord 40 relative to the housing 12 . For instance, as shown in FIG. 3 , if the retractable end 40 of the cord 30 is extended, the stationary segment 50 compensates for the strain caused by such an extension by twisting and untwisting the connectors 52 , 54 , 56 , 58 . Since the connectors can twist relative to the sheath, such twisting does not create movement in the stationary end 50 of the housing.
The above description is not intended to limit the meaning of the words used in the following claims that define the invention. Rather, it is contemplated that future modifications in structure, function or result will exist that are not substantial changes and that all such insubstantial changes in what is claimed are intended to be covered by the claims. For instance, the specific relationship between the status of the retractable end of the cord (i.e., extended or retracted) and the status of the connectors on the stationary end (i.e., twisted or untwisted) can be switched. That is the twisting of the connector can occur for a given assembly while the retractable cord is extended, or when it is retracted.
Similarly, while the preferred embodiments of the present invention are focused upon use with a rigid PTFE sheath 60 , those of skill in the art will understand that the invention has equal applicability other coverings which permit movement of the stationary segment portion of the connectors relative to such coverings. In addition, the placement of the sheath and the extension of the connectors 52 , 54 , 56 , 58 does not have to be at the center of the housing 12 . Persons of skill in the art will appreciate that the extension of the stationary end 50 may be better extend elsewhere from the housing 12 so as to avoid undue strain on cord 30 . Likewise, it will be appreciated by those skilled in the art that various changes, additions, omissions, and modifications can be made to the illustrated embodiments without departing from the spirit of the present invention. All such modifications and changes are intended to be covered by the following claims. | A cord reel assembly including a single, continuous cord having stationary and retractable segments, with the stationary segment including multiple connectors and sheath covering such connectors where the connectors twist and untwist relative to the sheath in response to the retract and extension of the retractable segment. | 1 |
This is a divisional application of patent application Ser. No. 07/876,493, filed Apr. 30, 1992, now U.S. Pat. No. 5,331,829.
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for liquid deflection for liquid spray generators utilized n impressing marking materials (e.g., dyes, inks, paints, coatings) onto substrates (e.g., fabric) and, more particularly, to a mechanism for producing a plurality of aligned streams of atomized droplets to produce a dye pattern on a substrate. This apparatus includes several arrays of closely spaced streams of marking material that are normally directed into corresponding collection surfaces or receptacles. Each stream in a given array has associated with it a source of pressurized air or other control fluid which, on command, forms and directs an atomizing control fluid stream into contact with the marking material whereby the stream of marking material is transformed into a mist of variously sized diverging droplets that are propelled in the direction of the substrate to be marked. By interrupting the streams of atomizing fluid in oscillatory fashion, uniform reproduction of various solid color or multi-hued patterns is possible. By employing such controlled pulsations, the marking material sources, directing fluid sources, substrate, droplet size distribution and the degree of droplet dispersion can be carefully controlled, yielding intricate patterns possessing great subtlety, delicacy, and variety that may be produced with a high degree of reproducibility. By providing for the nonsimultaneous actuation of adjacent atomizing fluid streams along a given array, a wide variety of side to side or fill direction patterns may be produced.
One of the major problems with this type of technology is the inadvertent misdirection of liquid, e.g., dye, into the air orifice and associated air lines and onto the substrate and other parts of the apparatus. Dye can wick into the air orifice as it runs past. This occurs when the dye speed through the orifice is too low to maintain a stable dye stream. Low dye flow occurs at the start-up, shut down or whenever a dye orifice is partially plugged. Furthermore, dye can mist and form droplets and then drip onto the substrate to be treated.
The present invention solves these problems in a manner not disclosed in the known prior art.
SUMMARY OF THE INVENTION
This invention relates to a method and apparatus for liquid deflection for liquid spray generators utilized in impressing marking materials (e.g., dyes, inks, paints, coatings) onto substrates (e.g., fabric) and, more particularly, to a mechanism for producing a plurality of aligned streams of atomized droplets to produce a pattern on a substrate. A constant air supply is utilized with a liquid marking material line that is low enough to prevent diverting of the stable liquid stream but high enough to keep the air orifice free of liquid. Shields are also utilized to control mist collection on the printing hardware and the subsequent runoff so as to prevent the runoff from dripping onto the fabric.
It is an advantage of this invention to utilize air pressure to prevent dye from wicking into an air orifice as it runs past by constantly outputting air while not unintentionally affecting the primary liquid marking material stream.
Still another advantage of this invention is the utilization of a shielding to prevent marking material liquid from inadvertently forming into droplets and striking the substrate.
Another advantage of this invention is that the use of constant air flow to prevent liquid marking material clogging that eliminates the need for ancillary peripheral devices and merely modifies the current air flow system.
A further advantage of this invention is the use of shielding is a very inexpensive and effective means of obviating droplet formation developed from liquid marking material mist.
Yet another advantage of this invention is the controllable collection mechanism that directs mist away from the substrate and out of the print zone.
In another advantage of this invention is that air is used to keep marking material mist out of the electronic circuitry utilized with the valves by creating a slightly higher pressure in the electronic enclosure associated therewith.
Still another advantage of this invention is the shielding reduces the need for extensive cleaning of difficult to clean components of the present invention.
These and other advantages will be in part apparent and in part pointed out below.
BRIEF DESCRIPTION OF THE DRAWINGS
The above as well as other objects of the invention will become more apparent from the following detailed description of the preferred embodiments of the invention when taken together with the accompanying drawings, in which:
FIG. 1 schematically depicts an elevational view of an apparatus embodying the invention which may be used to prevent the inadvertent misdirection of patterning liquid, e.g., dye, into the air orifice and associated air lines, and onto the substrate and other parts of the apparatus;
FIG. 2 is a sectional view through two rows of single piece modules, utilizing an apparatus to prevent the inadvertent misdirection of patterning liquid;
FIG. 3 is a cross section of the embodiment of FIG. 2, which shows a constant air flow system, through the air orifice while not patterning with liquid and while the dye stream is unstable;
FIG. 3A shows a detail of FIG. 3 as indicated;
FIG. 4 is a cross section of the embodiment of FIG. 2 which shows a constant air flow system through the air orifice while patterning with liquid and with a stable dye stream;
FIG. 4A shows a detail of FIG. 4 as indicated;
FIG. 5 depicts an embodiment of FIG. 2 in a perspective view in partial section, as viewed from above;
FIG. 6 is a cross-section of the embodiment of FIG. 2 taken along lines 6--6 of FIG. 7; and
FIG. 7 is a cross-section of the embodiment of FIG. 5 taken along lines 7--7 of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring more specifically to the Figures, FIG. 1, shows diagrammatically, an overall side elevation-view of apparatus suitable for patterning a web of moving substrate and preventing the inadvertent dispersion of liquid in accordance with the teachings herein. The embodiments depicted and described below in connection with FIGS. 1, 2, 3, 3A, 4, 4A, 5, 6 and 7 use dye as the marking material and air as the control fluid. Although certain components are referred to with respect to air or dye, it is understood that those same components would be used for other control fluids and marking materials, respectively. While any substrate material capable of being dyed or otherwise patterned by the procedures set forth below may be used, a preferred material is a textile substrate such as fabric or carpet in web form. Substrate 10 is supplied from any suitable source, and is drawn over idler rolls 12, 14 and under valve house 200 to idler roll 16, which rotates in bearings associated with platform 26. Substrate 10 is then directed into the interior of rolling frame 20, which is supported on wheels 22 and which may be moved along track 24 to adjust the distance between rolling frame 20 and valve house 200 and, correspondingly, between an array 100 of spray generators for marking material and the face of the substrate 10. This permits the effects of changing the spacing between the array 100 of spray generators and the face of the substrate 10 to be easily and immediately observed. The rolling frame 20 is manually moved by the handcrank 47.
Substrate 10 is directed around guide rolls 43, 44, and 45, respectively that are a part of an Erhardt & Liemer GmbH® fabric guider and position sensor 99 manufactured in West Germany and then around idler rolls 40, 42 and scroll roll 51 and through idling nip roll 46 and driven nip roll 48. Idling nip roll 46 is attached to triangular member 55. Triangular member 55 is pivotally attached to rolling frame 20 by means of pin 57. Idling nip roll 46 can disengage driven nip roll 48 by means of a pneumatic cylinder 53 that is attached to the rolling frame 20 at one end and the triangular member 55 at the other.
The substrate 10 is then presented, in a preferred embodiment, in a substantially vertical orientation to the array 100 of spray generators mounted on the face of the valve house 200 that encloses air control valves 140. As shown in FIG. 1, in the preferred embodiment, the substrate 10 may be separated from the appropriate backing member 50, which may be comprised if plastic or other dye-impervious material, by spacers 52, 54 positioned along the top and bottom edges of backing member 50 above and below the level of the array 100, and by intermediate spacers 56 located between spacers 52 and 54, thereby assuring no contact between the back of substrate 10 and the backing member 50. This prevents unwanted smearing on the back of the substrate 10 such as fabric and prevents excessive saturation or accumulation of dye visible on the face of the substrate 10. In a particular preferred embodiment, lower spacer 52 may be in the form of a trough-like collector which can serve to collect the sprayed liquid which may pass through substrate 10 and collect on backing member 50 or which may spray beyond the substrate edges and collect on backing member 50.
Substrate 10 is then directed over tension-generating rolls 60 and 62. Both tension generating rolls 60, 62 may have their surfaces covered with rubber or the like and may be overdriven, to assure that substrate 10 is relatively taut in the region opposite array 100. As shown, substrate 10 may then be guided by a fabric deflector 65 over idler roll 66 to an appropriate dye fixation means 30 or other post treatment processor.
FIG. 2 illustrates a preferred embodiment of the array of spray generators of the type depicted by numeral 100 in FIG. 1. There is a single piece module 110 that has air supply passages 133 bored therethrough as shown in FIGS. 3, 3A, 4, 4A, 6 and 7. Air supply passages 133 have air exit orifices 123 at one end and air fittings 134 at the other end, for connecting to air conduits or hoses 152, as shown in FIGS. 3, 3A, 4 and 4A. The air fitting 134 is preferably a stainless steel tube of a slightly larger diameter than the air conduit 152 inside diameter for a fluid tight interconnection. The air fitting 134 is seated into module 110 such that its inside diameter is the same as the air passage diameter 133. This requires a counter bore in the module 110 equal to the air fitting 134 outside diameter to seat the fitting. The air fitting 134 is glued into this counterbore and the module 110 is peened to hold the air fitting 134 in the module 110 and to create an air tight seal. The air conduits 152 are in fluid communication with the air supply passages 133 formed in module 110. The other ends of air conduits 152 are connected to fittings 164 in front wall 64 which, via additional suitable conduits, are ultimately connected to air control valves 140, as can best be shown in FIG. 2. Air control valve 140, controls the air delivered from air manifold source 143.
As can best be seen in FIG. 7, the air exit orifices 123 of air supply passages 133 are arranged to provide jets of air under pressure that intersect the dye stream 106 and break the dye stream 106 into a dye spray 108 and direct the dye spray 108 onto the moving substrate 10. Air control valve 140 controls the delivery of air, through air conduits 152 according to a preselected pattern. Bursts of air according to the pattern cause the dye spray 108 to impact on the substrate 10 and form the desired pattern. The dye forming the dye stream 106 is supplied by a dye supply manifold 142 via external dye conduit 150 to dye supply fittings 118 for fluid connection into the single piece module 110 as shown in FIG. 2. As can be seen in FIGS. 3 through 7, a trough 116, extending generally longitudinally almost the entire length of module 110, has a depth sufficient to hold and supply dye for spraying. Trough 116 has an open portion extending the entire length and width of the trough. Dye supply conduits 117 (diameter 0.159 inches) extend from the back surface of trough 116 and are fitted with dye supply fittings 118 for fluid communication with the rear wall 111 of the module 110. Threaded fitting 118 provides a means for connecting dye conduits 117 to external dye conduits 150, which in turn are connected to the dye supply manifold 142, as shown in FIGS. 2 and 7. As can best be seen in FIGS. 3, 3A, 4, 4A and 5, upper planar surface 112 of single piece module 110 has dye grooves 119 which extend from trough 116 to the dye orifices 120 on the front surface 113 of single piece module 110, forming a path for dye flow from trough 116 to dye orifice 120. Dye grooves 119 are longitudinally spaced along single piece module 110 at intervals of about 0.200 inch, with each groove 119 having the same predetermined uniform cross-sectional area, in the preferred embodiment.
As shown in FIG. 6, dye bypass conduits 146 (each preferably having a diameter of 0.062 inch) extend from the trough 116 to the bottom surface 131 of the single piece module 110 originating from the trough 116 bottom, and is fitted with a dye return fitting 147 for connection to a dye return system 148 through dye return conduit 127, as shown in FIGS. 2, 3 and 4. As shown in FIGS. 3A and 4A, air exit orifices 123 are preferably longitudinally spaced along single piece module 110 at intervals of about 0.200 inch, with each air exit orifice 123 being paired with a corresponding dye groove 119 with both the groove 119 and the air orifice 123 lying in the same vertical plane. Each air orifice 123 is preferably drilled and reamed to a constant radius of curvature throughout its length of about 0.011 inches. Each air orifice 123 is in communication with air supply channel 133. Fitting 134 joins air line 152 to air supply passage 133. As can be seen in FIGS. 3A and 4A, the planar front surfaces 113 and 125 of single piece module 110 preferably have air orifices 123 and dye orifices 120 separated by approximately 0.10 inches.
As shown in FIG. 5, the upper cover plate 129 is preferably a block of stainless steel, however any corrosion resistent metal, plastic, composite, and so forth will suffice. Upper cover plate 129 has a planar upper, lower, front, back and side surfaces as designated by numerals 129a, 129b, 129c, 129d and 129e, respectively. Mounting surface 135 is a planar front surface as shown in FIG. 5 and FIG. 7. A series of clamps 161 are arranged which interact with mounting surface 135. The module 110 is assembled by placing lower surface 129b of upper cover plate 129 on upper planar surface 112 of single piece module 110 such that the side surfaces 129e of the upper cover plate are flush with the side surfaces of single piece module 110 and such that the front surface 129c of the upper cover plate 129 is flush with front surface 113. Threaded bolt and washer assembly 138 are then placed through the clearance holes 130 in the clamps 161 and are threaded into the upper fastening holes 121. Mounting holes 137 (having clearance diameter 0.281 inch), extend through rear wall 111 of single piece module 110. Mounting clearance holes 137 are spaced to align with appropriately threaded holes associated with mounting fixtures on the apparatus in which the module 110 is used. Bolts 138 are tightened to cause clamps 161 to produce a liquid tight seal between the upper cover plate 129 and the upper surface 112 of single piece module 110, as shown in FIGS. 5 and 7. As an aid in creating a liquid tight seal the lower surface 129b of upper cover plate 129 is plated with a softer metal, typically gold or lead. Other materials could conceivably be used and parts of the upper planar surface 112 are sometimes plated with gold or lead.
Once assembled, single piece module 110 provides an array of dye conduits and air conduits for delivering dye and air through the module. The lower surface of upper cover plate 129 encloses dye grooves 119 to form covered dye conduits extending from trough 116 to dye orifice 120. A diverting lip or blade 162 is located between module 110 and moving substrate 10, in the path defined by dye grooves 119 (see FIGS. 3, 4, and 7). As best shown in FIG. 2, the dye or other marking material is delivered under pressure from dye supply manifold 142 is directed as a dye stream 106 toward diverting lip or blade 162. A catch trough 154 in communication with dye basin 160 is arranged in communication with the blade 162 to receive the liquid dye diverted by the blade 162 thereto. The dye collected in dye basin 160 is diverted through pipe reservoir 156 for reuse. The catch trough 154, dye basin 160 and pipe reservoir 156 constitute the previously referenced dye return system 148.
The assembled module 110 is used to spray patterns on a substrate. The module 110 is attached to a spraying machine that provides a pressurized dye source, a pressurized air source and means for selectively controlling the flow of air. The pressurized dye source, via manifold 142 and external dye conduit, is connected to dye supply fittings 118. Dye can then flow in a continuous path from the dye source, into trough 116, through the dye conduits formed by dye grooves 119 and out through dye orifices 120 and through the bypass conduits 146 into the dye return conduit system 148. The pressurized air source is connected to air supply fittings 134. When air flow is desired, air can flow in a continuous path from the air source 143, via fittings 164, air lines 152, fittings 134, air supply channels 133 and out through air exit orifices 123.
The operation of a spraying apparatus employing a module of the present invention can be described by considering the operation of a single air conduit/dye conduit pair and with reference to FIGS. 3, 3A, 4, 4A and 7. An air control valve 140 associated with the pressurized air source 143 prevents air from flowing through air conduit 191 to air supply fitting 134. Dye is continuously supplied by pressurized dye source 142 to dye supply fitting 118 and flows out dye orifice 120. The dye stream emanating from dye orifice 120 flows unimpeded into the surface of diverting lip or blade 162, which collects the dye in catch trough 154 for disposal or recirculation to dye basin 160 and then to the pipe reservoir 156 as part of the dye return system 148.
When dye from the dye stream is to be applied to the substrate 10, pulses of air generated by the opening and closing of the air control valve 140 are supplied from the pressurized air source 143 to air supply fitting 134. The air stream emanating from air exit orifice 123 impinges the dye stream, disrupting the regular flow of dye. As shown in the detail of FIG. 4A, the dye orifice 120 and air orifice 123 are positioned such that the dye is contacted with air after it exits from the dye orifice 120. As a result of the interaction of the higher pressure air stream (e.g., 20-40 p.s.i.g.) with the lower pressure dye stream (e.g., 2-4 p.s.i.g.) the dye stream is broken up into a spray of diverging droplets 108. The combined momentum of the two streams then carries the droplets to the surface of the substrate 10. Because the dye exits the dye orifice 120 outside of the airstream envelope 155, aspiration of dye from the dye supply conduit is eliminated, thereby eliminating the need to create uniform aspiration across the width of the module 110 as shown in FIG. 4A. To achieve the desired dying pattern, air control valves 140 for each conduit pair can be selectively opened and closed separately or in combinations according to pattern information supplied by controller 141, as shown in FIG. 2.
Two general dye flow streams exist in trough 116, as shown in FIG. 5 and 6. One stream (the supply stream) flows from the exit of each dye supply conduit 117 to the entrance of each dye conduit formed by dye groove 119. The second flow stream (the bypass steam) flows from the exit of each dye supply conduit 117 to the entrance of each dye bypass conduit 146. In the undesirable event that a solid contaminant lodges itself at the entrance to a dye conduit formed by dye groove 119, thus restricting dye flow through that dye conduit, it can easily be pushed away from the dye conduit entrance and out of the supply stream and into the bypass stream by inserting a properly sized wire into the conduit from the orifice 120. The solid contaminant would then exit the trough 116 by way of bypass conduit 146, through the dye return fittings 147 and into the dye return system 148 where it will be removed through filtration.
Additional information relating to the operation of such a spraying apparatus, including more detailed description of patterning and control functions, can be found in coassigned. U.S. Pat. No. 4,923,743, which is incorporated by reference as if fully set forth herein.
Variations in dye delivery onto a substrate using the module of the present invention (as shown in FIGS. 1 through 4A) and an array of separately manufactured and assembled components, as previously described and disclosed in coassigned U.S. Pat. No. 4,923,743, were compared. The maximum misalignment of the dye and air orifices in the latter apparatus was found to be 0.007 inch. The dye orifices in that apparatus were spaced 0.400 inch from each other and during dyeing the substrate was located 3-8 inches from the dye orifice. The relative angle between the air and dye streams is 26 degrees. Because of misdirectivity in the dye flow this angle varied from 22.5 to 29.5 degrees. This difference in relative angle varies the length of the dye stream in the diverging air stream. More specifically, the dye path length is 0.37 inches and 0.68 inches for the angles of 29.5 degrees and 22.5 degrees respectively. The length of dye stream in the air stream is atomized and deposited on the substrate. Because of the varying lengths of the dye stream in the air stream, a varying amount of dye is atomized and deposited on the substrate. This creates a visually obvious streak in the dye pattern.
In contrast, single piece module 110 has a relative angle between the air and dye stream in the range of 25.5-26.5 degrees. The dye stream lengths in the air stream are 0.458 inches and 0.499 inches for angles of 25.5 degrees and 26.5 degrees, respectively. Additionally, the maximum misalignment of the dye and air orifices is 0.001 inches. The preceding material represents the preferred parameters, while significant deviations therefrom are functionally possible.
Due to the minimal amount of dye stream length variation and misalignment, the present invention provides means for producing very precise and uniform spray pattern applications. The single piece module 110 is also non-adjustable and tamper proof, thereby providing an added advantage for extended commercial production. The efficiency of dye deposition on the substrate is also improved by the configuration of the present invention, wherein the dye orifice 120 is not in the air stream. As shown in FIG. 4, the dye orifice 120 is positioned substantially outside the air stream envelope 155. This configuration maximizes the dye stream length that is positioned within the air stream envelope 155, and thereby atomized and carried by the air stream in the form of dye spray 108 to the substrate 10.
One problem with this system, as shown in FIGS. 2, 3, 3A, 4, and 4A, is that dye or other liquid marking material can wick into the air orifice 123 when the dye dabbles down the face of the module 10. This occurs only when the dye speed through the dye orifice 123 is too slow to maintain a stable dye stream 106. Low dye flow occurs at start-up, shut-down or whenever the dye orifice 123 is partially plugged. Stable, high speed, dye flow is shown in FIGS. 4, 4A and 7. As shown in FIGS. 2, 3, and 4, there is a constant air flow manifold 177 that preferably provides constant air flow of 24 p.s.i.g. when the air control valve 140 is closed thereby cutting off the air manifold source 143 from the single piece module 110 via air conduit 191, as shown in FIG. 3. When there is air pressure in the air manifold source 143, then there will be air pressure in the constant air flow manifold 177. This constantly flowing air exits the constant air flow manifold 177 by means of exit tubes 178. There are four hundred (400) exit tubes 178 on each constant air flow manifold 177 in the preferred embodiment. At the end of each exit tube 178 is a tee-connection 180 that has a precision orifice restrictor 181, as shown in FIGS. 3 and 4. The precision orifice restrictor 181 has a 0.0063 inch diameter for two gunbars and a 0.0067 inch diameter for the remaining three gunbars in the preferred embodiment. The tee-connection 180 is attached to the air conduit 152 between the air control valve 140 and the single piece module 110. The precision orifice restrictors serve two functions. The first function is to restrict the air flow out of the air orifice 123 to the point where the stream of air is low enough not to affect the dye stream 106, but high enough to prevent dye from entering the air orifice 123 in the single piece module 110, as shown in FIGS. 4 and 7. If the air pressure is too high, it will divert the dye stream 106 over the top of the diverting lip or blade 162 and onto the substrate 10. Even a partial diversion of the dye stream must be avoided. This is shown in FIG. 4, in which the air flow from the air manifold source primarily exits through air control valve 140 to the air orifice 123, while a secondary air flow goes through the constant air flow manifold 177 at 24 p.s.i.g. and through the tee-connection 180 into air conduit 152 to join the primary air flow and also exit out of air orifice 123. It is important to have a higher air pressure in the exit tubes 178 than in the air conduit 152 in order to prevent air from flowing back into the tee-connection 180 and into the constant air flow manifold 177 and wasting air during the printing burst. The air control valve 140 only opens to deliver a burst of air to the single piece module 110 when printing. As shown in FIGS. 3 and 4, there is a flow tube 190 that connects the air manifold source 143 to the constant flow manifold 177. There is a flow tube 191 that connects the air manifold source 143 to the air control valve 140. The other side of the air control valve 140 is connected to air conduit 152 upon which precision orifice restrictor 181 is tee-connected thereto.
Referring now to FIG. 3, the operation of this system when the air control valve 140 is closed is that air exits the air manifold source 143 and passes through the flow tube 190 into the constant air flow manifold 177 and sends air into the precision orifice restrictor 181 that is part of the tee-connection 180. From the tee-connection the air flows in two directions. The first direction is back to the closed air control valve 140 which releases air into the valve house 200 via exhaust ports 145 communicating with the air control valves 140, as shown in FIG. 2. This release of air into the valve house 200 provides a benefit by surrounding the valves and associated electronic circuitry with clean filtered air that prevents dye laden air or other contaminants from entering the valve house 200 and causing the electrical and electronic circuitry to malfunction. The second direction is through air conduit 152 into single piece module 110 and out through air orifice 123. When the air pressure in the manifold source 143 is 35 p.s.i.g. the corresponding air pressure in the constant air flow manifold 177 is 24 p.s.i.g. When sixty (60) single piece modules 110 are utilized under this condition, seventy six and one-half (76.5) standard cubic feet per minute (scfm) of air is delivered through the exit tubes 178 to the tee-connections 180. Twenty-six percent (26%) of this air (19.9 scfm) passes through the single piece module 110 and out the air orifice 123. The remaining seventy-four percent (74%) (56.6 scfm) flows through the air control valve 140 to distribute air throughout the valve house 200. These standard cubic feet per minute flow values are based on an operating pressure in the air manifold source of 35 p.s.i.g., which is only the preferred value. Other operating pressures will create different flows. When the control valve 143 is closed, then no air will flow through flow tube 191.
Referring now to FIG. 4, the operation of this system when the air control valve 140 is open is that air exits the air source 143 in two directions. The first direction is through the flow tube 190 into the constant air flow manifold 177 and into the precision orifice restrictor 181 that is part of the tee-connection 180 for directing the air through air conduit 152 into single piece module 110 and out of air orifice 123. The second direction of air travel is into flow tube 191 through open air control valve 140 into air conduit 152 that intersects tee-connection 180 and then into single piece module 110 and out of air orifice 123. It is readily apparent the air flow in both directions merge at the tee-connection 180 for combined flow into the single piece module 110 with most of the air flow passing through the air control valve 140.
The vertical stacking of rows of single piece modules 110 that make up an array of spray generators 100 creates a problem of dye mist forming droplets contaminating the substrate 10 or other parts of the array 100. A solution to this problem is the utilization of drip shields to provide protection. As shown in FIG. 2, there is a top shield 170 that acts as a roof and keeps dirty contaminated dye from dripping onto that row of single piece modules 110 and the dye supply manifold 142 and into the dye return system 148. There are three representations of top shield 170 present in FIG. 2, with one for every row of twelve single piece modules 110 present in the array 100. There are five rows of twelve single piece modules that make up the array 100. Dye collects in the trough 173 for top shield 170 and flows out each end beyond the edges of the fabric and array 100 thereby avoiding any contamination of the fabric or the single piece modules 110 located directly below or the dye return system 148 located directly below. There is a middle shield 171 extending between an ell-shaped support member 195, upon which the dye supply manifold 142 is attached, and a row of twelve single piece modules 110 is attached. Middle shield 171 has an upper trough 185 that collects dye that runs off the top shield 170 and a lower trough 186 that collects dye that runs off the flat sloped portion 168 of middle shield 171. Both upper trough 185 and lower trough 186 drain out both ends beyond the row of single piece modules 110 in array 100 and beyond the edges of the substrate 10 and draining into the dye return system 148, thereby avoiding any contamination of the substrate 10. Bottom shield 172 is mounted to and follows the contours of the second diverting lip or blade 163 that is attached to the catch trough 154. This bottom shield 172 deflects dye away from the substrate 10 so that it can drip onto the top shield 170 of the next lower row of single piece modules 110. It is located between the second diverting lip or blade 163 and associated catch trough 154 and the substrate 10. In summary, these drip shields 170, 171 and 172 allow the mist to collect and form into larger drops that eventually run to the lowest point on the shield. Furthermore, the drip shields 170, 171 and 172 are shaped and positioned such that the running dye drops adhere to the shields until they reach the lowest point and at the lowest point the dye either fills any of the three troughs and flows harmlessly out the print zone, i.e., beyond the edges of the row of single piece modules 110, where they then drip onto the floor or into the pipe reservoir 156 for recirculation or the dye drips to the next lower row of single piece module's 110 top shield 170 at a distance from the substrate 10 that prevents the resulting splatter from reaching the substrate 10.
From the foregoing, it will be apparent to those skilled in the art that various modifications in the above described devices can be made without departing from the spirit and scope of the invention. Accordingly the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Present embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | This invention relates to a method and apparatus for liquid deflection for liquid spray generators utilized in impressing marking materials (e.g., dyes, inks, paints, coatings) onto substrates (e.g., fabric) and, more particularly, to a mechanism for producing a plurality of aligned streams of atomized droplets to produce a pattern on a substrate. A constant air supply is utilized with a liquid marking material line which is low enough to prevent diverting of the stable liquid stream but high enough to keep the air orifice free of liquid. Shields are also utilized to prevent the liquid mist accumulation from accidently getting on the substrate to be treated. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to an insole designed for supporting a foot after the insole is inserted into a shoe so as to abut a sole section of said shoe, where the insole comprises an integral plastic material forming a flexible planar base layer out of which numerous resilient studs arise. In addition, the present invention furthermore relates to a shoe comprising a removable insole of the described type.
BACKGROUND
[0002] Removable insoles for shoes are well-known. They consist of different material and are in many cases pre-shaped by thermoforming (e.g. EVA (ethyl vinyl acetate) foam) or forming in a closed mold (e.g. PU (polyurethane) foam). They form a footbed within the shoe the sole section of which may or may not sufficiently be shaped so as to form a footbed. Insoles of this type have a defined three-dimensional shaping so that many types have to be fabricated in order to fit customer's needs. Insoles of this type may extend over the whole length of the foot or may be designed to support only a part of the foot, e. g. the heel portion or a forefoot portion.
[0003] There are known insoles provided with a great number of resilient studs arising out of a flexible planar base layer so that the essential parts of the insole consist of an integral plastic material manufactured by injection molding. An example of an insole of this kind is described by US 2010/0175275 A1, the complete contents of which is herein incorporated by reference. The numerous resilient studs serve for providing a massaging and reflexology system by contacting the sole of the foot of a person by means of the top portions of the studs. Simultaneously, a shock absorption is achieved by means of the resilient studs. The top surface of the insole formed by the top portions of the studs may be contoured to generally match the contour of a human foot such that the massaging and reflexology system is maintained in substantially continuous contact with at least a portion of the bottom of user's foot. In this manner the interactive effects of massaging, shock absorption, muscle stimulation and blood circulation may be better administered to the wearer or user's foot. These types of insoles are usable only for users desiring a massaging or reflexology effect and who are prepared to tolerate the intensive punctual contacts between the insole and the sole of the foot which punctiform contact provides intensive stimuli to the foot which may be sensed as less comfortable, especially when the studs have a high hardness. U.S. 2010/0175275 Al discloses top portions of the studs which are cup-shaped thereby enlarging the contact area between the insole and the user's foot.
[0004] GB 2 418 129 A, the complete contents of which are herein incorporated by reference, discloses an impact absorbing insole having an upper layer of a woven fabric surface which provides the surface of contact for the user's foot. The lower layer comprises a cell membrane structure where the cells all have the same size and contain a chemically inert gel or fluid of sufficient viscosity to provide a cushioned effect when compressed. Which such a construction a shaping of the insole for forming a footbed must be made at the top layer in the above-mentioned conventional way.
SUMMARY
[0005] It is an object of the present invention to provide an insole of the above-mentioned kind which may be produced in an easy manner and provides a kind of footbed and a comfortable feeling.
[0006] According to the present invention, the insole is designed (configured) for supporting a foot after the insole is inserted in a shoe so as to abut a sole section of the shoe. The insole includes an integral plastic material forming a flexible planar base layer out of which numerous resilient studs arise. The planar base layer is designed to contact the surface of the foot. The studs are designed to extend from the base layer to the sole section of the shoe. The studs are shaped of different heights so that upon weight-loading by the foot the flexible planar base layer is deformed so as to conform with the shape of the underside of the foot as a three-dimensionally shaped footbed.
[0007] According to the present invention the studs are not used for massaging and reflexology, but instead for easily forming a footbed for the user's foot upon weight-loading. For this purpose the studs are made of different heights so that without weight-loading the insole contacts the sole section of the shoe only with some of the studs which have a relatively large height. In this state, the planar base layer remains planar. Upon weight-loading, the studs of smaller height are pressed against the sole section of the shoe so that the base layer is deformed to allow the smaller studs to contact the sole section of the shoe. The distribution of height of the studs is chosen such that by the deformation of the base layer a suitable footbed is formed by the base layer which serves as a contact surface for the foot. It should be noted that the base layer need not have a direct contact to the foot but may be covered with a flexible cover layer such as a textile, leather or other material which preferably has skin-friendly properties. The cover layer, however, does not substantially influence the deformation of the planar base layer which deformation is determined by the distribution and heights of the studs at the underside of the insole. Therefore, the base layer can be manufactured as a planar layer and nevertheless, form a footbed when the weight of the user is loaded onto the insole. Due to the studs at the underside, the insole may be manufactured with less material compared with an insole made of the same material and shaped to form a footbed of a conventional type. Due to the studs there is a plurality of interspaces between the studs for which no material is needed. In addition, the studs have elastic properties and produce a progressive spring characteristic since upon increasing weight loading more and more studs contact the sole section of the shoe thereby contributing to the overall spring strength of the insole. Due to the studs, the insole of the present invention may be produced with about 60% of the material, and thus of the weight, needed for an insole forming a footbed from the same fully shaped material. Due to the studs the insole according to the present invention has the capacity of adapting the deformation to the individual foot upon weight loading.
[0008] The studs may be distributed over the whole length of the insole. For some purposes it may be preferred to provide studs at the underside of the insole only over a part of the length of the insole, e. g. to provide only a heel portion, a heel and plantar arch portion and/or a toe portion with studs allowing the deformation of the base layer so as to form a footbed. For some purposes it may be preferred that the insole according the present invention extends only over a part of the length of the foot so as to support only a part of the foot length, such as the heel portion, the heel and plantar arch portion and/or the toe portion.
[0009] In a preferred embodiment of the present invention the hardness of the material from which the base layer and the studs are formed may lie between 30 and 50 Shore 00, more preferred between 33 and 45 Shore 00 and even more preferred between 35 and 40 Shore 00. The material, therefore, may be a comparably soft material differing in hardness from the material used for studs for massaging and reflexology where the hardness lies between 80 and 100 Shore 00 and even for a soft massaging sandal above 50 Shore 00.
[0010] In a preferred embodiment the insole extends over the whole length of the foot and there are studs of small height in the middle of a heel portion and of a toe portion of the insole and studs of greater heights are provided at the edge of the heel portion as well as in an intermediate portion between the heel portion and the toe portion. The intermediate portion will preferably be an instep portion of the insole.
[0011] For the sake of easy manufacturing the studs are preferably massive studs, i.e. without a hollow portion.
[0012] The studs are preferably designed for widening their diameter when being compressed under weight-load. The reduction of height due to the elastic weight-loading may, therefore, result in a corresponding widening of the diameter so that the studs extend into intermediate spaces between the studs.
[0013] In a preferred embodiment of the invention, a number of ventilation holes are positioned within the base layer in interspaces between the studs. The widening of the studs under weight-load reduces the interspace between the studs so that air may be pressed through the ventilation holes from the underside of the sole onto the lower surface of the foot exerting the weight-loading onto the insole.
[0014] A preferred material for the insole is a gel, especially a polyurethane gel. In a preferred embodiment the polyurethane gel may have a specific weight between 0.6 and 1.1 g/cm 3 . A suitable gel may be sticky so that in a preferred embodiment the gel is covered by a film of a non-adhesive material which again may be a polyurethane being, however, selected so as to be non-adhesive and non-sticky.
DESCRIPTION OF THE DRAWINGS
[0015] The invention will be described in more detail with reference to the accompanying drawing in which
[0016] FIG. 1 is a perspective view of the underside of a first embodiment of an insole;
[0017] FIG. 2 is a side view of the insole of FIG. 1 ;
[0018] FIG. 3 is a view from below the insole of FIG. 1 showing an exemplary distribution of the studs;
[0019] FIG. 4 is a perspective view of the underside of a second embodiment of an insole;
[0020] FIG. 5 is a view from below the insole of FIG. 4 ;
[0021] FIG. 6 is a schematic diagram showing the deformation of the studs when loaded with body weight;
[0022] FIG. 7 is a similar diagram to FIG. 6 highlighting a ventilation effect through ventilation holes;
[0023] FIG. 8 is a perspective view of the underside of an embodiment of an insole having studs only in a heel section;
[0024] FIG. 9 is a perspective view of the underside of an embodiment of an insole having studs only in the heel and plantar arch section;
[0025] FIG. 10 is a perspective view of the underside of an insole extending only over the heel section of a foot length.
DETAILED DESCRIPTION
[0026] The embodiment of FIGS. 1 to 3 is an integral insole from a plastic material having or consisting of a thin planar base layer 1 and a plurality of studs 2 on the underside of the base layer 1 . The upper side of the base layer is manufactured as a flat surface 3 serving as a contact surface to a user's foot. For this purpose the integral insole made from plastic material according to FIGS. 1 to 3 may be provided with a cover layer on the upper side of the flat surface 3 .
[0027] Furthermore, the material of the insole forming the base layer 1 and the studs 2 may be encased by a film of a similar material as the base layer 1 and the studs 2 but modified so as to be non-sticky or non-adhesive. It is understood that a cover layer for the flat surface 3 may be applied on the encasing film of base layer 1 and studs 2 when such an encasing film is used.
[0028] The insole can be produced by casting the material in liquid form into a casting mold having deeper cavities in the form of the studs 2 and in between a small flat cavity for the base layer. The cavities may be lined with the non-sticky film in a well-known manner, e.g., by applying vacuum to a film, by coating, or by applying a release agent. Then, the liquid material is cast and allowed to pour in the mold. After pouring, the mold may be covered with the cover layer which may be for example a textile, leather or microfiber material which thereby is fixedly adhered to the material of the insole during the curing of the material in the mold and serves as a contact surface.
[0029] As illustrated in the drawings the studs 2 at the underside of the base layer 1 have different heights. They may have a cylindrical shape with a rounded tip. The cross-section of the cylindrical shape is circular. The diameter of the studs within the cylindrical portion corresponds essentially to the height of the respective studs. It can be seen that there are higher studs 2 a at the edge of a heel portion 4 of the insole. The studs 2 a at the edge are higher and have a greater diameter than studs 2 b in the middle of the heel portion 4 .
[0030] At the other end of the insole, namely in a toe portion 5 , studs 2 c can be even smaller than the studs 2 b in the middle of the heel portion. Between the toe portion 5 and the heel portion 4 there is an intermediate portion 6 showing higher studs 2 d which in an arch plantar portion of the insole can be even higher than the studs 2 a at the edge of the heel portion. The studs 2 d at the lateral edge of the intermediate portion 6 may be about the same size as the studs 2 a at the edge of the heel portion 4 . The intermediate portion 6 establishes an instep portion of the insole being designed to (configured to) contact the instep portion of the user's foot.
[0031] As FIGS. 1 and 2 illustrate, the insole as manufactured will contact a support layer, like the sole section of a shoe into which the insole may have been inserted, only with the tips of the relatively highest studs 2 . In this state the base layer 1 remains flat and planar. The studs are directed to the support surface like the sole section of a shoe. If the user exerts weight-load on the insole, the insole will contact the sole section of the shoe with more of or generally all of the studs of different heights. Thereby, the base layer 1 will be deformed in accordance with the distribution of the studs 2 of different heights. The distribution of the studs 2 is selected so that the base layer is deformed to a footbed shape bedding the user's foot in a comfortable way.
[0032] In the embodiment, the insole only contacts the support surface, namely the sole section of a shoe, through the studs 2 so that there is no direct contact of portions of the base layer to the sole section of the shoe.
[0033] FIG. 3 illustrates an exemplary distribution of studs 2 over the whole surface of the underside of the base layer 1 . Since the heights of the studs 2 are essentially equal their diameter in the embodiment, it can be seen even from FIG. 3 where the studs of higher height are positioned.
[0034] It should be noted that the embodiment according to which the height equals the diameter of the studs 2 may be varied, for example, in the toe portion 5 , where the diameter can be different and may equal twice the height of the studs since the studs can be made very low in the toe portion 5 .
[0035] The second embodiment of FIGS. 4 and 5 shows an insole produced according to the same principle, however fitted with a somewhat thicker base layer 1 which still does not exceed 3 mm and from which the studs 2 arise. Again the heights of the studs 2 are distributed so as to form a footbed when the insole is loaded with the user's body weight.
[0036] FIG. 6 depicts the influence of the body weight transmitted by the user's foot 7 . There are shown the base layer 1 with the contour of studs 2 in the state as manufactured, i. e. without weight-load. There is a large interspace 8 between the studs 2 . When the weight pressure is exerted as indicated by arrows in FIG. 6 the studs will be compressed against the sole portion of a shoe and thereby be deformed as indicated at 2 ′. Thereby, the interspaces 8 ′ are heavily reduced in size. Simultaneously the contact surface 3 ′ of the base layer 1 being in pressure contact with the sole portion of foot 7 will adapt a contour corresponding to the contour of the sole portion of the foot 7 by different compression rates of the studs 2 ′.
[0037] In the embodiment of FIG. 7 the base layer 1 is provided with ventilation holes 9 which are through-holes connecting the interspace 8 between the studs 2 with the flat surface 3 of the base layer, i. e. with the underside of foot 7 when the insole is loaded by the weight pressure through the foot 7 . Upon the weight-loading the same deformation of the studs 2 into studs 2 ′ as illustrated in FIG. 6 occur. The diminished interspace 8 ′ between the studs 2 ′ squeezes out air from the interspace 8 ′ through the ventilation holes 9 ′ so that the sole portion of the foot 7 is ventilated upon each weight-loading of the insole during walking, running or standing.
[0038] Due to the large number of studs 2 there is a considerable squeezing out of air through the ventilation holes 9 . The effect can be enhanced by providing a seal edge at the outer contour of the insole whereby the interspaces 8 between the studs 2 as a hole are sealed against the ambiance so that a lateral squeezing out of air from the weight-loaded insole is prevented and the air is forced through the ventilation holes 9 . The sealing edge can have the form of a small lip so that it has no considerable influence on the resilient deformation of the studs 2 upon weight-loading.
[0039] The insole of the present invention can be manufactured with a planar flat base layer 1 which is deformed upon applying weight pressure so as to adapt to the shape of the foot 7 exerting the weight pressure and thus forming a kind of footbed.
[0040] FIG. 8 shows a modification of the insole which is similar to the insole of FIG. 1 in the heel portion 4 so that studs 2 at the underside provide a shaping of a footbed upon weight loading as described above. However, the other parts or sections of the insole which is designed to extend over the whole foot length are without studs 2 so there is a support with studs 2 only at the heel region whereas the insole consists only of the base layer 1 in the other portions.
[0041] A further modification of the insole which is similar to the embodiment of FIG. 1 is shown in FIG. 9 . The insole has studs 2 at the underside in the heel portion 4 and the intermediate portion 6 including the arch plantar portion. The distribution of the studs with different heights may be the same as described for the previous embodiments. Again the insole is designed to extend over the whole length of the foot but has studs 2 only in the heel portion 4 and the intermediate portion 6 and, e.g., not in the forefoot portion including the toe portion 5 .
[0042] It should be noted that all embodiments of FIGS. 1 to 9 show insoles with base layers 1 extending over the whole length of the foot 7 (or of the shoe) and have grooves or simples lines allowing to shorten the length of the insole so as to match to the length of foot 7 or shoe for the individual application.
[0043] FIG. 10 shows an example for an insole according the present invention which does not extend over the whole length of the foot 7 but instead only over a certain portion, namely the heel portion 4 in the embodiment of FIG. 10 . The insole according to this embodiment has a similar distribution of studs 2 at the underside as the embodiment of FIG. 1 so that a footbed is formed upon weight loading by the heel of a foot 7 . It is clear for people skilled in the art that in the same way insoles may be provided for which extend over other portions of the foot length, e.g. the arch plantar portion and/or a forefoot portion. The support of a forefoot portion may especially be suited for higher heel shoes which result in a principal weight load in the forefoot or toe portion of the foot 7 .
[0044] An insole extending only over a part of the length of the foot 7 may be protected against shifting or slipping within the shoe by being manufactured from a sticky material or by applying pads of sticky material to the underside of the insole, e.g., to the tips of the studs 2 , or to the contact surface 3 of the base layer 1 for fixing the insole to the foot 7 . Of course, other fixations, e. g. mechanical fixations by lateral extensions, may be used to form fit with corresponding lateral recesses of the shoe. | An insole designed for supporting a foot after the insole is inserted in a shoe and which abuts a sole section of the shoe includes an integral plastic material forming a flexible planar base layer out of which numerous resilient studs arise. The insole is easily manufactured and provides a comfortable feeling. The planar base layer is designed as a contact surface for the foot. The studs are designed to extend from the base layer to the sole section of the shoe, and are shaped of different heights so that upon weight-loading by the foot the flexible planar base layer is deformed so as to conform with the shape of the underside of the foot as a three-dimensionally shaped footbed. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to an optical sensor for detecting moisture on a window of a motor vehicle, in which sensor an attenuation of a light emitted from a transmitter upon reflection at an interface of the window by moisture is sensed with the aid of a receiver.
BACKGROUND OF THE INVENTION
[0002] An optical sensor of this kind operating according to the total reflection principle is known, for example, from German Patent Publication No. DE 42 09 680. Optical sensors of this kind are known in many variations, and are used at present in motor vehicles as so-called rain sensors, which can serve in particular to (automatically) control windshield wiper systems. These sensors typically, but not universally, use at least a portion of the (front) window as an optical waveguide.
[0003] The optical detection method predominantly used in present-day rain sensors is based firstly on the fact that as is known, light can propagate in a waveguide by total reflection because the reflection medium, i.e. the jacket or environment of the waveguide, has a lower refractive index than the waveguide core. The light introduced into the waveguide at a sufficiently large angle (>42°) with the aid of a coupling means (e.g. a prism) is at first totally reflected by the boundary surfaces of the window, since when the interface is dry, the light beam angle is large enough to prevent splitting into a reflected and a transmitted light bundle. If a raindrop then wets the light channel, the critical angle applicable to the media transition that is thereby modified (from glass/air to glass/water) is increased from 42° to 60°, so that a larger portion of the light—coupled in at an angle between 42° and 60° in terms of functionality as a rain sensor—now emerges through that droplet. The weakening light transmission capability of the channel as a function of moisture is measured at the outcoupling point (once again a prism or the like) with the aid of photodiodes or phototransistors.
SUMMARY OF THE INVENTION
[0004] Rain sensors usually use the vehicle's front window or windshield, or a region of the windshield which often extends over only a few centimeters and the wetting of which with raindrops or other moisture droplets is to be detected, as a waveguide into which light is coupled in from the inner side of the windshield by means of suitable coupling means, for example prisms or holographic coupling films, and coupled back out again. Because on the one hand the non-transparent parts of the rain sensor (transmitter/receiver, housing, evaluation electronics) must not interfere with the driver's field of view, and on the other hand the detection region of the sensor must be mounted in a region of the windshield that is cleaned by the windshield wiper system, sensor versions have now also been developed in which an additional waveguide, not constituted by the window itself, serves to span the distance between the detection region and the other parts of the rain sensor, i.e. to span those regions of the windshield not cleaned by the wipers.
[0005] For example, a rain sensor is known from German Patent Publication No. DE 199 43 887 A1 in which light is guided, in a flat waveguide disposed on the inner side of the windshield, bidirectionally between a peripherally disposed transmitter/receiver and a relatively central region of the window. At the desired region of the window, light is coupled out from the waveguide in such a way that it passes through the window to its outer side in the desired rain detection region, is totally reflected, and is then reflected back into the waveguide by a retroreflector disposed on the inner side of the window, once again with total reflection at the detection region. Also known, from German Patent Publication No. DE 102 29 239, is a rain sensor in which the additional waveguide is constituted in an intermediate layer of a laminated glass window. Here as well, light is coupled out at a suitable point only to the outer side of the window, totally reflected there, and coupled back into the internally located waveguide, so that moisture present in the detection region on the outer side of the window results, in desirable fashion, in attenuation of the light beam by partial outcoupling, which can then be evaluated in known fashion.
[0006] A problem that is known from the aforementioned German Patent Publication No. DE 42 09 680 of the species, in connection with the standard rain sensor type therein in which the light is totally reflected several times at the outer and the inner side of the vehicle window, is that any wetting of the inner side of the window, for example by condensation, also results in a partial outcoupling of the radiation, and thus in a beam attenuation that cannot be distinguished from the influence of the wetting (on the outer side of the window) that is actually to be detected. In order to exclude this influence that is considered undesirable, it is proposed in the context of the known rain sensor to dispose a reflective film on the inner side of the window so that even in the event of wetting thereon, moisture-dependent attenuation of the light beam thus no longer occurs.
[0007] On the other hand, however, the known rain-only sensor obviously cannot simply be implemented as a condensation-only sensor by way of a reflective film disposed on the outer side rather than the inner side of the window, since transparency from inside to outside then could not readily be ensured, or other problems might occur, for example in terms of the durability of the film that is then externally located.
[0008] Because there is also, independently, increasing interest in the detection of moisture on the inner side of the windows of a motor vehicle as well, e.g. for automatic activation of the fan present in the motor vehicle, it is the object of the invention to create moisture sensors of the kind described above, i.e. in the context of the technologies utilized for external detection, that are sufficiently variable in terms of configuration and function that they encompass a capability, implementable without complex adaptation actions, for selectable interior/exterior detection simultaneously, with good discrimination between exterior and interior wetting.
[0009] In the case of the alternative manner of achieving the object according to Claim 1 , the light is guided bidirectionally between the at least one transmitter and at least one receiver, in the window or in a light-guiding element, to a retroreflector disposed on the inner side of the window, the light being totally reflected several times at the outer side of the window. The retroreflector is furthermore embodied as a photorefractive phase-conjugated mirror (PCM) whose geometry is selected so that its reflectivity substantially disappears upon wetting of its surface with moisture. This configuration is usable both in a sensor in which the window itself serves as a optical waveguide and in a sensor type such as the one known from German Patent Publication No. DE 199 43 887 A1 described above. When a light beam is coupled in at an angle of between 42° to 60°, the sensor then functions (when the inner side of the window is dry) as a rain sensor; whereas when the inner side of the window is wet, the sensor indicates the presence of condensation because of the disappearance of the light beam and of the signal to evaluated, regardless of whether the outer side of the window is then dry or wet. In addition to this situation-dependent “self-switching” of the detection mode, the light beam can also be coupled in (with an otherwise identical configuration) at an angle of more than 60°, so that the sensor functions as a condensation-only sensor having two indicating states: signal unattenuated and signal disappeared. If applicable, it is also possible to provide, for selectable incoupling, a first transmitter with which a light beam is coupled in at an angle of more than 60°, and a second transmitter with which the light beam is coupled in at an angle of less than 60°.
[0010] In an alternative proposed manner of achieving the object according to the present invention, the light propagates in the window from the transmitter to the receiver, the light being totally reflected several times at the outer and the inner side of the window; and two holographically embodied grating structures, having different diffractive effects, are incorporated into an intermediate layer of the window, which structures diffract the light in such a way that it is totally reflected at the one side of the window at an angle of more than 60°, and at the opposite side of the window at an angle of between 42° and 60°. The result of this feature is that total reflection is disrupted only on one side of the optically guiding window by any moisture droplets that may possibly be present thereon, that side being selectable beforehand upon manufacture of the window or of the sensor. The system can thus be selectively adjusted, exclusively by holographic means, to detect as a rain sensor or a condensation sensor.
[0011] An advantageous variation of this alternative manner of achieving the object consists in the fact that the window is embodied as a laminated glass window; and that the holographic grating structures are incorporated into a photosensitively doped adhesive intermediate layer, or into a photosensitive polymer layer integrated into the laminated glass window.
[0012] In the case of the further alternative proposed manner of achieving the object according to the present invention, there is disposed on the inner or the outer side of the window a multimode foil- or film-like optical waveguide in which the light is coupled in from the transmitter and coupled out to a receiver in such a way that in the absence of any wetting with moisture on the exposed outer side of the optical waveguide, the light propagates in unattenuated fashion with total reflection. It is thus possible to produce a rain-only sensor when the thin waveguide is disposed externally on the window, and a condensation-only sensor when it is disposed internally.
[0013] In the case of the further alternative proposed manner of achieving the object according to the present invention, the light is guided between the transmitter and a receiver in a laminar waveguide that is disposed on the adhesive intermediate layer of a laminated glass window; and at least one coupling element is provided in order to couple the light out of the waveguide to the inner or the outer side of the window, and couple back into the waveguide the light that is totally reflected at least once at the respective side of the window. The placement between the adhesive intermediate layer and a glass layer yields a particularly large number of degrees of freedom for coupling the light beam out to the desired side of the window and thereby implementing a rain-only sensor or a condensation-only sensor. In addition, it is readily possible to dispose two laminar waveguides one above another or on different sides of the intermediate layer, thus resulting in a double sensor that can function simultaneously as a discriminating rain-only sensor and as a condensation-only sensor that is uninfluenced by external moisture.
[0014] This alternative manner of achieving the object is particularly advantageous in combination with a variant in which the waveguide is constituted by an infrared-reflecting polymer film integrated into the laminated glass for heat rejection, since considerable advantages in terms of manufacturing engineering result from utilization of the existing layer as a waveguide.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Exemplifying embodiments of the invention are explained below with reference to the drawings, in which, in each case schematically and in cross section:
[0016] FIG. 1 shows a moisture sensor according to the present invention in a first embodiment, with a PCM retroreflector.
[0017] FIG. 2 shows the operating principle of the PCM retroreflector according to FIG. 1 .
[0018] FIGS. 3 a and b show two different moisture-dependent operating modes of the sensor according to FIGS. 1 and 2 .
[0019] FIG. 4 shows an alternative embodiment of the sensor according to the present invention.
[0020] FIG. 5 shows a further alternative embodiment of the moisture sensor according to the present invention.
[0021] FIG. 6 shows a further alternative embodiment of the sensor according to the present invention.
[0022] FIG. 7 shows a variant of the sensor depicted in FIG. 6 .
DETAILED DESCRIPTION
[0023] The exemplifying embodiments according to each of FIGS. 1 to 3 are based on a glass window 5 as a waveguide, in which light beam 1 , 4 is guided bidirectionally with multiple reflection to both outer side 6 and inner side 7 of window 5 , light beam 1 being reflected back at a mirror 8 (phase-conjugated mirror, PCM) disposed on inner side 7 of window 5 . Also possible, however, is a variant (not depicted here) of this embodiment of the sensor according to the present invention having a PCM, in which a configuration is implemented having an additional waveguide disposed on the inner side of window 5 , approximately in the fashion that exists in the context of the existing art, mentioned and described above, according to German Patent Publication No. DE 199 43 887.
[0024] FIG. 1 depicts a light beam 1 that is coupled into window 5 , propagates by total reflection to phase-conjugated mirror 8 , is reflected there and guided back as phase-conjugated light beam 4 again by total reflection, then finally coupled back out of window 5 and conveyed via a beam splitter 9 to a receiver that, like the transmitter, is not depicted here or in any of the following Figures. Beam splitter 9 serves, in a manner known per se, for optical separation of the output from the input signal. PCM 8 is moreover approximately transparent. The phase-conjugated mirror 8 that is used has, firstly, the advantage of ensuring accurate reflection for bidirectional light wave guidance without requiring complex alignment actions as in the case of other retroreflectors used in moisture sensors. As usual, a water droplet 10 —located, for example as depicted in FIG. 1 , on outer side 6 of window 5 —results in known fashion, in accordance with the detection principle based on interference with total reflection (in this case at the interface between window exterior and water), in a detectable attenuation of light beam 1 or 4 .
[0025] Nonlinear photorefractive materials, for example photorefractive crystals, liquid crystals, or polymers, can advantageously be used for phase-conjugated mirror 8 , which is known per se.
[0026] FIG. 2 shows the implementation and function of a PCM by way of phase gratings (refractive-index gratings) 11 generated in photorefractive materials, using the example of a parallelepipedal photorefractive crystal 8 . So-called holographic or light-induced scattering is usually understood as the following nonlinear process: An incident light wave interacts with coherent scattered waves that are produced as a result of inhomogeneities in the interior or on the surface of a material. The resulting light patterns generate, in a photorefractive crystal, various refractive-index gratings at which the primary wave is in turn diffracted. Specifically, in accordance with the exemplifying embodiment depicted in FIG. 2 , beam 1 penetrates from the window/crystal interface into crystal 8 and experiences directional self-scattering 12 along the optical c axis of crystal 8 indicated in FIG. 2 . The unscattered portion of beam 1 passes through crystal 8 , while the scattered light, distributed in a specific region (beam 2 ), is totally reflected, as depicted, at interfaces (i) and (ii) and forms beam 3 . Beam 3 is refracted at phase grating 11 generated by beams 1 and 2 , and forms beam 4 that is phase-conjugated with beam 1 .
[0027] FIG. 3 shows the manner in which PCM 8 also, according to the present invention, performs a further moisture-dependent function in addition to its reflective function. If light 1 , 4 is coupled into window 5 at, for example, an angle φ of more than 60°, i.e. at a critical angle that is too large for partial outcoupling at an interface produced by any wetting of window 5 , no light intensity losses during bidirectional wave guidance in window 5 then occur even in the case of moisture 10 , e.g. condensation, on one or both sides 6 and 7 of window 5 . If, according to the present invention, the geometrical parameters of phase-conjugated mirror 8 are at the same time selected so that no beam outcoupling from PCM 8 itself occurs provided dry conditions exist on its surface, i.e. on window inner side 7 (cf. FIG. 3 a ), the sensor then functions here as a condensation-only sensor. The sensor accordingly reacts only to droplets 10 that are present on window inner side 7 and therefore also on the surface of the photorefractive material of PCM 8 . The reaction (cf. FIG. 3 b ) consists in a disappearance, associated with the moisture-related beam outcoupling, of the detector signal, thereby unequivocally indicating the presence of condensation.
[0028] As already mentioned above, other modes of operation can also be selected. For φ between 42° and 60°, the sensor (when inner side 7 is dry) functions as a rain sensor that, even when inner side 7 is wet, does not simply lose its discriminating property by permitting the inner-side wetting to have an unnoticed influence on the detected signal. Instead, in this case, in the presence of condensation the signal disappears entirely because of the moisture-sensitive reflection capability of PCM 8 , allowing an unequivocal evaluation as condensation; that evaluation then itself, in turn, remains uninfluenced by the presence or absence of moisture 10 on window outer side 6 . The rain-sensor functionality remains disabled as long as condensation is present.
[0029] FIG. 4 shows an exemplifying embodiment that refers to an alternative embodiment of the moisture sensor according to the present invention. It shows a wave-guiding laminated glass window 5 in which incoupled light 1 propagates from the transmitter to the receiver, light 1 being totally reflected several times at outer side 6 and inner side 7 of window 5 . Two holographically embodied grating structures 13 , 14 , having different diffractive effects, are incorporated into an intermediate layer 15 of window 5 . They diffract the light so that, in the exemplifying embodiment depicted, it is totally reflected at inner side 7 of window 5 at an angle α of more than 60°, and at the oppositely located outer side 6 of window 5 at an angle β of between 42° and 60°. This makes possible, without external optical or mechanical actions or means, a complete discrimination between external and internal wetting. In the example shown (a rain sensor), only water droplets 10 on outer side 6 influence the propagation of beam 1 and thus the detected signal. The separation of rain influences and condensation influences can, however, also be implemented, with the aid of reversed multiplex grating structures 13 and 14 and incoupling angles α and β, so that the sensor reacts only to moisture on inner side 7 of window 5 .
[0030] It is advantageous in terms of manufacturing engineering if the holographic grating structures 13 and 14 are incorporated into a photosensitively doped, adhesive intermediate layer 15 , or into a photosensitive polymer layer integrated into the laminated glass window.
[0031] FIG. 5 shows an exemplifying embodiment according to a further alternative manner of achieving the moisture sensor according to the present invention. In this example, there is disposed on inner side 7 of window 5 a multimode foil- or film-like optical waveguide 16 in which light 1 is coupled in from the transmitter at an angle of between 42° and 60°, and coupled out to a receiver, in such a way that in the absence of any wetting with moisture 10 on the exposed outer side 17 of optical waveguide 16 , light 1 propagates in unattenuated fashion by total reflection. The result is a condensation-only or rain-only sensor, depending on whether the thin waveguide 16 is mounted, for example by adhesive bonding, on inner side 7 or outer side 6 of window 5 . The condensation sensor shown in FIG. 5 can, advantageously, additionally be used as a conventional rain sensor.
[0032] A further alternative embodiment is shown in FIGS. 6 and 7 . Light 1 is guided between the transmitter and a receiver in a laminar waveguide 18 that is disposed on the adhesive intermediate layer 15 of a laminated glass window 5 . At least one coupling element 19 is also provided in order to couple light 1 out of waveguide 18 to inner side 7 or to outer side 6 of window 5 , and in order to couple light 1 , totally reflected at least once at the respective window side 6 or 7 , back into waveguide 18 . Light 1 can optionally also be coupled out with the aid of multiple coupling elements 19 successively, for example to two or three detection points on the respective window side, and coupled between them back into waveguide 18 for propagation to the next coupling element 19 . The embodiment according to FIG. 6 scans only one outcoupling point on inner side 7 of window 5 , i.e. is a condensation-only sensor, whereas the sensor according to the exemplifying embodiment depicted in FIG. 7 scans only outer side 6 and a detection point located thereon, i.e. functions as a rain-only sensor. It is, also possible in principle for two laminar waveguides 18 , having opposite detection sides, to be integrated above or next to one another in window 5 .
[0033] Advantageously, an infrared-reflecting polymer film already present in the laminated glass for heat rejection can be used as waveguide 18 . In general, a polymer or a glass layer approximately 200 μm thick is suitable as waveguide 18 .
[0034] On the other hand, the embodiment of the invention depicted in FIGS. 6 and 7 is also particularly suitable for vehicle windows in which the glass layers as a whole exhibit light-absorbing properties for heat rejection, so that because of absorption or other effects, the light could not propagate in unattenuated fashion in the waveguide constituted by window 5 itself. The light source of the transmitter usually operates in the infrared range so as not to disturb the driver. The intensity loss would also be associated with a diminution of detection accuracy. According to the present invention, with the present embodiment the light needs to propagate only through the thickness of the glass layer of laminated glass window 5 that remains to be penetrated in order to reach the respective outcoupling side, and that only a few times at most, so that any absorption effects can have almost no undesirable consequences. | In order also to allow the detection, for example, of condensation of the inner side of an interface (window) using motor-vehicle rain sensors that exploit the interference, at a window wetted with moisture, with total reflection of light irradiated by a transmitter, several sensors are proposed that are sufficiently variable in terms of configuration and function that they contain, without complex adaptation actions, an implementable possibility for selectable inside/outside detection simultaneously with good discrimination between outside and inside wetting. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an electric conductor and a method for improving the current capability of an electric conductor, and particularly relates to a test probe and a method for improving the current capability of a test probe.
[0003] 2. Description of the Prior Art
[0004] In the manufacturing process and package process of electronic elements, and after the manufacturing process of electronic elements is finished, a test is performed to recognize and confirm the quality of the electronic elements or chips. During the test process, it is necessary to provide an electric conductor for the electrical connection between an electronic element and a test apparatus, and for transferring test signals between the electronic element and the test apparatus. In general, a test probe is used as the electric conductor.
[0005] However, as electronic elements advance in popularity and diversification, various kinds of electronic elements have been and continue to be developed. Therefore, a test apparatus needs to be able to test various kinds of electronic elements. In test processes, different kinds of electronic elements need different test conditions, such as different electric currents and different voltages. In recent years, larger electric currents often need the testing of many kinds of electric elements. A typical or commonly used test probe is often too small to endure passage of larger electric currents. Such a test probe can be said to have a low current capability because of its small size. Because of this, in the test process of electric elements requiring large electric currents, the typical test apparatus must be halted and time must be expended to change the test probe(s) to a particular test probe(s) having a higher current capability. Therefore, the test cost and the test time are increased, and the test efficiency and test rate are commensurately reduced. In some instances, manufacture of a new test probe, afresh, can be necessary when large electric current testing is needed. It can be impossible, however, to generate a test probe having sufficient current capability by directly improving the test probe commonly used. This kind of preparation of new test probes having higher current capability can disadvantageously add to the test cost of test processes requiring large electric currents. Hence, there is a need to provide an electric conductor with good current capability and a method for improving the current capability of an electric conductor, and particularly to provide a method to change a typical test probe into a test probe having high current capability using only a simple step.
SUMMARY OF THE INVENTION
[0006] In view of the foregoing, it is an object of the present invention to provide an electric conductor with high current capability that is capable of improving the current capability of a common test probe, thereby reducing the test cost and increasing the test efficiency.
[0007] Another object of the present invention is to provide a method which can be used for improving the current capability of an electric conductor, and which is capable of improving the current capability of a common test probe, thereby reducing the test cost and increasing the test efficiency.
[0008] Still another object of the present invention is to provide a method for improving the current capability of a typical or common electric conductor by implementing only a simple step, without destroying the surface of the electric conductor or the plated layer on the surface of the electric conductor. This method also can be performed for increasing the hardness of the surface of the electric conductor.
[0009] According to one or more of the objects, an embodiment of the present invention provides an electric conductor with high current capability. The electric conductor comprises a body, at least one conducting part disposed on the body for connecting with an electric element or elements, and a plurality of dents formed on the surfaces of the body and the conducting part. The surface of the electric conductor can be formed as a lumpy surface owing to the existence of dents formed on surfaces of the body and the conducting part. In contrast to the relatively smooth surface of a typical or common test probe, the electric conductor of the present invention has a rough surface and a correspondingly larger surface area. Therefore, the electric conductor of the present invention is capable of enduring the passage of large electric currents, and thus can be said to possess good current capability.
[0010] According to the objects, another embodiment of the present invention provides a method for improving the current capability of an electric conductor, and particularly provides a method for improving the current capability of a common or typical electric conductor by way of only a simple step. This method does not destroy or damage the surface of the electric conductor or the plated layer on the surface of the electric conductor. First, an electric conductor is provided. The electric conductor can be a test probe or any conductor used to electrically connect any element with any apparatus. The electric conductor can be, for example, any sort of a test probe. Next, a plurality of dents are formed on the surface of the electric conductor for increasing the roughness and the surface area of the electric conductor. Therefore, the electric conductor allows and endures the passage of large electric current, and the current capability of the electric conductor is improved.
[0011] An effect achieved by the present invention which is not present in the prior art is the provision of an electric conductor with high current capability that is capable of performing a test process with large electric current. The test process need not be interrupted to stop the test apparatus and expend time changing test probes. Accordingly, additional test cost and test time caused by the changing of test probes can be omitted, and the test efficiency can be improved. Another effect achieved by the present invention which is absent from the prior art is the provision of a method that is capable of improving the current capability and the hardness of a typical or common electric conductor (e.g., test probe) without destroying, damaging, or wearing the surface of the electric conductor or of a plated layer on a surface of the electric conductor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A and FIG. 1B are a stereophonic view and a cross-sectional view, respectively, of an electric conductor with good current capability according to one embodiment of the present invention;
[0013] FIG. 2 is a side view illustrating an electric conductor with good current capability according to another embodiment of the present invention;
[0014] FIG. 3 is a stereophonic view illustrating an electric conductor with good current capability according to still another embodiment of the present invention; and
[0015] FIG. 4 is a flow chart illustrating a method for improving the current capability of an electric conductor according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The following is a detailed description of the embodiments of the present invention. It is appreciated that the processes and structures described below do not entirely encompass whole processes and structures. The present invention can be practiced in conjunction with various fabrication techniques, and only the commonly practiced processes are included to provide an understanding of the present invention.
[0017] Referring to FIG. 1A , depicted is a stereophonic view illustrating an electric conductor 10 with good current capability according to one embodiment of the present invention. The electric conductor 10 comprises a body 12 and at least one conducting part 14 , wherein the conducting part 14 is disposed on the body 12 for contacting an electric element. Furthermore, there are a plurality of small dents 16 formed and spread (e.g., distributed) on the surfaces of one or more of the body 12 and the conducting part 14 (or on the surfaces of the sidewalls of the body 12 and the conducting part 14 ). Both of the surfaces of the body 12 and the conducting part 14 become lumpy surfaces because of the dents 16 formed on the surfaces of the body 12 and the conducting part 14 . Therefore, both of the body 12 and the conducting part 14 have a rougher surface and a larger surface area.
[0018] In general, electric current moves on the surface of an electric conductor, and the electric current is transferred to one or more electric elements through the surface of the electric conductor. Therefore, the larger surface area the electric conductor has, the more paths for transferring the electric current the electric conductor has. This relationship means more electric current can pass over and/or through the electric conductor at the same time providing the electric conductor with better current capability. Consequently, the current capability of an electric conductor can be said to be determined by the size of the electric conductor. The present invention uses the above-mentioned principle to form the dents 16 on surfaces of one or more of the body 12 and the conducting part 14 by, for example, one or more of shot penning, sand brush, laser beam striking, or embossing. Therefore, in contrast to common test probes currently used, the electric conductor of the present invention has a larger surface area and has better current capability because of the larger surface area. The term “laser beam striking” means a laser beam is applied to strike the surface of an object to form dents thereon. Referring to FIG. 1B , a top view or a cross-section view illustrating the electric conductor 10 is provided, in which the peripheral line of each cross-section of said electric conductor 10 is longer than the peripheral line of each cross-section of the common test probe used currently because of the dents 16 . This characteristic means that the electric conductor 10 has a larger surface area than that of the common test probe used currently. Therefore, the electric conductor 10 can be provided with a larger surface area for electric current pass whereby the electric conductor 10 is enabled with a higher current capability. The term “peripheral line” means the circumference of a cross-section of the object and all peripheral lines of the object are integrated together to constitute the surface of the sidewalls of the object.
[0019] According to a user's need and design, the electric conductor 10 can be composed of various kinds of materials, for example metal, alloy, etc. Therefore, the composition of the electric conductor 10 is not intended to be limited by the examples provided in the current disclosure of the present invention. Now, in this embodiment of the present invention, the electric conductor 10 is a pogo pin, and particularly is a test probe with single head or a pogo pin with single head. Also, in the embodiment the body 12 is the body of the test probe with a single head, and the conducting part 14 is the head of the test probe with a single head.
[0020] FIG. 2 illustrates an electric conductor 10 A with good current capability according to another embodiment of the present invention. The electric conductor 10 A is a test probe with two heads. The electric conductor 10 A comprises a conducting part 14 A disposed on one end of the body 12 and another conducting part 14 B disposed on another end of the body 12 . Both of the conducting part 14 A and the conducting part 14 B are the heads of the test probe. A plurality of dents 16 are formed on the surfaces of the body 12 , the conducting part 14 A and the conducting part 14 B, thereby transforming the surface of the electric conductor 10 A to a lumpy surface and providing the electric conductor 10 A with a rougher surface and a larger surface area. The rougher surface and the larger surface area result in the electric conductor 10 A having a substantially better current capability.
[0021] According to certain aspects, the electric conductor of the present invention need not be limited to the above-described embodiments in which the electric conductor is a test probe with single head or a test probe with two heads. Indeed, the electric conductor can comprise various kinds of and various shapes of, for example, test probes according to the user's need and design. For instance, a test probe with an S shape, such as, for example, manufactured by JONSTECH company, etc., can comprise an electric conductor 10 B with good current capability, as illustrated in FIG. 3 according to still another embodiment of the present invention. The electric conductor 10 B is a test probe in the form of an electric conductor 10 B which, when viewed from the side, comprises or resembles the shape of an S shaped slab with a relatively small size. The electric conductor 10 B as depicted comprises a body 12 ′ which is the body of the S-shaped test probe, and two conducting parts 14 C and 14 D which are the curved heads of the S-shaped test probe. The conducting part 14 C and the conducting part 14 D are disposed on two (e.g., opposing) ends of the body 12 ′ respectively. Similarly, a plurality of the dents 16 are formed on the surfaces of the body 12 ′ and the conducting parts 14 C and 14 D for increasing the surface roughness and the surface area of the electric conductor 10 B. Therefore, the resulting electric conductor 10 B can have higher current capability. The S-shaped test probe can be fixed on a test apparatus by inserting two rubber strips into the two concaves of the S-shaped test probe respectively.
[0022] However, in any electric conductor of the embodiments of the present invention, one or several plated layers could be formed on the surface of the body, the surface of the conducting part or both surfaces of the body and the conducting part for providing various functions. For example, a plated layer or layers can form either or both of a protective layer for protecting the body and/or conducting part from oxidization or an impact endurance layer for improving the impact resistance of the electric conductor. The protective layer can be, but is not limited to, an Au layer, and the impact endurance layer can be, but is not limited to, a Ni layer. Such items can be composed of various materials according to the user's need. The dents on the electric conductor can comprise dents on the surface of the electric conductor and/or dents on a plated layer formed over an impact endurance layer, wherein the plated layer is not damaged and worn to expose the underlying plated layer or the surface of the electric conductor under the plated layer.
[0023] The present invention further provides a method for improving the current capability of an electric conductor while not damaging or wearing the surface of the electric conductor or the plated layer on the surface of the electric conductor. With reference to FIG. 4 , a flow chart is presented illustrating the method for improving current capability of an electric conductor according to one embodiment of the present invention. First, an electric conductor is provided at step 400 . The electric conductor can be any conductor for electrically connecting an element with an apparatus or for electrically connecting one apparatus with another apparatus, for example a common or typical test probe, a test probe with single head, a test probe with two heads, or a test probe with an S shape. The composition and the shape of the electric conductor described above are not mentioned again. One or more plated layers can be formed on the surface of the body of the electric conductor, on the surface of the conducting part of the electric conductor, or on the surfaces of both of the body and the conducting part for providing various functions, such as that of a protective layer for protecting the body and/or conducting part from oxidization or an impact endurance layer for improving the impact resistance of the electric conductor.
[0024] Next, at step 402 a plurality of dents are formed on surfaces of the body and the conducting part by a process such as shot penning, sand brush, laser beam striking, or embossing. The surface of the electric conductor is transformed to a lumpy surface as a result of the dents, and the electric conductor consequently has a better current capability because of the lumpy surface. Consistent with principles mentioned above, when plating is present on the surface of the electric conductor, the dents can be formed on either or both of the surfaces of the electric conductor and the plated layer. Therefore, the present invention provides a method for improving the current capability of a common electric conductor using a simple step, which is capable of effectively improving the current capability of a typical or common electric conductor currently used.
[0025] When the dents are formed on surfaces of both the body and the conducting part of the electric conductor by shot penning or sand brush, small particles are applied to impact or strike the surface of the electric conductor to form the dents on the surface of the electric conductor. If there is a plated layer on the surface of the electric conductor, the small particles can be directed to impact or strike the surfaces of the electric conductor and the plated layer thereby forming dents on the surfaces of the electric conductor and the plated layer. The small particles are softer than the electric conductor and/or softer than the plated layer on the surface of the electric conductor. Therefore, when the small particles are applied to impact or strike the surface of the electric conductor and the plated layer on the electric conductor, only dents are formed on the surface of the electric conductor or the plated layer on the electric conductor without any damage and wearing to the electric conductor. The small particles are steel balls, glass sand particles, or sand, but are not intended to be limited to such items. Various small particles can be applied according to the kind of electric conductor to be used and the user's needs. It may be necessary in certain implementations that the surfaces of the electric conductor and the plated layer thereon are not damaged and worn by the small particles. Furthermore, the hardness of the electric conductor is increased as a result of the arrangement of the crystal lattice of the electric conductor being changed by the small particle impacts or the crystal lattice of the electric conductor being deformed by the small particle impacts.
[0026] Similarly, a laser beam striking or embossing technique can be applied only to impact or oppress the surface of the electric conductor or the plated layer thereon for forming the dents on the surface of the electric conductor or the plated layer thereon, or on both of the surfaces of the electric conductor and the plated layer. Therefore, a lumpy surface can be formed on the electric conductor for increasing the surface area of the electric conductor. It may be necessary that the surface of the electric conductor and the plated layer thereon are not damaged and worn by this way, either.
[0027] Accordingly, the present invention provides an electric conductor with a high current capability. The surface area of the electric conductor is increased by the formation of dents for obtaining better current capability. In accordance with the present invention, stopping of the test apparatus and expending time to change test probes can be avoided. Accordingly, additional test costs and test times caused by having to change test probes can be omitted, and the test efficiency can be improved. Furthermore, the present invention provides a method for improving the current capability of an electric conductor by forming dents on a typical or common electric conductors in a simple manner. By the method of the present invention, the roughness of the surface of the electric conductor and the surface area of the electric conductor are increased for improving the current capability of the electric conductor, while not destroying, damaging, or wearing the surface of the electric conductor or the plated layer on the surface of the electric conductor. | The present invention relates to an electric conductor with large current capability and a method for enhancing current capability of an electric conductor, and particularly relates to a test probe with good current capability and a method for improving the current capability of a test probe. In the present invention, dents are formed on the surface of an electric conductor to make the surface rough, so that the electric conductor can have a greater surface area. The larger surface area of the electric conductor provides more paths for passage of the electric current in order to improve the current capability of the electric conductor. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and hereby claims priority to International Application No. PCT/EP2012/064999 filed on Aug. 1, 2012 and German Application No. 10 2011 081 015.3 filed on Aug. 16, 2011, the contents of which are hereby incorporated by reference.
BACKGROUND
[0002] The invention relates to a method for reprocessing wastewater, and also to a water treatment machine.
[0003] Aseptic packages are a basic requirement, in particular in food technology, in order to ensure the shelflife of perishable foods even without cooling. Wet disinfection of plastic packages, such as, for example, PET bottles, with dilute peracetic acid has developed to be one of the standard processes used therefor in the food industry and particularly in the drinks industry. The disinfection is carried out in this case using aqueous peracetic acid solution which contains a mixture of typically 2000 mg per liter of peracetic acid and hydrogen peroxide in water. In order to remove the residues of the disinfectant before the foods are charged, washing with high purity sterilized water is performed. The resultant wastewater always still contains considerable amounts of the disinfectant, that is to say the peracetic acid, and therefore cannot be fed without pretreatment to a biological effluent treatment plant.
[0004] A separation of water and acid by distillation, owing to the closely adjacent boiling points of the substances participating, is not possible technically. Therefore, even a partial recovery of the rinse water is not currently possible.
[0005] For disposal, therefore, lye is added in a controlled manner, which lye neutralizes the aqueous solution of peracetic acid and acetic acid. The neutralized lye is then fed to the standard wastewater. Although this procedure solves the disposal problem, it does not contribute to lowering water and energy consumption in wet disinfection, e.g. in the food industry.
[0006] In a commercially conventional plant for wet disinfection, per rinsing line, several thousand liters of rinse water per hour are produced. In addition, there is also the energy consumption for producing the sterile water.
[0007] In the patent document U.S. Pat. No. 7,163,631, it is proposed to pass peracetic acid-containing wastewaters through a tank in which they are intensively contacted with air before further treatment is performed, e.g. by contacting with anaerobic biologically active sludges. The data reported there on residence times and aeration rates in the aeration tank allow it to be concluded that the aeration tank requires a capacity which corresponds to the rinse water consumed in 2.5 hours and that, per m 3 of rinse water, around 15 m 3 must be bubbled through the aeration tank in order to make subsequent chemical reduction of the peracetic acid superfluous. This may reduce the costs of the chemical treatment of the wastewater, but recovery of rinse water is not achieved thereby.
SUMMARY
[0008] One possible object is to decrease the water consumption in industrial purification processes, in particular in wet disinfection of food packages, wherein the potential for saving energy is to be provided.
[0009] The inventors propose a method for reprocessing an industrial process wastewater that comprises an acid. This method involves:
[0010] Firstly, to the wastewater which originates, for example, from a rinse process in the production of packaging, is fed a base (lye) by which at least part of the acid (usually peracetic acid and/or acetic acid) contained in the wastewater is neutralized. The neutralized wastewater is then introduced into a heat-exchange process. In this case, a heat-exchange medium is used, which is formed in such a manner that the wastewater that is to be treated is heated to a vaporization temperature which is between 60° C. and the boiling point of the wastewater. The heat-exchange medium can be either a liquid or a gaseous medium. The temperature of the heat-exchange medium can be in the range in which the wastewater is to be heated, but it can also have a markedly higher temperature, in particular in the case of gaseous media. The amount of heat which is transferred in the heat-exchange process from the heat-exchange medium to the wastewater depends very greatly on the mass flow rates and also on the state of matter of the heat-exchange medium.
[0011] Second, the wastewater, which has the abovedescribed temperature between 60° C. and the boiling point of the wastewater, is vaporized and then recondensed. It may be pointed out that, according to the proposal, this concerns a vaporization process below the boiling point of the wastewater. The neutralized wastewater that is purified in the vaporization and condensation process is then returned to the industrial process. However, it can, in principle, be fed to the general water supply since it is effectively microbe-free.
[0012] The proposed method has various advantages. The first advantage is that, using the proposed method, up to 80% of the process water used, that is to say the rinse water from the packages, which occurs as wastewater, can be recovered and returned to the process. In this case the process of the method is markedly less energy consuming than the expenditure of fresh water for process water.
[0013] The method described is beneficial energetically, especially, when the heat-exchange medium is in a thermal circuit with the waste heat of a second thermal process. In particular, since the evaporation of the wastewater is a vaporization process which takes place at relatively low temperatures, it is also possible to use waste heat from industrial processes which are below 100° C. Generally, processes having waste heat in this temperature range, from 60° C. to 100° C., cannot be recovered, but are discharged to the environment. This is therefore an energetically expedient and ecological method.
[0014] In a further advantageous embodiment, fresh water for an industrial process is treated, wherein the fresh water is subjected to a high-temperature treatment of above 100° C., in particular above 140° C. As a result of such a high-temperature disinfection, all microbes still possibly present in the fresh water are definitively eliminated. For energetically expedient configuration of this per se energy-intense high-temperature disinfection, it is expedient to preheat the fresh water by waste heat. In this case, for example, the fresh water can be passed in advance through a condenser of the condensation device, wherein the heat of condensation is transmitted at the condenser to the fresh water. After the high-temperature disinfection, a further heat exchanger can be provided which removes the heat again from the heated fresh water. This heat which is taken off from the fresh water can in turn profitably be employed for heating up the wastewater to a vaporization temperature or approximate vaporization temperature (The term vaporization temperature is understood to mean a temperature of between 60° C. and the boiling point, which promotes the vaporization). Afterwards, it can be expedient to use the heat energy taken off from the heated fresh water again for heating up new fresh water for the high-temperature disinfection.
[0015] The inventors further propose a water treatment machine for reprocessing a wastewater that contains an acid. This machine comprises a neutralization device for neutralizing the wastewater by a base, and also a wastewater collecting device, and is distinguished in that a heat exchanger is provided for heating up the wastewater to a vaporization temperature which is between 60° C. and the boiling point of the wastewater. The boiling point of the wastewater, depending on pressure conditions and the substances dissolved in the wastewater (after the neutralization, in particular salts), is generally between 95 and 110° C. In addition, the machine comprises an evaporation device, wherein the evaporation device serves for partial vaporization of the heated wastewater. After the vaporization, the vaporized wastewater is condensed in a condenser.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] These and other objects and advantages of the present invention will become more apparent and more readily appreciated from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings of which:
[0017] FIG. 1 shows a schematic process depiction for the water flow of rinse water for rinsing packages in the food industry as per the related art,
[0018] FIG. 2 shows a rinse water recovery system having an evaporator and condenser and UV radiation in schematic form,
[0019] FIG. 3 shows a more detailed depiction of the rinse water recovery system as per FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout.
[0021] The current related art for treatment and disposal of rinse water, as is employed, for example in the food industry, is explained on the basis of FIG. 1 . Firstly, fresh water 20 is added to a reverse osmosis system 18 , wherein the fresh water thus treated 20 ′, for achieving an absolute freedom from microbes, is subjected to a further thermal high-temperature treatment, this proceeds in a high-temperature disinfection system 24 . The fresh water 20 ″ which is made microbe-free by these processes, is then added to an industrial process. For example, PET bottles, for example for the drinks industry, can be rinsed by this process. This process, which can have as many embodiments as desired, is designated in FIG. 1 and in the following figures schematically as water utilization device 26 . If one remains with the example that PET bottles must be rinsed for the drinks industry, a wastewater 2 which arises after the rinse operation, is contaminated with peracetic acid or with acetic acid and H 2 O 2 . This originates from the fact that the peracetic acid is used quite generally for disinfection of PET bottles in the drinks industry and in the food industry.
[0022] The wastewater 2 which then contains the organic acid peracetic acid, or else acetic acid, is collected in a wastewater collecting device, wherein this wastewater collecting device is shown here schematically by a funnel. Alternatively in this case, this can be only a conduit tube, a corresponding collecting tank need not necessarily be present. According to the related art, the wastewater 2 thus contaminated with an organic acid is pumped into a neutralization device 27 , wherein, from a base container, a base or a lye is added to the neutralization device 27 in such a manner that the wastewater 2 therein possesses a pH as neutral as possible. The acetic acid or peracetic acid present therein is therefore neutralized with a suitable lye or base. The wastewater 2 thus neutralized is passed as residual water 32 into the sewage system.
[0023] The residual water 32 ′ is not reused in the related art.
[0024] Although the described method of the related art leads to no contaminated water being delivered into the surroundings, a very large amount of fresh water which likewise must be treated in an energetically expensive manner is required.
[0025] In FIG. 2 , a water treatment device 1 is shown in a simplified manner schematically starting from FIG. 1 , which water treatment device 1 in this example is likewise based on the system according to FIG. 1 and it should likewise be assumed by way of example thereof that at this point PET bottles are disinfected with peracetic acid and are rinsed with the fresh water 20 . This likewise proceeds in a water utilization device 26 , wherein wastewater 2 arises. This wastewater 2 is conveyed into a neutralization device 27 , with base being fed in from a base container to neutralize the peracetic acid. The aim here is for addition of base matched stoichiometrically to the acid content of the wastewater. The neutralization, though, must proceed only to an extent such that the pH of a residual water is environmentally compatible—this pH may also be slightly basic.
[0026] In contrast to the related art as per FIG. 1 , in FIG. 2 , the wastewater 2 is collected in the wastewater collecting device 8 and added to a wastewater treatment device 28 . The wastewater treatment device 28 is shown in very simplified form in FIG. 2 , it comprises, inter alia, a vaporization device 12 and a condenser device 14 .
[0027] In this case, the wastewater 2 is preheated by a heat exchanger 10 to a vaporization temperature which causes a vaporization of the wastewater 2 . Vaporization in this case is taken to mean water passing from the liquid phase to the gas phase, wherein the temperature is below the boiling point.
[0028] This has the advantage that, for the heat-exchange process for heating up the wastewater 2 , waste heat from a further industrial process 46 can be utilized which otherwise would be released unrestrictedly to the surroundings on account of the relatively low temperature thereof. This concerns, in particular, waste heat which is typically associated with temperatures between 60° C. and 100° C.
[0029] In processes 46 having gaseous waste heat, the temperature can also typically be 400° C. (waste heat from a gas turbine). Here, it is possible that the gaseous waste-heat medium is fed directly as heat-exchange medium 4 to the heat exchanger 10 or whether a further heat-exchange process which is not shown is connected intermediately. Gaseous heat-exchange media have a lower heat-transfer coefficient than liquid heat-exchange media. To achieve the desired vaporization temperatures of the wastewater 2 , accordingly, the heat-transfer coefficients must be taken into account and the required mass flow rates must be calculated from the waste heat of the process 46 according to the available temperature.
[0030] These relatively low temperatures from the waste heat of the process 46 can be utilized a further time in an energetically rational manner using the wastewater treatment device 28 described, which in this embodiment, is advantageous for the entire energy balance of the water treatment device 1 .
[0031] Around the wastewater treatment device 28 , a conduit 30 is drawn in schematically, which is intended to illustrate the fact that the vaporization and condensation process of the wastewater 2 can possibly proceed many times repetitively.
[0032] The purified water 44 can, as is shown by the arrow, having the number 44 in FIG. 2 , be added back to the rinse process, represented by water utilization device 26 . The water 44 purified by the described water treatment device 28 is in itself aseptic and also preferably has no residues of acids, but for use in the food industry an additional high-temperature disinfection 24 can be required, for which reason the purified water 44 is added a further time to such a disinfection device 24 , before it is again available for the rinse process.
[0033] In FIG. 3 , the water treatment device 1 described schematically in FIG. 2 is shown in more detail. In particular, in FIG. 3 , the wastewater treatment device 28 with the evaporation device 12 and the condenser device 14 , and the interaction of individual heat exchangers 10 , 11 , which contribute to minimizing the energy requirement, are described.
[0034] As already discussed with reference to FIG. 2 , a fresh water 20 is added to a reverse osmosis system 18 , the thus pretreated fresh water 20 ′ is heated to about 140° to 150° C. in a high-temperature disinfection device 24 in order to ensure the absolute freedom from microbes of the thus treated fresh water 20 ″, which is used as rinse water in a water utilization device 26 .
[0035] If the arrow labeled with the reference sign 20 ′ and which exits from the reverse osmosis system 18 is followed, the fresh water 20 ′, before it is passed into the high-temperature disinfection device 24 , is first passed into a condenser 15 ′, which is part of the wastewater treatment device 28 . In the condenser 15 ′, the fresh water 20 ′ is preheated, since in the condensation process, which will be considered further hereinafter, heat of condensation is liberated by the condensation, wherein the condenser 15 ′ acts as heat exchanger and the fresh water 20 ′ is preheated using the heat of condensation. The energy requirement which is needed in the high-temperature disinfection device 24 and which is added, in particular, in steam form, for example via a steam generator, is already decreased in this case, since the waste heat from the condensation process can be profitably used for the high-temperature disinfection 24 . The high-temperature disinfection 24 also takes place only for a very short time which is sufficient to kill off all microbes from the fresh water 20 ′. The fresh water 20 ″ treated in this manner, which in turn has a relatively high temperature, is then sent via a further heat exchanger 11 in which it is again cooled to a temperature which is usable for the rinse operation. The heat exchanger 11 and the heat exchanger 23 in the high-temperature disinfection system 24 are thus in constant interchange, and so in this process, only very little heat energy is lost. The heat taken off from the fresh water 20 ″ in the heat exchanger 11 is used further at another point of the process, which will be considered further.
[0036] In principle, it can also be expedient to utilize the heat taken off from the fresh water 20 ″ after the high-temperature disinfection for preheating the fresh water 20 ′ for the high-temperature disinfection process. This is not shown in this form in FIG. 3 , but is outlined in FIG. 2 by a preheating device 22 . A heat exchanger 23 of the high-temperature disinfection device 24 is therefore in constant thermal exchange with a heat exchanger of the preheating device 23 . In the case of good thermal insulation, the heat energy which is required for the high-temperature disinfection and needs to be constantly supplied to the system is very low.
[0037] To return to FIG. 3 : the fresh water 20 ″ is then added to the water utilization device 26 , that is to say, as already repeatedly described by way of example, PET bottles are rinsed. After the rinse operation, the former fresh water 20 ″ is a wastewater 2 contaminated with organic acid. This wastewater 2 is collected in the wastewater collecting device 8 and pumped by a pump 38 ′ into the neutralization device 27 . There, the neutralization takes place as described in FIG. 2 .
[0038] The neutralized wastewater 2 ′ is subsequently passed into the wastewater treatment device 28 , as is indicated by the pump 38 ′. Hereinafter, the mode of action of the wastewater treatment device 28 will be considered in more detail. The relatively cold wastewater 2 ′, in an advantageous embodiment, is firstly passed through a condenser 15 , the mode of action of which will be considered hereinafter. As already mentioned, this condenser 15 gives off heat of condensation, which is utilized for heating up the wastewater 2 ′. Subsequently, the wastewater 2 ′ is sent through the abovementioned heat exchanger 11 , as a result of which it is further heated. Finally, the wastewater 2 ′ is further heated up in the heat exchanger 10 , wherein a heat medium 4 can be in thermal contact with the waste heat of a further industrial process 46 . The wastewater 2 is heated by the heat exchangers 11 and 10 to a temperature which is between 60° C. and the boiling point of the wastewater 2 ′. The boiling point of the wastewater 2 ′ can fluctuate around the boiling temperature of the pure water, depending on the dissolved substances (acetic acid, peracetic acid, surfactants or salts). Boiling temperatures between 95° C. and 110° C. can usually occur.
[0039] The wastewater 2 ′ that is preheated to this vaporization temperature is then introduced into the evaporation device 12 and atomized there. The wastewater 2 ′ lands on vaporizer surfaces 34 , which can be fabricated from differing materials, for example from cellulose materials. The vaporizer surfaces 34 are distinguished, in particular, in that they have a very high surface area in relation to their base area. The wastewater 2 ′ is converted on the vaporizer surfaces 34 into the gas phase by vaporization, wherein the wastewater 2 ″ then present in gaseous form is introduced via the conduit marked 2 ″ into the condenser device 14 . In the condenser device 14 , condensers 15 and 15 ′ are arranged, the mode of action of which has already been described. On the condensers 15 and 15 ′, the wastewater 2 ″ condenses to re-form water which is in itself then microbe-free and purified. It is removed from the condenser device 14 as purified water 44 .
[0040] Since, depending on the embodiment of the wastewater treatment device 28 and depending on the configuration of the vaporizer surfaces 34 , and also depending on the amount of the wastewater 2 ′ introduced into an evaporation and condensation cycle, not all of the wastewater 2 ′ can be evaporated, in the evaporation device 12 collection funnels 26 are provided in which the non-evaporated wastewater 2 is collected, and is pumped off from the evaporation device 12 by a pump 38 . The wastewater 2 ′ that is thus collected again is likewise passed through the condenser 15 , it is heated again in this process by the heat of condensation and in a further cycle is passed through the heat exchangers 11 and 10 back into the evaporation device 12 . This corresponds to the arrow 30 indicated in FIG. 2 that leads back a return line of the wastewater 2 for further repetitive vaporization and condensation. In addition, there is a further conduit between the condensation device 14 and the evaporation device 12 , wherein, via a fan 40 , air is exchanged via an air equalization device 42 between these two devices 12 and 14 .
[0041] A small part of the wastewater 2 which is concentrated with salts and surfactants which cannot be treated by the device described is fed as residual water 32 to the sewage system.
[0042] The purified water 44 can then again be fed to the rinse process or the water utilization device 26 . There are two alternatives therefor. For extremely high demands which are of relevance to freedom from microbes, the purified water 44 can be subjected a further time to the high-temperature disinfection 24 and passed via the bypass as fresh water 20 ″ through the heat exchanger 11 to the water utilization device 26 . Since the purified water is in itself already virtually microbe-free, it can be expedient in various applications to conduct a direct conduit, which is shown with dashed lines in FIG. 3 with 44 ′, to the water utilization device 26 and to feed in there directly this purified water 44 again. In this case, an energetically more complex high-temperature disinfection could be dispensed with.
[0043] The invention has been described in detail with particular reference to preferred embodiments thereof and examples, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention covered by the claims which may include the phrase “at least one of A, B and C” as an alternative expression that means one or more of A, B and C may be used, contrary to the holding in Superguide v. DIRECTV, 69 USPQ2d 1865 (Fed. Cir. 2004). | A method reprocesses waste water containing an organic acid from an industrial process. A base is added to the acid-containing waste water. A salt dissolving in the waste water is produced due to a neutralization reaction. The waste water is subsequently guided in a heat exchanger process, a heat exchange medium being used such that the waste water which is to be treated is partially evaporated and is condensed into purified water on a condensation device. A concentrate enriched with the salt forms a residue and the purified water is guided back into the industrial process. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a division of application Ser. No. 537,213, filed Sept. 29, 1983, now U.S. Pat. No. 4,541,987.
BACKGROUND OF THE INVENTION
1. Technical Field
This invention relates generally to a method and apparatus for detecting the presence of blood in an aqueous solution. More specifically, the present invention relates to a method and apparatus in which a dry reagent and dry peroxygen compound are packaged in a test pad for in-home testing of fecal material or urine in a toilet bowl.
2. Prior Art
Early detection of gastrointestinal cancers is vital to successful treatment. One sign of gastrointestinal cancer is the presence of blood in fecal material or urine. Frequently when blood is visible the cancer has already progressed to a late stage. Tests for detecting blood in such samples before it is visible are very useful but have suffered from certain problems and deficiencies.
U.S. Pat. No. 2,838,377 to Fonner discloses one method for detecting the presence of occult, unseen, blood in feces and urine. In Fonner, an envelope of sheet material contains a dried reagent material that is adapted to be dropped into a toilet bowl containing water and either feces, urine or both with the reagent changing color if blood is present in the solution. The reagent mixtures are selected from the group consisting of o-tolidine, benzidine, or o-toluidine. The primary disadvantage of the Fonner test is that the reagents used are either suspected or known carcinogens. Another problem with the Fonner test is its lack of specificity causing it to frequently yield a positive test result when no blood is actually present in the sample.
U.S. Pat. No. 3,996,006 to Pagano discloses a specimen test slide comprising of a multi-fold cardboard package having a sheet of test paper impregnated with a guaiac based reagent material enclosed therein. The test is performed by applying samples of feces on one side of the test paper after opening a flap formed in the test slide and sending the test slide to a laboratory for analysis. Laboratory analysis is performed by applying a peroxide solution to the opposite side of the test paper and observing the test paper to determine whether a color reaction caused by the presence of blood occurs. The necessity of handling fecal material and sending the specimen to a laboratory for later analysis is a serious disadvantage of the Pagano test.
U.S. Pat. No. 4,175,923 to Friend discloses a method for determining the presence of occult blood in the bowl of a toilet by first spraying a developing solution of ethyl alcohol and hydrogen peroxide on a sheet of guaiac impregnated test paper and then dropping the test paper into the bowl. One problem with Friend is that patients are reluctant to use liquid reagents. Also, the ethyl alcohol and hydrogen peroxide solution is caustic which may cause irritation if it comes into contact with a patient's skin. Even though the above problems are encountered when an activating solution of hydrogen peroxide is applied to a test pad, Friend teaches that such a solution is essential for a test using a guaiac reagent in a cold water environment.
Various other tests for the presence of occult blood in fecal material and urine samples have been proposed, however, none have realized the advantages of the present invention wherein a patient may conveniently test for the presence of occult blood in a toilet bowl without the use of carcinogenic materials and without the need for activating solutions.
SUMMARY OF THE INVENTION
The present invention relates to a method and apparatus for determining the presence of blood in an aqueous solution containing a sample to be tested wherein a pad having a solid peroxyen compound and a solid guaiac substitute reagent is floated on the surface of the solution and observed for a chromogen reaction. The term "guaiac substitute" refers to a chromogen which may be utilized in place of guaiac.
The breakthrough achieved by the preferred chemistry of the invention is that the reagents are soluable and functional in a cold water environment without using an activating solution and without using known carcinogenic materials.
The guaiac substitute reagent is preferably guaiacolsulfonate and the peroxygen compound is preferably potassium monopersulfate. The guaiac substitute reagent and peroxygen compound are both water soluble and become activated upon contact with the aqueous solution. The chromogen reaction will occur even if only a small amount of blood is present in the sample and is therefore very sensitive. The preferred reagents are not easily catalyzed by oxidants other than hemoglobin or hemin based substances which makes the test very specific.
In accordance with the present invention, the test for occult blood does not require handling of reagent materials or activating solutions. The test is performed entirely within the toilet bowl and does not require sending samples or specimens to a laboratory for further analysis or testing.
Another aspect of the present invention is the provision of controls on a test pad to verify the accuracy of the test. A comparative positive site (positive control) may be included on the test pad that would include the same reagent and peroxygen compound as used in the test pad test area plus a small amount of catalyst material that should always yield the positive test results. If a negative result is indicated on the positive control the test should be repeated with another test pad because the first test pad falsely indicated that the test result was negative when all of the components for a positive test were present in the test pad.
A comparative negative site (negative control) may also be included in the test pad for indicating falsely positive results and for comparison with the test area if the test area indicates that no blood is present. The negative control would include a substance similar in appearance to the contents of the test area such as the dry peroxygen powder without inclusion of the guaiac substitute reagent. Since the guaiac substitute reagent is not present in the negative control, under no circumstances should a chromogen reaction occur. The negative control also permits the test area to be compared to the negative control wherein if no color reaction occurs the two areas should have the same appearance.
The invention will be better understood upon studying the following detailed description with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a test pad disposed in a sealed envelope with the top layer of the sealed envelope partially removed for access to the test pad.
FIG. 2 is a plan view of the test pad having a test area, a comparative positive site and a comparative negative site.
FIG. 3 is a cross-sectional view taken along the line 3--3 in FIG. 2.
FIG. 4 is a test pad having a single deposit of reagent material in a test area.
FIG. 5 is a test pad having a test area and a comparative positive site.
FIG. 6 is a test pad having a plurality of spaced apart test areas, a comparative positive site and a comparative negative site.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, the test kit 10 is shown to include a test pad 12 which is enclosed within the envelope 13. The envelope provides a hermetically sealed pocket for the test pad to protect it from contamination or exposure to moisture during shipment and storage. The test pad 12 includes a top layer of an absorbant material, preferably paper, and a bottom layer 16 likewise formed of a absorbant material such as paper. Between the top and bottom layers 15 and 16, pockets are formed for enclosing a dry powder material.
A test area 17 is provided which includes a reagent material and a dry peroxygen compound. The test area 17 is the area on the test pad 12 which undergoes a chromogen reaction when the test pad 12 is placed in a toilet bowl containing water and fecal material containing blood. If occult blood is present, even in small amounts, the chromogen reaction should occur.
The test area 17 preferably contains a solid peroxygen compound such as potassium monopersulfate and a monopersulfate potassium salt reagent, preferably guaiacolsulfonate. This combination of materials is activated by the water in the toilet bowl and is very sensitive to the presence of blood in the solution. It has been found that guaiacolsulfonate and potassium monopersulfate are highly specific and do not under most circumstances yield false positive indications when no blood is present in the solution.
The test pad 12 floats on the surface of the toilet bowl, due to the lightweight paper and selected adhesives of the test pad, to facilitate analysis of the test. The test pad 12 is preferably biodegradable to permit disposing of the test pad 12 by simply flushing the toilet after the test is completed.
It is preferred that the top layer 15 of the test pad include blue-green pigmentation to provide a good contrast with the red-orange colored compound formed when the guaicolsulfonate and potassium monopersulfate are catalyzed by blood.
The top and bottom layers 15 and 16 of the test pad 12 are preferably bonded together by means of an adhesive or a heat seal process which is effective to keep the reagent materials in place on the test pad 12.
A positive control 18 may also be included on the test pad 12 to indicate when the result of the test is falsely negative. The positive control 18 includes the solid peroxygen compound and the reagent as well as a small amount of a catalyzing agent such as hemoglobin which will in all cases cause the positive control 18 to undergo the chromogen reaction yielding a red-orange colored compound if the reagent and peroxygen compound are present and functioning properly. The quantity of catalyst in the positive control 18 should be limited so that all of the catalyst is used up by the reagent in the control 18 and is not permitted to migrate to the test area 17. If the positive control 18 fails to undergo the chromogen reaction the test results should be disregarded since all of the components for a positive test result are present in the positive control.
The positive control 18 also provides an example for comparison with the test area if the test area undergoes a chromogen reaction.
A negative control 18 may also be provided that should not undergo a chromogen reaction. The negative control 19 would contain a substance having a similar appearance to the substance contained in the test area 17. The substance in the negative control 19 may be the solid peroxygen compound without any of the solid reagent material. The peroxygen compound should not undergo a chromogen reaction unless the test pad is contaminated, manufactured improperly, or an interfering substance is present in the toilet bowl.
The negative control 19 may also be used as a point of reference for the test area 17 when no chromogen reaction occurs at the test area 17. If the negative control 19 and the test area 17 have the same appearance after the test has been performed the patient may then assume that the test was negative.
As shown in FIGS. 1, 2 and 3, the test pad may include positive and negative controls 18 and 19 in addition to the test area 17. Alternatively, as shown in FIG. 4, the test pad may include only the test area 17. Or, as shown in FIG. 5, the test pad may include the test area 17 and positive control 18. In another alternative, shown in FIG. 6, more than one test area 17 may be provided on a pad 12 to permit verification of a test with a single pad 12. Positive and negative controls 18 and 19 are also provided for comparison purposes as previously described.
An example of a reagent and solid peroxygen compound combination may be equal parts of potassium guaiacolsulfonate (PGS), a guaiac substitute material also known as 1-hydroxy-2-methoxy-benzene-4 (or -5) sulfonic acid, and a compound (MPS) sold by DuPont Co. under the trademark "Oxone" which comprises two moles of potassium monopersulfate, one mole of potassium hydrogen sulfate and one mole of potassium sulfate. Depending upon the purity or strength of the PGS, the acceptable range of mixtures may vary from 1/3 PGS and 2/3 Oxone to 2/3 PGS and 1/3 Oxone. Both the peroxygen compound and reagent are known industrial chemical products.
When used together in a test pad the preferred peroxygen compound and reagent offer sensitivity and specificity not realized in the prior art products. PGS has the chemical formula C 7 H 7 KO 5 S or in its dipotassium water complex form C 7 H 7 K 2 O 5 S.H 2 O with the chemical structure as follows: ##STR1##
One important advantage of PGS is that it is freely soluble in water within a wide range of temperatures. Another advantage is that PGS is not a suspected carcinogenic chemical. PGS is a chromogen which yields a red-orange color when exposed to an appropriate oxidizing substance. PGS is safe to use and eliminates the need for a patient to use caustic solutions of alcoholic peroxide as recommended by some prior art tests.
The preferred compound, identified hereinafter as MPS, has the chemical formula 2KHSO 5 .KHSO 4 .K 2 SO 4 , with the major component having the chemical structure: ##STR2## Oxone is soluble in water and actively releases oxygen. Oxone is a triple salt which has been found to yield superior results than a combination of its three component salts. Oxone is not as sensitive to trace metal impurities as most peroxygen compounds, while cobalt, nickel, copper, and manganese ions will catalyze the decomposition of Oxone with the evolution of oxygen gas, this catalysis does not interfere with the occult blood test in levels normally encountered in a toilet bowl.
Specificity
The mixture of PGS and MPS powder in a test pad also exhibits superior specificity in testing for blood in a solution. The mixture proposed by the present invention is less likely to result in false positive tests because it is not effected by metal ions and other contaminants commonly found in a toilet bowl.
The following chart represents an analysis of the present invention, denoted MPS/PGS, as compared to guaiac impregnated paper activated by an alcoholic hydrogen peroxide solution. The guaiac impregnated paper and alcoholic hydrogen peroxide system used is currently sold by Helena Laboratories under the trademark ColoScreen. In the test the MPS/PGS system and ColoScreen kit were exposed to various solutions including the substances listed in the left column. The results of the test are set forth in Table I.
TABLE I______________________________________Specimen ColoScreen MPS/PGS______________________________________Water - -Horseradish ++++ +PeroxidaseFe.sup.+3 ion ++ -Fe.sup.+2 ion ++ -Urine - -CuCl.sub.2 +++++ -CaCl.sub.2 ++ -Cu(OH).sub.2 - -(Not in solution)Cu(C.sub.2 H.sub.3 O.sub.2).sub.2 +++++ -Pb(C.sub.2 H.sub.3 O.sub.2).sub.2 +++ -NaHOCl ++++ +(5.25%)Cleanser - +Na.sub.2 CO.sub.3 - -______________________________________ Legend: - No Color Change + Color Change ++ Pronounced Color Change +++ Strong Color Change ++++ Very Strong Color Change +++++ Maximum Color Change
Sensitivity
The mixture of PGS and MPS powder in the test pad exhibits excellent sensitivity to the presence of occult blood in very small quantities. The sensitivity has been determined to be relatively unaffected by contaminants commonly found in a toilet bowl.
The sensitivity to hemoglobin of the MPS/PGS system was tested in solutions having different concentrates of FeSO 4 . The purpose of the test being to determine the effect of FeSO 4 on the chromogen reaction catalyzed by hemoglobin. The results of the test are set forth in Table II.
TABLE II______________________________________Hemoglobin 2 mg % 4 mg %Concentration Water 1 mg % Hemo. Hemo.______________________________________FeSO.sub.4 Concentration600 mg % ± -++ + +(1.5 × 10.sup.-3 mole %)400 mg % - -+ ± + +(1.0 × 10.sup.-3 mole %)200 mg % - ± + +(5.1 × 10.sup.-4 mole %)100 mg % - - -+ ± +(2.5 × 10.sup.-4 mole %)0 mg % - - -+ ± +______________________________________ Legend: - -+ Minor Trace ± Trace -++ Minor Color Change + Color Change
Thus, the test indicates sensitivity is not adversely affected by iron compounds in the solution. In extreme concentrations of 400 mg % to 600 mg %, where an iron precipitate is observable a color change may occur in the water surrounding the pad but not at the site of the reaction. Such a reaction occurs after two minutes and would not be confused with a positive test. However, the test is sensitive to very small concentrations of hemoglobin (1 mg%) regardless of the amount of iron in the sample.
This feature is important because iron is frequently present in toilet bowl water of older buildings or it may be present in the feces or urine of a patient. It has been determined that the MPS/PGS system does not undergo a color change until approximately 1×10 -2 M. of Fe +2 ion or 4×10 -2 M. of Fe +3 ion is present in the solution.
When MPS and potassium guiacolsulfonate (PGS) are combined in the test pad of the present invention, the sensitivity of the chemicals to blood in a solution is equivalent to that of the combination proposed by Friend in his U.S. Pat. No. 4,175,923 which requires the use of a strong caustic alcohol peroxide solution.
The sensitivity of the MPS/PGS system was evaluated in solutions containing an iron sulfate and varying amounts of hemoglobin with the result that sensitivity was found to be unaffected.
The invention has been in described in conjunction with a specific embodiment, however, there are many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations that fall within the scope of the appended claims. | A test pad having a water activated reagent and a water activated peroxygen compound which undergo a chromogen reaction in an aqueous solution including hemoglobin. The reagent is potassium guaiacolsulfonate, a guaiac substitute material. The peroxygen compound is a monopersulfonate compound comprised of two moles of potassium monopersulfonate, one mole of potassium hydrogen sulfate and one mole of potassium sulfate. The test pad features a test area containing the above materials in powdered form and may also include controls for checking the results of the test. A method for using the test pad is also disclosed. | 8 |
This application is a continuation-in-part of provisional application Ser. No. 60/069,371, filed Dec. 12, 1997.
BACKGROUND OF THE INVENTION
Asthma is a complex disease involving the concerted actions of multiple inflammatory and immune cells, spasmogens, inflammatory mediators, cytokines and growth factors. In recent practice there have been four major classes of compounds used in the treatment of asthma, namely bronchodilators (e.g., β-adrenoceptor agonists), anti-inflammatory agents (e.g., corticosteroids), prophylactic anti-allergic agents (e.g., cromolyn sodium) and xanthines (e.g., theophylline) which appear to possess both bronchodilating and anti-inflammatory activity.
Theophylline has been a preferred drug of first choice in the treatment of asthma. Although it has been touted for its direct bronchodilatory action, theophylline's therapeutic value is now believed to also stem from anti-inflammatory activity. Its mechanism of action remains unclear. However, it is believed that several of its cellular activities are important in its activity as an anti-asthmatic, including cyclic nucleotide phosphodiesterase inhibition, adenosine receptor antagonism, stimulation of catecholamine release, and its ability to increase the number and activity of suppressor T-lymphocytes. While all of these may actually contribute to its activity, only PDE inhibition may account for both the anti-inflammatory and bronchodilatory components. However, theophylline is known to have a narrow therapeutic index and a wide range of untoward side effects which are considered problematic.
Of the activities mentioned above, theophylline's activity in inhibiting cyclic nucleotide phosphodiesterase has received considerable attention recently. Cyclic nucleotide phosphodiesterases (PDEs) have received considerable attention as molecular targets for anti-asthmatic agents. Cyclic 3',5'-adenosine monophosphate (cAMP) and cyclic 3',5'-guanosine monophosphate (cGMP) are known second messengers that mediate the functional responses of cells to a multitude of hormones, neurotransmitters and autocoids. At least two therapeutically important effects could result from phosphodiesterase inhibition, and the consequent rise in intracellular adenosine 3',5'-monophosphate (cAMP) or guanosine 3',5'-monophosphate (cGMP) in key cells in the pathophysiology of asthma. These are smooth muscle relaxation (resulting in bronchodilation) and anti-inflammatory activity.
It has become known that there are multiple, distinct PDE isoenzymes which differ in their cellular distribution A variety of inhibitors possessing a marked degree of selectivity for one isoenzyme or the other have been synthesized.
The structure-activity relationships (SAR) of isozyme-selective inhibitors has been discussed in detail, e.g., in the article of Theodore J. Torphy, et al., "Novel Phosphodiesterase Inhibitors For The Therapy Of Asthma", Drug News & Prospectives, 6(4) May 1993, pages 203-214. The PDE enzymes can be grouped into five families according to their specificity toward hydrolysis of cAMP or cGMP, their sensitivity to regulation by calcium, calmodulin or cGMP, and their selective inhibition by various compounds. PDE I is stimulated by Ca 2+ /calmodulin. PDE II is cGMP-stimulated, and is found in the heart and adrenals. PDE III is cGMP-inhibited, and inhibition of this enzyme creates positive inotropic activity. PDE IV is cAMP specific, and its inhibition causes airway relaxation, antiinflammatory and antidepressant activity. PDE V appears to be important in regulating cGMP content in vascular smooth muscle, and therefore PDE V inhibitors may have cardiovascular activity.
While there are compounds derived from numerous structure activity relationship studies which provide PDE III inhibition, the number of structural classes of PDE IV inhibitors is relatively limited. Analogues of rolipram, which has the following structural formula (A): ##STR7## and of RO-20-1724, which has the following structural formula (B): ##STR8## have been studied.
U.S. Pat. No. 4,308,278 discloses compounds of the formula (C) ##STR9## wherein R 1 is (C 3 -C 6 ) cycloallyl or benzyl; each of R 2 and R 3 is hydrogen or (C 1 -C 4 ) alkyl; R 4 is R 2 or alkoxycarbonyl; and R 5 is hydrogen or alkoxycarbonyl.
Compounds of Formula (D) are disclosed in U.S. Pat. No. 3,636,039. These compounds are benzylimidazolidinones which act as hypertensive agents. ##STR10## Substituents R 1 -R 4 in Formula D represent a variety of groups, including hydrogen and lower alkyl.
PCT publication WO 87/06576 discloses antidepressants of Formula E: ##STR11## wherein R 1 is a polycycloalkyl group having from 7 to 11 carbon atoms; R 2 is methyl or ethyl; X is O or NH; and Y comprises a mono-or bicyclic heterocyclic group with optional substituents.
Rolipram, which was initially studied because of its activity as an anti-depressant, has been shown to selectively inhibit the PDE IV enzyme and this compound has since become a standard agent in the classification of PDE enzyme subtypes. There appears to be considerable therapeutic potential for PDE IV inhibitors. Early work focused on depression as a CNS therapeutic endpoint and on inflammation, and has subsequently been extended to include related diseases such as dementia, including vascular dementia, multi-in-farct dementia and Alzheimer's Disease, and asthma. In-vitro, rolipram, RO20-1724 and other PDE IV inhibitors have been shown to inhibit (1) mediator synthesis/release in mast cells, basophils, monocytes and eosinophils; (2) respiratory burst, chemotaxis and degranulation in neutrophils and eosinophils; and (3) mitogen-dependent growth and differentiation in lymphocytes (The PDE IV Family Of Calcium-Phosphodiesterases Enzymes, John A Lowe, III, et al., Drugs of the Future 1992, 17(9):799-807).
PDE IV is present in all the major inflammatory cells in asthma including eosinophils, neutrophils, T-lymphocytes, macrophages and endothelial cells. Its inhibition causes down regulation of inflammatory cell activation and relaxes smooth muscle cells in the trachea and bronchus. On the other hand, inhibition of PDE III, which is present in myocardium, causes an increase in both the force and rate of cardiac contractility. These are undesirable side effects for an anti-inflammatory agent. Theophylline, a non-selective PDE inhibitor, inhibits both PDE III and PDE IV, resulting in both desirable anti-asthmatic effects and undesirable cardiovascular stimulation. With this well-known distinction between PDE isozymes, the opportunity for concomitant anti-inflammation and bronchodilation without many of the side effects associated with theophylline therapy is apparent.
The increased incidence of morbidity and mortality due to asthma in many Western countries over the last decade has focused the clinical emphasis on the inflammatory nature of this disease and the benefit of inhaled steroids. Development of an agent that possesses both bronchodilatory and antiinflammatory properties would be most advantageous.
It appears that selective PDE IV inhibitors should be more effective with fewer side effects than theophylline. Clinical support has been shown for this hypothesis. Furthermore, it would be desirable to provide PDE IV inhibitors which are more potent and selective than rolipram and therefore have a lower IC 50 so as to reduce the amount of the agent required to effect PDE IV inhibition.
OBJECTS AND SUMMARY OF THE INVENTION
It is accordingly a primary object of the present invention to provide new compounds which are more effective selective PDE IV inhibitors than known prior art compounds.
It is another object of the present invention to provide new compounds which act as effective PDE IV inhibitors with lower PDE III inhibition.
It is another object of the present invention to provide methods for treating a patient requiring PDE IV inhibition.
It is another object of the present invention to provide new compounds for treating disease states associated with abnormally high physiological levels of inflammatory cytokines, including tumor necrosis factor.
It is another object of the present invention to provide a method of synthesizing the new compounds of this invention.
It is another object of the present invention to provide a method for treating a patient suffering from disease states such as asthma, allergies, inflammation, depression, dementia, including vascular dementia, multi-in-farct dementia, and Alzheimer's Disease, a disease caused by Human Immunodeficiency Virus and disease states associated with abnormally high physiological levels of inflammatory cytokines.
Other objects and advantages of the present invention will become apparent from the following detailed description thereof.
With the above and other objects in view, the present invention comprises compounds having the general formula (I): ##STR12## wherein:
Z is selected from the group consisting of alkylene groups such as CH 2 , CH 2 CH 2 , CH(CH 3 ); alkenylene groups such as CH═CH; alkynylene groups such as C.tbd.C; and NH, N(C 1 -C 3 alkyl), O, S, C(O)CH 2 and OCH 2 ;
R 1 and R 2 are independently selected from the group consisting of hydrogen and a C 1 -C 8 straight or branched alkyl or C 3 -C 8 cycloalkyl;
R 3 is a C 1 -C 12 straight or branched alkyl;
R 4 is a C 3 -C 10 cycloalkyl optionally substituted with OH, or a C 3 -C 10 cycloalkenyl optionally substituted with OH, and
R 8 is a C 1 -C 8 straight or branched alkyl or a C 3 -C 8 cycloalkyl, optionally substituted with OH.
The present invention is also related to methods of using compounds of formula (I) for treating patients who can benefit from a modification of PDE IV enzyme activities in their bodies.
The invention also comprises methods of making compounds of formula (I), according to a four step synthetic scheme as generally set forth in Scheme 1. The stated conditions in Scheme 1 are includes as examples only, and are not meant to be limiting in any manner. ##STR13##
The invention is also related to a method of treating mammals with the above compounds.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to compounds having the general formula (I): ##STR14## wherein:
Z is selected from the group consisting of alkylene groups such as CH 2 , CH 2 CH 2 , CH(CH 3 ), alkenylene groups such as CH═CH; alkynylene groups such as C.tbd.C; and NH, N(C 1 -C 3 alkyl), O, S, C(O)CH 2 and OCH 2 ;
R 1 and R 2 are independently selected from the group consisting of hydrogen and a C 1 -C 8 straight or branched alkyl or C 3 -C 8 cycloalkyl;
R 3 is a C 1 -C 12 straight or branched alkyl;
R 4 is a C 3 -C 10 cycloalkyl optionally substituted with OH, or a C 3 -C 10 cylcoalkenyl optionally substituted with OH; and
R 8 is a C 1 -C 8 straight or branched alkyl or a C 3 -C 8 cycloalkyl optionally substituted with OH.
As used herein, the following terms are intended to have the meaning as understood by persons of ordinary skill in the art, and are specifically intended to include the meanings set forth below:
"Alkyl" means a linear or branched aliphatic hydrocarbon group having a single radical. Examples of alkyl groups include methyl, propyl, isopropyl, butyl, n-butyl, isobutyl, sec-butyl, tert-butyl, pentyl, hexyl, heptyl, cetyl, and the like. A branched alkyl means that one or more alkyl groups such as methyl, ethyl or propyl are attached to a linear alkyl chain.
The term "cycloalkyl" means a non-aromatic mono- or multicyclic ring system having a single radical. Exemplary monocyclic cycloalkyl rings include cyclopentyl cyclohexyl and cycloheptyl. Exemplary multicylic cycloalkyl rings include adamantyl and norbornyl.
The term "cycloalkenyl" means a non-aromatic monocyclic or multicyclic ring system containing a carbon-carbon double bond and having a single radical. Exemplary monocyclic cycloalkenyl rings include cyclopentenyl, cyclohexenyl or cycloheptenyl. An exemplary multicyclic cycloalkenyl ring is norbornenyl. "Alkylene" means a linear or branched aliphatic hydrocarbon group having two radicals. Examples of alkylene groups include methylene, propylene, isopropylene, butylene, and the like.
The term "alkenylene" means a linear or branched aliphatic hydrocarbon group containing a carbon-carbon double bond, having two radicals.
The term "alkynylene" means a linear or branched aliphatic hydrocarbon group containing a carbon-carbon triple bond and, having two radicals.
"Alkoxy" means an alkyl-O-group in which the alkyl group is as previously described Exemplary alkoxy groups include methoxy, ethoxy, n-propoxy, i-propoxy, n-butoxy and heptoxy.
The term "cycloalkoxy" means a cycloalkyl-O-group in which the cycloakyl group is as previously described. Exemplary cycloalkoxy groups include cyclopentyloxy.
As used herein, the term "patient" includes both human and other mammals.
The present invention also includes organic and inorganic salts, hydrates, esters, prodrugs and metabolites of the compounds of formula I.
The compounds of the present invention can be administered to anyone requiring PDE IV inhibitor. Administration may be orally, topically, by suppository, inhalation or insufflation, or parenterally.
The present invention also encompasses all pharmaceutically acceptable salts of the foregoing compounds. One skilled in the art will recognize that acid addition salts of the presently claimed compounds may be prepared by reaction of the compounds with the appropriate acid via a variety of known methods. Alternatively, alkali and alkaline earth metal salts are prepared by reaction of the compounds of the invention with the appropriate base via a variety of known methods. For example, the sodium salt of the compounds of the invention can be prepared via reacting the compound with sodium hydride.
Various oral dosage forms can be used, including such solid forms as tablets, gelcaps, capsules, caplets, granules, lozenges and bulk powders and liquid forms such as emulsions, solutions and suspensions. The compounds of the present invention can be administered alone or can be combined with various pharmaceutically acceptable carriers and excipients known to those skilled in the art, including but not limited to diluents, suspending agents, solubilizers, binders, retardants, disintegrants, preservatives, coloring agents, lubricants and the like.
When the compounds of the present invention are incorporated into oral tablets, such tablets can be compressed, tablet triturates, enteric-coated, sugar-coated, film-coated, multiply compressed or multiply layered. Liquid oral dosage forms include aqueous and nonaqueous solutions, emulsions, suspensions, and solutions and/or suspensions reconstituted from no-effervescent granules, containing suitable solvents, preservatives, emulsifying agents, suspending agents, diluents, sweeteners, coloring agents, and flavorings agents. When the compounds of the present invention are to be injected parenterally, they may be, e.g., in the form of an isotonic sterile solution. Alternatively, when the compounds of the present invention are to be inhaled, they may be formulated into a dry aerosol or may be formulated into an aqueous or partially aqueous solution.
In addition, when the compounds of the present invention are incorporated into oral dosage forms, it is contemplated that such dosage forms may provide an immediate release of the compound in the gastrointestinal tract, or alternatively may provide a controlled and/or sustained release through the gastrointestinal track. A wide variety of controlled and/or sustained release formulations are well known to those skilled in the art, and are contemplated for use in connection with the formulations of the present invention. The controlled and/or sustained release may be provided by, e.g., a coating on the oral dosage form or by incorporating the compound(s) of the invention into a controlled and/or sustained release matrix.
Specific examples of pharmaceutically acceptable carriers and excipients that may be used to formulate oral dosage forms, are described in the Handbook of Pharmaceutical Excipients, American Pharmaceutical Association (1986), incorporated by reference herein. Techniques and compositions for making solid oral dosage forms are described in Pharmaceutical Dosage Forms: Tablets (Lieberman, Lachman and Schwartz, editors) 2nd edition, published by Marcel Dekker, Inc., incorporated by reference herein. Techniques and compositions for making tablets (compressed and molded), capsules (hard and soft gelatin) and pills are also described in Remington's Pharmaceutical Sciences (Arthur Osol, editor), 1553-1593 (1980), incorporated herein by reference. Techniques and composition for making liquid oral dosage forms are described in Pharmaceutical Dosage Forms: Disperse Systems, (Lieberman, Rieger and Banker, editors) published by Marcel Dekker, Inc., incorporated herein by reference.
When the compounds of the present invention are incorporated for parenteral administration by injection (e.g., continuous infusion or bolus injection), the formulation for parenteral administration may be in the form of suspensions, solutions, emulsions in oily or aqueous vehicles, and such formulations may further comprise pharmaceutically necessary additives such as stabilizing agents, suspending agents, dispersing agents, and the like. The compounds of the invention may also be in the form of a powder for reconstitution as an injectable formulation.
The dose of the compounds of the present invention is dependent upon the affliction to be treated, the severity of the symptoms, the route of administration, the frequency of the dosage interval, the presence of any deleterious side-effects, and the particular compound utilized, among other things.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As used herein, the term "Et" refers to any ethyl group, and the term "Bu" refers to a butyl group. "Bu" refers to a tertiary butyl group. The term "THF" refers to tetrohydrofuran. The term "DMAC" refers to dimethyl acetate. The term "Ph" refers to a phenyl group. The terms Z; R 1 ; R 2 ; R 3 ; R 4 ; and R 8 refer to the terms as defined in this application.
The synthetic pathway described in Scheme 1 for producing xanthine compounds of FIG. I is described as follows:
In step (a) of the synthetic scheme, a pyrimidine compound (II) wherein Q is a halide, preferably chloride, is reacted with an acid e.g. an acid chloride such as isobutyrylchloride, or an acid anhydride, to form compound (III), as depicted below: ##STR15##
The acid reaction preferably occurs from about 50° C. to about 150° C., although other temperatures ranges can be used if necessary. This reaction may occur in the presence of a suitable solvent e.g. acetonitrile (CH 3 CN), DMF or a combination thereof.
Step (b) of the synthetic scheme involves the 6-halo group of compound (III) being transformed to the amine by displacement to give compound (IV) of the invention, for example as shown below: ##STR16##
The displacement reaction occurs in the presence of ammonia, preferably aqueous ammonia in an aqueous solvent or an alcoholic solvent e.g. n-butanol. This reaction preferably occurs from about 50° C. to about 150° C., although other temperatures ranges can be used if necessary.
Step (c) of the synthetic scheme, compound (IV) is first reacted with a base e.g. phosphorous oxychloride, sodium or potassium alkoxide or other alkali metal salts (e.g. calcium sulfate, sodium chloride, potassium sulfate, sodium carbonate, lithium chloride, tripotassium phosphate, sodium borate, potassium bromide, potassium fluoride, sodium bicarbonate, calcium chloride, magnesium chloride, sodium citrate, sodium acetate, calcium lactate, magnesium sulfate and sodium fluoride), or a non-nucleophilic alternative such as saspotassium t-butoxide, to cause cyclization to the 6-halopurine intermediate. The 6-halo group is then transformed to the amine by displacement to give compound (V) of the invention, for example as shown below: ##STR17##
The displacement reaction occurs in the presence of ammonia or an amine, an aqueous solvent or an alcoholic solvent e.g. ethanol. This reaction preferably occurrs from about 50° C. to about 100° C., although other temperatures ranges can be used if necessary. The displacement reaction can optionally occur in a nitrogen atmosphere.
In step (d) of the reaction, compound (V) is reacted with 3-cyclopentyloxy-4-methoxybenzylhalide as shown in compound VI, wherein X is a halogen, preferably chloride, to yield compound (I) of the invention, for example as shown below: ##STR18##
Step (d) preferably occurs in the presence of DMF or acetonitrile as solvents, although other solvents can be used. This reaction preferably occurs at at a temperature range from about 0° C. to about 200° C., preferably from about 75° C. to 175° C.
EXAMPLE 1
3-(3-Cyclopentyloxy-4-methoxybenzyl)-6-ethylamino-8-isopropyl-3H-purine
The title compound was prepared by the following synthetic pathway: ##STR19##
The pathway occured under the conditions set forth in Table 1 below. The pathway can occur under other suitable conditions known in the art and the particular conditions disclosed herein are not meant to be limiting.
______________________________________Step Compound Conditions Yield______________________________________(i) (III) i-PrCOCl (2.8 eq),100EC, 5 min 89%(ii) (IV) NH.sub.3 (aq, 3 eq), n-BuOH,100EC, 24 82%(iii) (V) POCl.sub.3,100° C. 75% EtNH.sub.2,EtOH(iv) (I) DMF, 150° C.,Compound VI 60%______________________________________
Step (i) 5-Isobutyrylamido-4,6-dichloropyrimidine
4,6-dichloro-5-aminopyrimidine (II)(ex Aldrich), (5.65 g, 34.4 mmol) and isobutyrylchloride (10 ml, 95.55 mmol) were heated together at reflux (internal temperate 100° C., oil bath temperature 130° C.) for 10 minutes. The mixture was cooled to room temperature at which point crystallisation occurred. The mixture was triturated with ether (50 ml) to give the title compound (7.15 g, 89%) as a buff coloured crystalline solid, m.p. 161.5°-162° C. tic (SiO 2 , DCM:MeOH, 20:1) Rf=0.43 detection U.V.
Step (ii) 4-Amino-6chloro-5-isobutyrylamidopyrimidine
5-isobutyrylamido- 4,6-dichloropyrimidine (III)(6.0 g, 26 mmol) was dissolved in n-butanol (30 ml). Aqueous ammonia (density=0.88 g/ml) (3 ml) was added and the mixture heated to 115° C. for 24 h. Tlc (SiO 2 , DCM:MeOH, 20:1) showed the reaction to be about 60% complete. A further 4 ml of aqueous ammonia was added and the mixture heated at reflux for 7 h. The cooled mixture was partitioned between ethyl acetate:methanol (10:1, 300 ml) and 8% aqueous sodium bicarbonate solution (300 ml). The organic phase was separated, dried (MgSO 4 ) and the solvent removed in vacuo to leave a yellow solid. Ethanol (100 ml) was added followed by ether (150 ml) and the mixture filtered, and dried overnight in-vacuo at 40° C. to give the title compound as a white solid (4.47 g, 82%) m.p. 224-225° C. Tlc, (SiO 2 , DCM:MeOH, 20:1) Rf=0.11, detection U.V.
Step (iii) 6-Ethylamino-8-isopropyl-3H-purine
4-Amino-6-chloro-5-isobutyrylamidopyrimidine (IV)(4.0 g, 18.7 mmol) and phosphorus oxychloride (30 ml) were heated together at 110° C. for 20 h. The excess phosphorus oxychloride was removed in vacuo, and the residue triturated with ether (4H50 ml) and dried to give the intermediate chloropurine (6.3 g) m.p. 209°-211° C. The chloropurine was dissolved in ethanol (50 ml) and ethylamine (70% solution in water) (20 ml) was added and the solution heated at 70° C. under a nitrogen atmosphere for 24 h. The solvent was removed in vacuo and the residue partitioned between 10% aqueous potassium carbonate solution (100 ml) and dichloromethane:methanol (10:1, 100 ml). The organic phase was separated and the aqueous phase furthere extracted with dichloromethane-methanol (10:1, 3H100 ml). The combined organics were dried (MgSO 4 ) and evaporated to dryness in vacuo to leave a pale yellow solid (4.2 g). This was recrystallised from toluene (250 ml) to give the title compound (2.88 g, 75%) as a fluffs white crystalline solid m.p.=183-184° C. Tlc (SiO 2 ,ethyl acetate:methanol 10:1), Rf=0.59 detection U.V.
Step (iv) 6-Ethylamino-3-[(3-cyclopentyloxy-4-methoxy)benzyl]-8-isopropyl-3H-purine hydrochloride
6-Ethylamino-8-isopropyl-3H-purine (V)(7.52 g,36.65 mmol) and 3-cyclopentyloxy4-methoxybenzylchloride (10.59 g,43.98 mmol) were dissolved in acetonitrile (30 ml) in a high pressure vessel and the resulting mixture heated at 120° C. for 24 h. On cooling to room temperature a solid precipitated from the solution. The solvent was removed in vacuo, cold water (10 ml) and diethyl ether (100 ml) were added to the solid residue, the mixture stirred vigourously and then filtered. The filter cake was washed with ice-cold ethyl acetate (50 ml) and the solid obtained was oven dried in vacuo at 80° C. to give the title compound (9.51 g, 58%) as a slightly off-white solid. The combined filtrates and washings were concentrated in-vacuo, then water (5 ml) and diethyl ether (100 ml) added, and the mixture treated as before to give further title compound (0.718 g, 5%) as awhite solid, m.p.=205-207° C. Combined yield (10.23 g, 63%). Tlc, SiO 2 (dichloromethane: methanol, 10:1) Rf=0.49, detection U.V., Dragendorff=s reagent.
While the invention has been illustrated with respect to the production and use of particular compounds, it is apparent that variations and modifications of the invention can be made without departing from the spirit or scope of the invention. | The present invention comprises a method of synthesizing compounds having the formula (I): ##STR1## wherein: Z, R 1 , R 2 , R 3 , R 4 and R 8 are defined herein, which comprises the steps of
(a) reacting a compound of the formula (II) ##STR2## wherein Q is a halogen, with an effective amount of a compound selected from the group consisting of an acid anhydride or an acid halide; to form a compound of the formula (III) ##STR3## b) transforming the 6-halo group of said compound (III) to an amine by displacement with ammonia to form compound (IV) ##STR4## (c) reacting said compound (IV) with a base to cause cyclization to a 6-halo intermediate, said 6-halo group is then transformed to an amine by displacement with an amine to form compound (V) ##STR5## (d) reacting said compound (V) with an effective amount of compound (VI) ##STR6## wherein X is a halogen; to form the compound of formula (I). | 2 |
BACKGROUND
The Health Insurance Portability and Accountability Act (HIPAA), enacted in 1996 includes provisions intended to help people maintain privacy with regard to their health information. Title II of HIPAA, known as the “Administrative Simplification” (AS) provisions, includes a privacy rule that addresses the security and privacy of health data. The Privacy Rule, which took full effect in 2004, regulates the use and disclosure of Protected Health Information (PHI) held by covered entities such as health insurers and medical service providers. PHI is defined as any information held by a covered entity which concerns health status, provision of health care or payment for health care that can be linked to an individual person.
Classic identifiers include identifying information such as name, patient number, and Social Security number. In general, a classic identifier is any information that is meant to identify the person as an individual. One of the conventional methods used to protect a patient's privacy includes hiding classic identifiers such as name, Social Security number (SSN), medical record number (MRN), and patient identification number. It is possible, however, to identify a person based on a non-classic identifier or by using a combination of non-classic identifiers. That is, in some cases, a field or a combination of fields may be identifying. This may be a problem in those systems that combine clinical, geographic and demographic data, e.g. cancer site, county and race may be identifying, particularly in regions of low population density.
A conventional method for assessing the risk of potential breach of patient confidentiality via non-classic identifiers in a set of data records is the “Record Uniqueness” method. The Record Uniqueness method is disclosed in “Method to Assess Identifiability in Electronic Data Files” by Holly L. Howe, et al., American Journal of Epidemiology, December 2006. The Record Uniqueness method generates frequencies for every variable and combination of variables in a data set. For each frequency distribution, the Record Uniqueness method counts the number of records with a frequency of one, which is defined as a unique record, and the number of records with a frequency of five or less, which is defined as a unique record set.
The Record Uniqueness method, however, does not take classic identifiers into account. Thus, a non-classic identifier may be overlooked as a result of data redundancy, when in fact, the redundancy is an attribute of the data record and not the non-classic identifier. Accordingly, assessing the risk of breach of confidentiality without classic identifiers can compromise patient confidentiality and can also compromise the integrity of the dataset.
For the foregoing reasons, there is a need for a more trustworthy method to analyze data records for personal identifiability.
SUMMARY
The present invention is directed to a system and method for analyzing datasets with classic identifiers, to identify single non-classic identifying elements and combinations of non-classic identifying elements in order to protect personal privacy. In the context of the present disclosure, there are three user tiers: record holders, researchers, and the general public. Record holders administrate patient records associated with a particular healthcare database. Researchers analyze a subset of patient records to discover trends in health. The general public can review outcomes published by researchers in science journals. A record holder is authorized to access any PHI within a healthcare database so long as it is pertinent to his or her job. A HIPAA-trained researcher is authorized to analyze the minimum PHI associated with a healthcare database required to answer a scientific inquiry, so long as the corresponding research protocol has been approved by the record holder. The general public has no access to PHI.
Since the minimum amount of PHI required to assist a scientific inquiry is not well-defined, record holders generally err on the side of caution by reducing the data's resolution prior to releasing it to researchers. While this ensures compliance with HIPAA and local PHI regulations, it also often significantly reduces the data's value to researchers. Embodiments of the present invention provide advantages in reducing ambiguity associated with the release of data to researchers, thereby potentially increasing the amount of available data to researchers. Embodiments of the present invention benefit researchers in disclosure of investigative results in that results of a scientific inquiry may be made available to the general public with reduced concern of breaching patient privacy. Record holders are similarly benefited in that optimal support of scientific inquiry is possible in balance with protection of the data in the record holder's database.
Embodiments of the present invention include a system and method to analyze a dataset for identifying attributes creates a first subset of identifiers including classic identifiers and a second subset of data elements that are non-classic identifiers. Redundant records are removed. The second subset is tested for uniqueness from singletons, single data elements, through a defined number of combinations of data elements. The system further includes a threshold of uniqueness where the threshold can be set to a value greater than one. Accordingly, the system and method of the present invention can accommodate the requirements of regulations and other privacy policies while meeting the needs of providing valid data for research.
In one embodiment, the method for assessing identifiability in a set of data records in a computer wherein the data records include a plurality of elements having at least one classic identifier includes the step of receiving the set of data records. The computer is provided with classic identifiers and forms a first subset of elements that are classic identifiers and a second subset of elements that are not classic identifiers. In the second subset, the computer tests combinations of elements for record uniqueness and generates as output non-classic identifiers and combinations of non-classic identifiers. In this way, data records having identifiability through non-classic identifiers are discovered.
In a first alternative embodiment, the computer tests singletons for uniqueness. In this way, a complete set of non-classic identifiers is discovered. In a second alternative embodiment, the computer identifies and removes redundant records. Data sets having redundant records can result in a flawed redacted dataset that shows a plurality of instances of combinations of elements where for example only one instance exists. This can also result in a failure to accurately uncover non-classic identifiers. In a further alternative embodiment, the computer has a threshold of uniqueness that enables it to assess those records having instances between one and the threshold of uniqueness as identifiable. In a still further embodiment, the computer has a testing threshold that enables it to test combinations of elements up to the testing threshold for uniqueness. This can increase the efficiency of review of data records by limiting the number of elements in a tested combination.
In another embodiment, the system that assesses the identifiability of a set of data records includes a library to store classic identifiers. The system further includes a set generator configured to receive the set of data records and to form, from the set of data records, a first subset of elements that are classic identifiers and a second subset of elements that are not classic identifiers. The system further includes a uniqueness generator configured to test combinations of elements of the second subset for uniqueness. The system assesses a set of data records for the identifiability of non-classic identifiers both singly and in combination, by comparing their level of uniqueness to a classic identifier.
In an alternative arrangement, the system further includes a redundancy tester configured to test the set of data records for redundant data records. In a second alternative arrangement, the uniqueness generator has a threshold of uniqueness such that the uniqueness generator identifies those combinations having instances up to the threshold of uniqueness as being unique. In a third alternative arrangement, the uniqueness generator further includes a testing threshold such that combinations of elements from one to the threshold are tested.
The present invention together with the above and other advantages may best be understood from the following detailed description of the embodiments of the invention illustrated in the drawings, wherein:
DRAWINGS
FIG. 1 is a table showing an example dataset suitable for use by embodiments of the present invention;
FIG. 2 is a simplified data table representative of a format of a dataset suitable for use by embodiments of the invention;
FIG. 3 is a flow chart of the operation of an embodiment of the alternate key detection system;
FIG. 4 is a flow chart of the uniqueness testing method according to principles of the invention;
FIG. 5 is a block diagram of a first embodiment of the alternate key detection system according to principles of the invention; and
FIG. 6 is a block diagram of a second embodiment of the alternate key detection system according to principles of the invention.
DESCRIPTION
Embodiments of the present invention identify and track fields or combinations of fields in repositories of information that may jeopardize patient privacy. Embodiments of the invention offer data repositories and record holders heightened awareness of potential identifiers, thereby reducing ambiguity when releasing data to an investigator. Further, embodiments of the present invention filter datasets such that published data is largely not identifying, even when coupled with available census, or other demographic data. For example, given a requested patient set, the systems and methods according to the present invention determine that a combination of data elements (for example, age, gender, and cancer site) is a unique key and automatically prompts the system user. This combination can then be reviewed, for example, by a Data Utilization Committee. The combination can then be accepted or rejected as a valid key, before proceeding with an investigator's request for patient data.
In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. One skilled in the art will understand that the present invention may be practiced without some of these specific details. In addition, the following description provides examples, and the accompanying drawings show various examples for the purposes of illustration. These examples, however, should not be construed in a limiting sense as they are merely intended to provide examples of the present invention rather than to provide an exhaustive list of all possible implementations of the present invention. In other instances, well-known structures and devices are shown in block diagram form in order to avoid obscuring the details of the present invention.
Portions of the following detailed description may be presented in terms of certain processes and symbolic representations of operations on data bits. These process descriptions and representations are used by those skilled in the data processing arts to convey the substance of their work to others skilled in the art. An algorithm, as described herein, refers to a self-consistent sequence of acts leading to a desired result. The acts are those requiring physical manipulations of physical quantities. These quantities may take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. Moreover, principally for reasons of common usage, these signals are referred to as bits, values, elements, symbols, characters, terms, numbers, or the like.
These and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise, it is understood that discussions utilizing terms such as “processing” or “computing” or “calculating” or “determining” or “displaying” or the like, refer to the action and processes of a computer system, or similar device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's devices into other data similarly represented as physical quantities within the computer system devices such as memories, registers or other such information storage, transmission, display devices, or the like.
One of skill in the art will understand that the present invention can be practiced with computer system configurations other than those described below, including hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, digital signal processing (DSP) devices, network PCs, minicomputers, mainframe computers, and the like. The invention can also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. Structures for a variety of these systems will appear from the description below.
It is to be understood that various terms and techniques are used by those skilled in the art to describe communications, protocols, applications, implementations, mechanisms, etc. One such technique is the description of an implementation of a technique in terms of an algorithm or mathematical expression. That is, while the technique may be, for example, implemented as executing code on a computer, the expression of that technique may be more aptly and succinctly conveyed and communicated as a formula, algorithm, or mathematical expression.
Thus, one skilled in the art would recognize a block denoting A+B=C as an additive function whose implementation in hardware and/or software would take two inputs (A and B) and produce a summation output (C). Thus, the use of formula, algorithm, or mathematical expression as descriptions is to be understood as having a physical embodiment in at least hardware and/or software (such as a computer system in which the techniques of the present invention may be practiced as well as implemented as an embodiment).
In one embodiment, the methods of the present invention are embodied in machine-executable instructions. The instructions can be used to cause a general-purpose or special-purpose processor that is programmed with the instructions to perform the steps of the present invention. Alternatively, the steps of the present invention might be performed by specific hardware components that contain hardwired logic for performing the steps, or by a combination of programmed computer components and custom hardware components.
In one embodiment, the present invention may be provided as a computer program product which may include a machine or computer-readable medium, or a computer-usable medium, having stored thereon instructions which may be used to program a computer (or other electronic devices) to perform a process according to the present invention. The computer-readable medium may include, but is not limited to, floppy diskettes, optical disks, Compact Disc, Read-Only Memory (CD-ROM), and magneto-optical disks, Read-Only Memory (ROM), Random Access Memory (RAM), Erasable Programmable Read-Only Memory (EPROM), Electrically Erasable Programmable Read-Only Memory (EEPROM), magnetic or optical cards, flash memory, hard drive or the like.
Accordingly, the computer-readable medium includes any type of media/machine-readable medium suitable for storing electronic instructions. Moreover, embodiments of the present invention may also be downloaded as a computer program product. As such, the program may be transferred from a remote computer (e.g., a server) to a requesting computer (e.g., a client). The transfer of the program may be by way of data signals embodied in a carrier wave or other propagation medium via a communication link (e.g., a modem, network connection or the like).
FIG. 1 is an example dataset of the type suitable for use by embodiments of the present invention. An application of the present invention is to ensure that PHI is not compromised while performing clinical research. The dataset in FIG. 1 is a collection of patient records.
The dataset is presented as a table having a plurality of rows and columns. Each row represents a data record and each column an element with the exception of the leftmost column. The leftmost column provides record numbers which are provided for the sake of clarity in this description. The elements in the columns are Accession number of the patient, Age at diagnosis, Clinical stage, Pathological stage, Histology Description, Class and Site (of cancer). Of these elements, the first, Accession number of the patient, is an established identifier and a classic identifier. As described above, a classic identifier is a piece of data associated with a person meant to identify that person such as a name or patient number. An established identifier is a piece of data determined to be identifying such as a classic identifier. The remaining elements are characteristics of the patient, generally grouped according to a particular health problem such as cancer type.
As it is possible for a single patient to have more than one condition, such as more than one type of cancer, a single patient can have more than one data record in the set as shown by record number 23 and record number 24 . Also, as data in a set is often drawn from a number of sources, redundant records can be common. In this example, record number 25 is the same as record number 12 and record number 26 is the same as record number 24 .
The elimination of the Accession number from the dataset removes the classic identifier from the records, however, the problem of identifying a particular patient from one of the other elements or combination of other elements remains. For example, there is a single instance of a person with a diagnosis age of 34 and a diagnosis of ductal carcinoma (record 21 ). The patient of record 21 is therefore potentially identifiable even without the Accession number.
Data sets used in research are generally far larger than the example provided here. While the embodiments described here operate in the areas of health care and health research, the present invention is not limited to those areas. The present invention is applicable in other situations in which personal identifiers are to be removed for privacy reasons. These other situations include market research and economic research.
FIG. 2 is a simplified data table representative of a format of a dataset suitable for use by embodiments of the invention. The simplified data table is provided to show that data sets can contain a complex variety of identifying data and potentially identifying data. This example has several established identifiers, also referred to as known keys. Embodiments of the present invention take a set of patient data having a set of known keys, such as {A,B,C, (D,E)} and requested data {E, F, G, H, I, J, K} and determines alternative keys, for example {K, (G,H), (E,I,J)}. The method of determining alternate keys is described below with regard to FIG. 3 .
FIG. 3 is a flow chart of the operation of an embodiment of an alternate key detection method. The method operates, for example, in a programmed computer system. Other systems that execute the method are described below with respect to FIGS. 4 and 5 .
At step 300 , the system receives a set of data records such as that shown in FIG. 1 . The data set has one established identifier, also referred to as a classic identifier, which is the Accession number of the patient. The data set has a number of elements of research data which are all non-classic identifiers. These elements are as follows: age at diagnosis, clinical stage, pathology stage, histology description, class and site.
At step 305 , the system forms a first subset of elements that are classic identifiers. In the example data set, the first subset includes only one element, the Accession number of the patient.
At step 310 , the system identifies and removes redundant records. One method of identifying redundant records is to perform a search for identical classic identifier values in the data set and then to compare the associated records. The present invention is not limited to this method of identifying redundant records. Those skilled in the art will recognize that other types of search and elimination methods for redundant records are possible within the scope of the invention. When identical records are found, all but one are removed from the data set. In the example data set, records 12 and 25 and 24 and 26 are redundant. So, for example, records 25 and 26 are removed from the data set at this step.
Since data sets actually used in research are generally large and often taken from more than one source, redundant records are not unusual. If redundant records are not removed, however, the result may be compromised research data. In the present example, failure to remove a redundant record results in a doubled incidence of one form of cancer. Further, failure to remove redundant records can also result in missed potential identifiers as will be understood from the description below.
At step 315 , the system forms a second subset of elements that are not established identifiers. In this case, all of the non-classic identifiers are also not established identifiers. Therefore the second subset of elements includes: age at diagnosis, clinical stage, pathology stage, histology description, class and site.
At step 320 , the system tests the second subset for record uniqueness. This is an iterative process. The system searches for a unique element or combination of elements in the second subset. That is, where the second subset has n elements, for k=1 to n, the system tests combinations of k elements for uniqueness in the second subset. This portion of the method is explained in greater detail with regard to FIG. 4 below. In step 320 , the non-classic identifiers in the data set are discovered.
At step 325 , the system generates the set of non-classic identifiers discovered in step 320 . The system in an alternative embodiment includes a uniqueness threshold U. The uniqueness threshold is an integer greater to or equal to one. The uniqueness threshold U is the number of instances of a combination of data elements (non-classic identifiers) in the dataset that triggers an assessment of “unique”. Where the threshold is U and the total of non-redundant records in the dataset is r, where 1<U<r, a combination of k data elements would pass the uniqueness test and be assessed as identifying if the combination failed no more than U of r instances. In other words, a threshold of one results in assessments of unique for only those non-classic identifiers (or combinations of non-classic identifiers) with values (or combination of values) that appear once in the dataset. A threshold, for example, of six, results in assessments of unique for all those non-classic identifiers (or combinations of non-classic identifiers) with values (or combinations of values) that appear up to six times in the dataset. The threshold of uniqueness takes into account those types or combinations of identifiers that, while not absolutely unique, could compromise a patient's privacy. In the alternative embodiment, the system generates a set of non-classic, or established, identifiers determined in step 325 to be comparable to any of the classic identifiers, relative to threshold U.
At this stage, the data-holding institution can optionally review or have the established identifiers reviewed. The reviewer or review committee reviews the established identifier typically for the purposes of maximizing the data available for research without compromising patient privacy.
At step 330 , the system generates an output of data records filtered according to the set of established identifiers. This output, having been examined by the system for potentially identifiable information, may then be released to researchers.
FIG. 4 is a flow chart providing an embodiment of testing combinations of elements for uniqueness in the data set, step 320 of FIG. 3 . In this embodiment, the system has a threshold T which is a combinations threshold whose value is defined by the system's users and a threshold U which is a uniqueness threshold whose value is defined by the system's users.
At step 400 , the system initializes a power set which is defined as a set of possible combinations of data elements where the number of elements in the combination is less than or equal to the combination threshold T; an identifiers set which is defined as a set of non-classic identifiers and is initialized as an empty set, and a counter, K, is set to 1,
At step 405 , the system tests K-tuple combinations from the power set in step 400 . Typically, the K-tuple combinations are tested in size and placement order; however the present embodiment is not limited to that order. If any K-tuple is uniquely identifying relative to U, it is placed in the identifiers set, and all elements of the power set containing this K-tuple are removed.
At step 410 , if K<T, the system increments the counter K by 1 and returns to step 405 . If K=T, the system proceeds to step 415 .
At step 415 , the identifiers set is reported.
FIG. 5 is a block diagram of a first embodiment of an alternate key detection system 500 according to principles of the invention. The system 500 includes a set generator 505 , a library of established identifiers 510 , a redundancy tester 515 , and a uniqueness generator 520 . The uniqueness generator 520 further includes a threshold of uniqueness 525 and a testing threshold 530 . The system 500 can be operated in a single computer or in a distributed computing system. The system 500 could also be operated in a networked computing system. In a further alternative embodiment, the system 500 is programmed as a series of commands on a computer-usable medium. The library of established identifiers stores classic identifiers and other established identifiers that are found in patient health records, for example.
In operation, the system 500 takes as input the data set as described above with regard to FIGS. 1 and 2 . The set generator 505 takes the data set as input and creates a first subset of elements of established identifiers according to the listing of established identifiers in the library 510 . The set generator 505 also creates a second subset of non-established identifier elements. The redundancy tester 515 locates and eliminates redundant records in the data set. The uniqueness generator 520 then examines the data set, as described above with regard to FIGS. 3 and 4 , for elements or combinations of elements that are unique and therefore assessable as identifying. The uniqueness generator 520 further includes a threshold of uniqueness 525 where the uniqueness generator 520 assesses elements or combinations of elements as identifying if they appear in the data set a number of times fewer than or equal to the threshold of uniqueness 525 . The uniqueness generator 520 further includes a testing threshold 530 that provides a limit on the number of elements in a combination to be tested. In a large data set with many non-established identifiers, it can be inefficient to examine the larger combinations. In some cases, it can be assumed that the larger combination having a large number of elements are identifying. The testing threshold 530 increases the efficiency of the system 500 by limiting the combinations to be tested.
FIG. 6 is a block diagram of a second embodiment of the alternate key detection system. The system 600 is implemented in a computer having a processor 605 and a data storage device 610 , and an input/output interface 615 . The input/output interface 615 is capable of communicating with a network 620 such as a local area network, wide area network or the Internet. The input/output interface 615 is also capable of communicating with a display device 625 .
The processor 605 has a set generator 630 , redundancy tester 635 and a uniqueness generator 640 . The uniqueness generator 640 includes a uniqueness threshold 645 and a testing threshold 650 . The data storage device 610 includes a library of established identifiers 655 . The library of established identifiers 655 stores listings of classic identifiers and other data assessed as identifying.
In operation, the system 600 takes as input the data set 660 as described above with regard to FIGS. 1 and 2 . The set generator 630 takes the data set as input and creates a first subset of elements of established identifiers according to the listing of established identifiers in the library 655 . The set generator 630 also creates a second subset of non-established identifier elements. The redundancy tester 635 locates and eliminates redundant records in the data set. The uniqueness generator 640 then examines the data set, as described above with regard to FIGS. 3 and 4 , for elements or combinations of elements that are unique and therefore assessable as identifying. The uniqueness generator 640 further includes a threshold of uniqueness 645 where the uniqueness generator 640 assesses elements or combinations of elements as identifying if they appear in the data set a number of times fewer than or equal to the threshold of uniqueness 645 . The uniqueness generator 640 further includes a testing threshold 650 that provides a limit on the number of elements in a combination to be tested. In a large data set with many non-established identifiers, it can be inefficient to examine the larger combinations. In some cases, it can be assumed that the larger combination having a large number of elements are identifying. The testing threshold 650 increases the efficiency of the system 500 by limiting the combinations to be tested.
The present invention has been described with regard to health data applications; however, one skilled in the art will understand that embodiments of the invention may be applied to other types of data records such as marketing and healthcare data.
It is to be understood that the above-identified embodiments are simply illustrative of the principles of the invention. Various and other modifications and changes may be made by those skilled in the art which will embody the principles of the invention and fall within the spirit and scope thereof. | The system and method of analyzing record uniqueness allows for the optimized delivery of patient data to researchers while maintaining the requirements of HIPAA regulations and other privacy policies. The system and method analyze the data set for redundant data and then tests the data for uniqueness from single factors through a defined multiple of factors. The system further enables a threshold of uniqueness to be set enabling additional privacy protection by identifying records that are nearly unique. | 6 |
BACKGROUND OF THE INVENTION
This invention relates to an inside diameter machining method suitable for turning machining in order to form a machining hole, such as a bag hole having the entrance of a hole smaller than the machining diameter of its inside.
In this kind of bag hole machining in a conventional way, a cutting tool for boring fitting to the machining diameter of the inside can not be inserted into the inside of a workpiece since the entrance of a hole is smaller than the machining diameter of the inside. Then, the machining with the cutting tool for boring is impossible. So, the machining is performed in such a state that the formed tool formed in the shape to be machined in advance is set in a workpiece.
But, since in such a way it is necessary to prepare a specific formed tool, this way can not be used for general purposes. Besides, complex arrangement, such as setting a formed tool in a workpiece, is necessary, and efficient machining is impossible.
In addition, it is difficult to improve the machining accuracy in the machining with a formed tool.
The object of the present invention is to provide inside diameter machining method capable of performing bag hole machining using a normal cutting tool, such as a cutting tool for boring, without using formed tool, taking the above-mentioned circumstances into consideration.
SUMMARY OF THE INVENTION
The invention of claim 1 is inside diameter machining method in boring machining for machining inside a workpiece using a turning tool having cutting portion at an end portion of its main body in the shape of a bar, comprising:
at the time of turning machining on the machining hole where the size of a tool insertion hole of the workpiece into which the turning tool (for instance, the diameter D 2 , is not always a circular hole) is inserted is smaller than the machining diameter of the portion to be machined inside the workpiece,
moving said turning tool in a first axial direction and in a second axial direction orthogonal to each other (for instance, the X-axis direction and the Z-axis direction) and in a rotational direction (for instance, the B-axis direction) with a third axial direction orthogonal to both first and second axial directions (for instance, the Y-axis direction) as its center from said tool insertion hole of a workpiece to be machined along tool shape of said turning tool so as to position cutting portion of said turning tool at the portion to be machined inside the workpiece; and
starting turning machining on the portion to be machined of said workpiece in the above-mentioned state.
In the invention of claim 1 , by moving the turning tool in the rotational direction (for instance, the B-axis direction) with the third axial direction (for instance, the Y-axis direction) as its center, the cutting portion of the turning tool can be positioned at the portion to be machined of the inside of the workpiece with no interference between the turning tool and the workpiece. Then, the machining for forming machining hole, such as a bag hole, is possible without using a formed tool as a turning tool.
In the invention of claim 2 , turning tool is held by turning tool holding means provided with a spindle side for rotating and driving said workpiece at the time of machining of the inside of said workpiece so as to prevent chatter of the turning tool.
According to the invention of claim 2 , accurate inside diameter machining is possible since the chatter of the cutting tool can be effectively prevented by the cutting tool holding means.
In the invention of claim 3 , firstly, the top end portion of said turning tool is inserted into said tool insertion hole, subsequently the main body portion of the turning tool continuing to the top end portion is inserted, and furthermore the main body portion of the turning tool continuing to the inserted main body portion is inserted when the turning tool is inserted into said workpiece.
According to the invention of claim 3 , the turning tool is gradually inserted into the tool insertion hole along the whole length of the tool body, starting the top end portion thereof. Then, the turning tool can pass through the tool insertion hole of the workpiece, making use of the portion which section is the smallest, and the occurrence of the interference between the workpiece and the turning tool can be effectively prevented.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing an example of bag hole machining with a machine tool to which the present invention is applied;
FIG. 2 is a view showing an example of moving state of a tool;
FIG. 3 is a view showing passing coordinates of a tool rest and a tool edge in FIG. 2 with their B-axis rotational angle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A machine tool 1 has a spindle 2 rotatably and drivably provided around an axial center CT parallel to Z-axis, as shown in FIG. 1. A chuck 3 is rotatably provided with the spindle 2 around the axial center CT together with the spindle 2 . A plurality of claws 3 a are movably and drivably provided with the chuck 3 in the direction as shown by arrows M and L which is the radial direction orthogonal to the axial center CT (the Z-axis). A workpiece 5 on which boring machining is performed is held by the claws 3 a corresponding the center CL of the workpiece with the axial center CT of the spindle.
A through hole 2 a is formed in the spindle 2 in the direction as shown by arrows J and K which is the axial center CT direction. A chatter prevention bar 6 is provided with the through hole 2 a, being free to move and drive in the direction as shown by the arrows J and K by a cylinder driving unit which is not shown. A pusher 6 a is supported by the top end portion of a main body 6 b of the chatter prevention bar 6 , being relatively rotatable with respect to the main body 6 b (it is not always relatively rotatable, but the pusher 6 a may be fixed with respect to the main body 6 b ). An engagement slot 6 c which section has V-character shape is formed on the top end portion of the pusher 6 a in the direction as shown by the arrows M and L which is orthogonal direction with respect to the axial center CT. A hole 6 e is formed on the main body 6 b of the chatter prevention bar 6 in the axial center CT direction, and a coiled spring 6 d is provided with the hole 6 e so as to shrink.
On the right hand of the spindle 2 of the figure, a tool holder 7 installed on a tool rest (not shown) is movably and drivably provided in the direction as shown by the arrows J and K which is the Z-axis direction and in the X-axis direction orthogonal to the Z-axis direction, that is, in the direction as shown by the arrows N and P. The tool holder 7 is provided being free to rotate, position and drive in the direction as shown by the arrows Q and R with a predetermined axis CT 2 orthogonal to the paper, that is, the Y-axis orthogonal to the X-axis and the Z-axis as its center, that is, in the B-axis direction. Furthermore, a cutting tool 9 for boring is attachably and detachably installed on the tool holder 7 .
The cutting tool 9 has a main body 9 a formed such that the top end of a bar member having the diameter D 3 is bent in the shape of key. A projection 9 b having the shape corresponding to the engagement slot 6 c of the chatter prevention bar 6 in its section is formed at the top end portion of the main body 9 a. The top end of the main body 9 a is bent on the upper hand of FIG. 1, and a chip 9 c is installed on its end.
On the other hand, the workpiece 5 installed on the chuck 3 through the claw 3 a has a main body 5 a formed in almost sphere shape as a whole. On both sides, right and left of the figure of the main body 5 a, through holes 5 b, 5 c which diameter is D 2 , are formed, corresponding the workpiece center CL with its center. An inside space 5 d in the shape of almost sphere is formed inside the main body 5 a. Inner cylindrical faces 5 e on which turning machining is performed, which diameter is D 1 , are formed on the lower and upper hands of the figure facing the inside space 5 d of the main body 5 a. On this occasion, the diameter D 2 of the through hole 5 c is bigger than the diameter D 3 of the bar member comprising the main body 5 a of the cutting tool 9 . Furthermore, the diameter D 1 of the inner cylindrical face 5 e is bigger than the diameter D 2 of the through hole 5 c, then it is a so-called bag hole.
The machine tool 1 has the above-mentioned structure. Then, in order to perform inside diameter machining on the inner cylindrical face 5 e of the workpiece 5 as shown by the hatching of FIG. 1, programming is performed in such a manner that the chip 9 c which is on the top end of the cutting tool 9 for boring held by the tool holder 7 is positioned at a predetermined machining start point H (see FIG. 2) of the inner cylindrical face 5 e of the workpiece 5 with a numerically controlled machine of the machine tool 1 (not shown).
When the cutting tool 9 is moved on the left hand of the figure, that is, in the Z-axis direction, corresponding the axial center CL 1 of its main body 9 a with the workpiece center CL as shown in FIG. 1, the cutting tool 9 and the workpiece 5 interfere with each other, as clear from FIG. 1, then the chip 9 c which is on the top end of the cutting tool 9 can not be positioned at the machining start point H. Then, the tool pass is instructed in the program as shown in FIGS. 2 and 3 in such a manner that the axial center CL 1 of the cutting tool 9 is positioned in the direction parallel to the X-axis direction, and in this state, the tool holder 7 is moved and driven in the X-axis direction (in the direction as shown by the arrows N and P) and in the Z-axis direction (in the direction as shown by the arrows J and K), and at the same time, is rotated and driven in the B-axis direction (in the direction as shown by the arrows Q and R) which is the rotational direction with the Y-axis as its center, which is orthogonal direction with respect to the X-axis and the Z-axis so as to position a top end 9 d of the chip 9 c at the machining start point H via the points A, B, C, D, E, F and G from the waiting point S, as shown in FIG. 2 . On this occasion, the tool rest may be moved in the Y-axis direction together with the tool holder 7 so as to prevent the interference between the cutting tool 9 and the workpiece 5 , if necessary.
By such a programming, the cutting tool 9 is entered into the through hole 5 c of the workpiece 5 with no interference with the workpiece 5 , rotating the whole in the right direction of FIG. 2 such that the bar-shaped main body 9 a is along the bent shape of the main body 9 a so as to position the top end of the chip 9 c at a predetermined machining start point H, as shown in FIG. 2 . Since the diameter D 2 of the through hole 5 c of the workpiece 5 is bigger than the diameter D 3 of the main body 9 a of the cutting tool 9 , the interference between the cutting tool 9 and the workpiece 5 can be prevented by entering the cutting tool 9 into the through hole 5 c along the bent shape of the cutting tool 9 . Such a program can be easily composed by using a known teaching.
When the above-mentioned program is composed, the spindle 2 is rotated and driven so as to rotate the workpiece 5 with the axial center CT as its center through the chuck 3 . In this state, the chip 9 c portion of the top end portion of the cutting tool 9 is faced on the right hand of the FIG. 2 of the through hole 5 c (waiting position S) by the above-mentioned program. Subsequently, the chip 9 c is moved in the direction as shown by the arrow J of the figure, and the top end of the chip 9 c is inserted into the top end portion of the right hand of the figure of the through hole 5 c (the points A and B). In this state, the top end of the chip 9 c is gradually moved in the direction as shown by the arrow J so as to enter the top end portion of the cutting tool 9 into the through hole 5 c. And, the main body of the cutting tool 9 is gradually rotated in the direction as shown by the arrow R so as to enter a bent portion 9 e into the through hole 5 c with no interference between the bent portion 9 e of the top end of the cutting tool body 9 a and the workpiece 5 (the points C, D, E, F, and G) . The cutting tool 9 is gradually inserted into the inside space 5 d from the through hole 5 c, starting from its top end portion in such a manner that by rotating the cutting tool 9 in the direction as shown by the arrow R, while being moved a predetermined distance in the direction as shown by the arrow J in this way, the top end portion of the main body 9 a of the cutting tool 9 is inserted into the through hole 5 c, the main body 9 a portion of the cutting tool 9 continuing to the top end portion is inserted into the through hole 5 c, and furthermore, the main body portion of the cutting tool 9 continuing to the inserted main body portion is inserted into the through hole 5 c. In this way, the top end 9 d of the chip 9 c is inserted into the inside space 5 d from the through hole 5 c of the workpiece 5 so as to position at a predetermined machining starting point H. By doing so, the cutting tool 9 can pass the through hole 5 c of the workpiece 5 , making use of the portion which section is the smallest, and occurrence of interference between the workpiece 5 and the cutting tool 9 can be effectively prevented.
Subsequently, the chatter prevention bar 6 in the spindle 2 is projected and driven in the direction as shown by the arrow K of FIG. 1 through a cylinder driving unit which is not shown and the coiled spring 6 d so as to project the pusher 6 a of the top end inside the inside space 5 d of the workpiece 5 . Then, the top end of the pusher 6 a and the top end of the cutting tool 9 advanced into the workpiece 5 are abutted to each other, the projection 9 b of the top end of the cutting tool 9 is inserted in and engaged with the engagement slot 6 c of the pusher 6 a in the rotating state, and furthermore, the pusher 6 a is relatively pushed and moved in the direction as shown by the arrow J with respect to the coiled spring 6 d against the elasticity of the coiled spring 6 d by pushing the chatter prevention bar 6 by the cylinder driving unit through the coiled spring 6 d in the direction as shown by the arrow K.
Then, the cutting tool 9 positioned at the machining starting point H becomes to be pressed state in the direction as shown by the arrow K by a predetermined pressing force caused by the elasticity of the coiled spring 6 d of the chatter prevention bar 6 by engaging the projection 9 b of the cutting tool 9 with the engagement slot 6 c of the chatter prevention bar 6 . In this state, the cutting tool 9 is properly moved in the X-axis direction and in the Z-axis direction, similar to normal boring machining, and the top end 9 d of the chip 9 c moved to a machining finish point I as shown in FIG. 2 . Then, turning machining is performed on the inner cylindrical face 5 e so as to cut and form a bearing surface 5 f by machining and removing the hatching portion of the figure. On this occasion, the chatter attendant on the machining of the bearing surface 5 f is effectively restricted and accurate machining face is formed since the top end of the cutting tool 9 is in the state pressed in the direction as shown by the arrow K by the chatter prevention bar 6 , as mentioned before. Since the chatter prevention bar 6 is movably held by the coiled spring 6 d in the direction as shown by the arrows J and K in the spindle 2 as mentioned before, the engagement state between the cutting tool 9 and the chatter prevention bar 6 is held even if the cutting tool 9 is moved in the direction as shown by the arrows J and K at the time of machining. Then, the occurrence of chatter of the cutting tool 9 is restricted.
After the top end of the chip 9 c of the cutting tool 9 reaches a predetermined machining finishing point I and the machining of the bearing surface 5 f finishes in this way, the chatter prevention bar 6 is retracted in the direction as shown by the arrow J of FIG. 1 so as to release the engagement state between the cutting tool 9 and the chatter prevention bar 6 . Subsequently, the tool holder 7 is rotated and driven in the B-axis direction (in the direction as shown by the arrows Q and R) while being moved and driven in the X-axis direction (in the direction as shown by the arrows J and K) and in the Z-axis direction (in the direction as shown by the arrows N and P) so as to move the top end 9 d of the chip 9 c to a waiting point S via the points I, G, F, E, D, C, B and A as shown in FIG. 2 in the order opposite to the before-mentioned. Then, the machining on the workpiece 5 finishes.
The above-mentioned embodiment refers to the case where programming is performed by teaching or so in advance when the turning tool, such as the cutting tool 9 , is moved in the X-axis direction, in the Z-axis direction and in the B-axis direction from the tool insertion hole, such as the through hole 5 c of the workpiece to be machined along the tool shape of the turning tool so as to position the machining portion, such as the top end of the chip 9 c at the portion to be machined, such as the inner cylindrical face 5 e inside the workpiece. But, in the present invention, the turning tool may be positioned at the portion to be machined by moving the turning tool in the X-axis direction, in the Z-axis direction (in the Y-axis direction, if necessary) and in the B-axis direction from the tool insertion hole, such as the through hole 5 c of the workpiece along the tool shape of the turning tool so as not to interfere the turning tool and the workpiece with each other, being judged the interference state between the turning tool and the workpiece by a numerically controlled unit of a machine tool, in addition to the above-mentioned method.
The present invention is explained on the basis of the embodiments heretofore. The embodiments which are described in the present specification are illustrative and not limiting. The scope of the invention is designated by the accompanying claims and is not restricted by the descriptions of the specific embodiments. Accordingly, all the transformations and changes belonging to the claims are included in the scope of the present invention. | An inside diameter machining method for machining inside a workpiece uses a turning tool utilized within a main body in the shape of a bar with a hook-shaped top end portion which has a cutting portion. When the machining diameter of the portion to be machined inside the workpiece is bigger than the workpiece's tool insertion hole, the workpiece interferes with the tool when the turning tool's top end portion is moved linearly. To overcome the interference, moving the turning tool's top end portion in two axial directions orthogonal to each other and in a rotational direction with a third axial direction orthogonal to the other two axial directions as its center permits the top end portion to be inserted into the tool insertion hole. The turning tool's cutting portion is then positioned at the portion to be machined inside the workpiece. Turning machining subsequently can be commenced. | 1 |
BACKGROUND OF THE INVENTION
The invention is intended mainly for use in integrated circuit chips where both digital and analog functions are employed simultaneously. Analog, or linear, circuits are employed in conjunction with RTL, TTL, ECL or CMOS logic configurations in many applications. The logic circuit choice is based upon the desired performance characteristics and the analog circuits are selected to provide the required function and to be compatible with the logic circuit manufacturing process.
Typically, an integrated circuit is designed to operate at a specified supply voltage, but it will function normally over a range of supply voltages. Unfortunately, when a logic system is operated at a low voltage it can produce false outputs and thus perform incorrectly. Accordingly, it has become standard practice to provide a circuit function that responds to a low supply voltage condition and shuts off or locks out the digital circuit outputs when the low voltage condition exists. Actually, while the invention mainly relates to the lockout of digital circuits, it can also be applied to linear circuits alone.
One of the best ways of providing a low voltage lockout is to specify or identify a low voltage state and then provide a circuit that will reliably sense it and produce a signal that can be used for the electrical discontinuance of circuit operation. Specifying such a voltage can be a problem because the circuit response can result in a low voltage response tolerance. Also, the circuit that responds to the low voltage can have a tolerance. These combined tolerances can produce a large range of uncertainty so that the circuit design must take into account all of the tolerances involved and respond in such a way that successful lockout will occur under all conditions. These tolerances are exacerbated by temperature effects that must be taken into account. The result is that the low voltage response must be conservatively applied and is therefore considerably higher than would be required for most conditions.
One well known application of combined lineardigital circuitry is the motor control chip. In this device a motor is controlled by the use of high efficiency switching-mode or digital controllers operated by pulses created in response to linear circuitry. It is important to prevent the production of false pulses if the motor is to remain off when it is supposed to be off. Additionally, it is important that the motor not be commanded to drive simultaneously in both forward and reverse directions which could damage the motor and/or its controllers.
DESCRIPTION OF THE PRIOR ART
FIG. 1 is characteristic of the typical prior art low voltage lockout circuit. Although not shown in FIG. 1, it is to be understood that the circuit will include a conventional voltage regulator circuit that will produce V REF . Clearly, the supply voltage will have to be at some minimum value above V REF to avoid dropout. The circuits are operated from a V S power supply connected+ to terminal 10 and- to ground terminal 11. A plural or multiple collector lateral transistor 12 has its emitter returned to +V S . Its base is coupled to one collector and to a constant current sink 13. Thus, I 1 flows in the lower collector of transistor 12. If all three collectors are of the same effective length and spacing, I 2 and I 3 each equal I 1 . I 2 flows in zener diode 14 and thereby biases it into reverse breakdown. I 2 also flows into the base of transistor 15 and ultimately through diode 16. I 3 flows in the collector of transistor 15. Since I 2 =I 3 transistor 15 will be in saturation and thereby turn transistor 17 off because resistor 19 returns the lower emitter of transistor 17 to the emitter of transistor 15. Under these conditions the upper emitter of transistor 17 cannot rise appreciably above about 0.1 volt and this will hold transistors 20-22 off. Thus, the digital logic will be permitted to function normally.
If for some reason V S drops to a low value, at some level, zener diode 14 will cease conduction and I 2 will stop flowing. However, I 1 and I 3 will continue to flow. For example, if the zener voltage is 6.3 volts, when the V S voltage drops to about 7.6 volts, the zener will start to drop out. With a slight further supply reduction, zener 14 will cease conduction and I 2 will cease to flow. This turns off transistor 15. I 3 , which formerly flowed into transistor 15, will now flow into the base of transistor 17 thereby turning it on. The lower emitter of transistor 17 will operate at a potential of one diode plus the voltage drop across resistor 19. The upper emitter will conduct a similar current and develop a similar voltage drop across resistor 23. This will be coupled, via resistors 24-26, to transistors 20-22 which will thereby be turned on. Conduction in transistors 20-23 will act to disable the related digital circuit and a low voltage lockout is achieved.
As a practical matter, I 1 , I 2 and I 3 are made quite small. Actually, the current is made just large enough to reliably bias diode 14 into reverse bias breakdown. Since transistor 17, when on, has I 3 flowing into its base, a considerably higher current flows out of the emitters and reliable switching of transistors 20-22 is present. However, the circuit switching level is related to the zener diode breakdown which has a tolerance as well as a temperature coefficient. Furthermore, the transistor circuits have tolerances and all of the tolerances are subject to temperature. Accordingly, it is important that the zener diode voltage be high enough that the low voltage lockout occurs above a critical minimum.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a low voltage lockout based upon the onset of saturation of a transistor in the IC.
It is a further object of the invention to select the transistor most likely to go into saturation and to provide it with a saturation detector which produces a lockout signal at the onset of saturation.
It is a still further object of the invention to select a lateral PNP transistor and a vertical NPN transistor as the most likely to saturate at low supply voltages and to provide them with saturation detectors each one of which will actuate a lockout function at the onset of saturation.
These and other objects are achieved in the following manner. A multiple collector lateral PNP transistor is employed as a plural current source for the linear circuits. A voltage regulator, operating on the silicon bandgap principle, is employed to develop a reference voltage. An NPN transistor in the linear circuitry is selected as the most likely to saturate at low supply voltages and it is provided with a saturation detector that produces an output current at the onset of saturation. A similar detector is provided for the collector of the PNP lateral transistor collector that is most likely to saturate at low supply voltages. These two detectors are coupled to a common circuit node. While one of these two detectors will provide the first indication of saturation it cannot be predicted which one it will be. However, when either one of the two detector-equipped collectors starts to saturate, the circuit node is pulled up and associated circuitry provides the lockout function. The circuit node is also provided with a pull up current derived from a circuit that senses when the supply potential is below the regulator drop out level. This latter function provides for reliable lockout operation for extremely low supply voltages that might fail to reliably operate the saturation detectors.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram of a commonly used prior art low voltage lockout circuit.
FIG. 2 is a schematic diagram of the circuit of the invention.
FIG. 3 is a topographical showing of the PNP plural collector lateral transistor of FIG. 2 showing the construction of the saturation detector.
FIG. 4 is a topographical showing of the NPN vertical transistor of FIG. 2 showing the construction of the saturation detector.
DESCRIPTION OF THE INVENTION
FIG. 2 is a schematic diagram showing an application of the invention. Where the elements are the same as those of FIG. 1 the same designations are used. Note that the logic lock-out elements 20-26 are the same.
Rail 29 carries V REF which is regulated and is obtained as follows. The heart of the regulator is a bandgap reference circuit 30 which is of the variety set forth in U.S. Pat. No. RE30,586. Transistors 31 and 32 are operated at differential current densities so that ΔV BE potential appears across resistor 33. A current mirror load 34 determines the collector currents flowing in transistors 31 and 32. To obtain the current density differential the two transistors can be ratioed in area and operated at the same currents or they can be of the same size and their currents ratioed. Alternatively, the areas can be ratioed along with a current ratio. Since the ΔV BE appears across resistor 33 it is clear that the collector current flowing in transistor 32 is proportional to absolute temperature (PTAT). Accordingly, the current flowing in resistor 35 is also PTAT. If the voltage across resistor 35 added to the V BE of transistor 31 equals the bandgap of silicon extrapolated to absolute zero (about 1.2 volts) the voltage of the bases of transistors 31 and 32 will remain at about 1.2 volts over a wide temperature range. The positive (or PTAT) temperature coefficient of voltage across resistor 35 will be cancelled by the negative temperature coefficient of the V BE of transistor 31.
Current mirror load 34 drives amplifier 36, the output of which sets the level of V REF line 29. The resistor divider composed of resistors 37-39 is set up so that when 1.2 volts appears at the bases of transistors 31 and 32 the desired value of V REF is present on line 29. In the example employed by applicant V REF is +5.00 volts. Resistor 35 is made variable and is adjusted in a production trim so that V REF can be accurately calibrated.
It will be noted that a plural collector lateral transistor 41 has its emitter connected to the +V S rail. The various collectors 42-46 act as current sources for various circuit functions, some of which will now be discussed.
Collector 42 is returned to the base to create a current mirror in which the current pulled out of collector 42 determines the sourcing capability of all of the other collectors. Collectors 42 and 43 are connected to bias generator 48 which supplies bias for transistor 49. The operation of this circuit is set forth in U.S. Pat. No. 3,930,172. The bias voltage supplied to transistor 49, which controls the current that flows in resistor 57, is controlled by the circuit 48 to be independent of V S . The function of transistor 49 will be further discussed hereinafter.
Circuit node 50 is the lockout trip node and it functions as follows. Transistor 51 is shown as a dual emitter NPN device. Actually, the connection shown operates the transistor in its inverted state so that it functions as a dual collector device with one collector returned to its base. The other collector is returned to node 50. Thus, transistor 51 acts as a pair of low Beta NPN transistors and thereby creates a weak current mirror. The current from collector 45 of transistor 41 flows into the current mirror and transistor 51 will weakly reflect this current out of node 50. Thus, node 50 is pulled low in normal operation. This will turn transistor 52 off. Under this condition the current in source 53 will flow into the base of transistor 54 thereby turning it on. The current flow in transistor 54 will pull the base of transistor 56 low so that it cannot act to bias transistors 20-22 into conduction. Since transistors 20-22 are off, the logic circuits associated with the circuit of FIG. 2 will be fully operative. It is to be understood that the current flowing in the output of current mirror transistor 51 is relatively small and can easily be overpowered.
In an early circuit analysis in the design phase it was determined that collector 44 of transistor 41, which supplies a current to amplifier 36, would be the first to saturate as V S is lowered. Accordingly, in accordance with the invention, a saturation sensing transistor 58 was added. Its base is common to the base of transistor 41 and its emitter is actually the collector 44. When collector 44 saturates it reemits minority carriers (holes) which can be collected by the collector of transistor 58 which is connected to node 50. Under normal operation when no collector saturation is present, virtually no current will flow in transistor 58. However, when collector 44 saturates, transistor 58 will pull node 50 up because the action of transistor 51 will be overpowered. This will turn transistor 52 on and this will turn transistor 54 off. Thus, the current in source 55 will flow into the base of transistor 56 which will turn on and base current will flow into transistors 20-22. This in turn clamps the digital circuits so as to lock them out. In summary from the above, when node 50 is pulled high the digital circuits are locked out and when node 50 is left alone it will go low and the digital circuits are operative.
Transistor 60 is a vertical NPN device that was determined as another transistor on the IC chip that could go into saturation. Under some conditions it can go into saturation before transistor 41. Accordingly, in accordance with the invention transistor 60 is provided with a saturation detector 61 which also has its collector connected to node 50. Thus, when transistor 60 goes into saturation, transistor 61 will pull node 50 high and the digital circuits will be locked out.
Transistor 60 has its emitter returned to IC pad 62 by way of resistor 63. Pad 62 can be left open or returned to either +V S or ground. In the cases of open or return to +V S , transistor 64 clamps the emitter of transistor 60 to V REF +V BE or one diode above the potential on line 29. Transistors 65 and 66 clamp the base return circuit of transistor 60 within a range of ±V BE of V REF . Their emitters are coupled to the base of transistor 60 by way of resistor 67. Current source 68 supplies currents to the base of transistor 60 to render it conductive. The current in source 68 is established by a current reflection from the current flowing in elements 69, which are in series with the collector of transistor 60. The current in source 68 will largely flow in resistor 67 and in transistor 65 to ground.
When terminal 62 is left open or is returned to ground, by way of a high value resistor (greater than 100 k ohms), there is little chance that transistor 60 will saturate. However, if a moderate resistance (20 k ohms or less) is present between terminal 62 and ground, it is likely that transistor 60 will saturate first as V S is lowered. This is when transistor 61 becomes important. When transistor 60 saturates, the base to emitter potential of transistor 61 will turn it on and the collector will pull node 50 high.
From the above it can be seen that when either transistors 58 or 61 sense saturation, node 50 will be pulled high to invoke digital circuit lockout. As V S is lowered still further a point will be reached where V REF also decreases. At this point, regulator 30 can be regarded as dropped out. In other words, the potential on line 29 is no longer regulated and will fall off as V S decreases further. Under this condition the transistor saturation condition may no longer be a reliable indicator of reduced V S . A condition of saturation that developed as V S was reduced may disappear as V S is lowered still further. Therefore, some means of responding to the still lower V S voltage is in order.
A reference circuit 70 operates as a dummy regulator and as such duplicates the reference circuit associated with reference 30. Circuit 20 is called a dummy regulator because it is configured as a regulator, but does not regulate. Current density ratioed transistors 71 and 72 have their emitters commonly returned to ground by resistor 73 and the ΔV BE appears across resistor 74. Thus, transistor 71 is the high current density device. Load transistors 75 and 76 respectively supply collector currents to transistors 72 and 71. They duplicate the action of load 34. The bases of transistors 71 and 72 are connected to the juncture of resistors 37 and 38. This ensures that transistors 71 and 72 are operated at a potential that normally exceeds the bandgap reference by about 100 millivolts. This means that the collector at transistor 71 will normally be low. This will force transistor 77 into conduction so that the collector of transistor 49 will be high. Thus, the current flowing in transistor 49 (and resistor 57) will also flow through transistor 77 from line 29. Under this condition neither transistor 78 nor transistor 79 will conduct.
For low V S values when the V REF level is lost and line 29 falls below 5 volts, a point will be reached where the bases of transistors 71 and 72 will fall below the silicon bandgap reference established by circuit 70. When this happens the collector of transistor 71 will go high and turn off transistor 77. Now, the current flowing in transistor 49 will flow in diode-connected transistor 78. Since transistor 79 is connected into a current mirror configuration, the current in transistor 78 is reflected into node 50. Thus, as long as the bases of transistors 71 and 72 are below bandgap, node 50 will be held high regardless of the performance of transistors 58 and 61. This ensures reliable digital circuit lockout at very low V S values.
EXAMPLE
The circuit of FIG. 2 was constructed using conventional monolithic silicon, junction isolated elements. FIG. 3 illustrates the construction of transistor 58 and its relationship to transistor 41. The drawing shows the topography of the various transistor elements, but the oxide, passivation and metallization have been omitted for clarity. The drawing portrays a portion of an IC chip surface with ring 81 representing a P+ isolation diffusion that completely penetrates an N type epitaxial layer. Thus, region 82, inside ring 81, represents an N type tub that is electrically isolated from the remainder of the chip. Transistor 41 has been constructed using two emitters 83 and 84 which are connected together by metallization (not shown). P-type collectors 42 and 44 are spaced from and substantially surround emmitter 83. Collectors 43, 45 and 46 are spaced from and substantially surround emitter 84. N+ diffused region 85 slightly overlaps collector 42. Region 85 forms an ohmic connection to the N type epitaxial tub 82 and comprises the transistor base.
The rectangle 86 represents the area of an oxide contact cut within which subsequently applied metallization simultaneously contacts regions 42 and 85 where they overlap. This contact connects collector 42 to the transistor base. A similar contact region 87 makes provision for an electrical connection to collector 44. It will be noted that another P type region 88 exists just outboard of collector 44. Region 89 represents the metallic connection to collector 88. In normal operation collector 44 collects substantially half of the minority carriers injected by emitter 83. Very few, if any, of these carriers find their way to collector 88 and its current is close to zero. However, when collector 44 saturates it proceeds to reemit its collected carriers and adjacent collector 88 will collect them. Thus, transistor 58 exists as a lateral transistor in which the emitter is collector 44, the base is the N type material existing between collectors, and its collector is region 88. Because of its geometry transistor 58 actually exists electrically only when collector 44 goes into saturation.
FIG. 4 is a showing similar to that of FIG. 3, but relating to the topography of transistor 60. Ring 91 represents a P+ isolation ring that isolates N type tub 92 from the rest of the IC chip. P region 93 represents the P type transistor base and rectangle 94 is where an ohmic base contact is made to metallization (not shown). N+ region 95 is the emitter while rectangle 96 is the emitter contact. N+ region 97 is an N+ diffusion that makes ohmic contact to N type tub 92 and is in turn contacted via rectangle 98. P diffusion 99 is spaced apart from and confronting base 93 while rectangle 100 is a contact region thereto. Thus, base 93 of transistor 60 forms an emitter of lateral transistor 61 in which 99 is the collector and the intervening N type material forms the lateral transistor base.
While not shown in FIGS. 3 and 4, each of the active transistors is located over an N+ buried layer created between the silicon substrate wafer and its epitaxial layer. Such N+ buried layers are well known in IC construction.
______________________________________COMPONENT VALUE UNITS______________________________________Resistor 23 5 k ohmsResistor 24 4 k ohmsResistor 25 4 k ohmsResistor 26 4 k ohmsResistor 33 2 k ohmsResistor 35* 9.5-11.128 k ohmsResistor 37 7.23 k ohmsResistor 38 300 ohmsResistor 39 2.46 k ohmsCurrent Source 53 2 to 50 microamperesCurrent Source 55 200 microamperesResistor 57 2.03 k ohmsResistor 63 100 ohmsResistor 67 100 ohmsResistor 73 9 k ohmsResistor 74 2 k ohmsCurrent Source 68** 1-1000 microamperes______________________________________ *Resistor 35 is trimmed to set V.sub.REF at 5.00 volts. **Current source 68 is programmed by the current in transistor 60 which i set by the element connected to terminal 62.
The circuit was designed to operate over a supply voltage range of 9 to 40 volts. V REF was 5 volts ±1% over the entire supply range. As the supply voltage as lowered, with terminal 62 open, it was found that the lockout circuits became operative at about 8.8 volts. The lockout remained active down to about 2 volts.
The invention has been described and an operating example detailed. When a person skilled in the art reads the foregoing description, alternatives and equivalents, within the spirit and intent of the invention, will be apparent. For example, while a combined digital/linear embodiment is detailed in the example, the invention could be employed in an all linear structure. Accordingly, it is intended that the scope of the invention be limited only by the claims that follow. | An integrated circuit is shown in which provision is made for terminating or locking out the operating circuitry when the supply voltage has fallen below a level that can cause anomalous or unreliable operation. Certain selected transistors are provided with saturation sensors which operate to produce a current when the transistors go into collector saturation. When any of the sensors indicates the onset of saturation, clamping circuitry is energized to provide lock out. In addition, a temperature compensated dummy bandgap circuit is included to sense extremely low supply voltages and provide the lockout function under conditions where a reliable saturation indication might not be available. | 7 |
This application is a continuation of U.S. patent application Ser. No. 10/281,787, filed Oct. 28, 2002, which issued as U.S. Pat. No. 6,616,142 which is a continuation of application Ser. No. 09/994,245 filed on Nov. 26, 2001, which issued as U.S. Pat. No. 6,494,454 which is a continuation of U.S. patent application Ser. No. 09/664,257, filed on Sep. 18, 2000, which issued as U.S. Pat. No. 6,322,078, which is a continuation of U.S. patent application Ser. No. 08/838,178, filed on Apr. 16, 1997, which issued as U.S. Pat. No. 6,120,031, which is a continuation of U.S. patent application Ser. No. 08/500,532, filed on Jul. 11, 1995, which was abandoned, which is a continuation-in-part of U.S. patent application Ser. No. 08/311,781, filed on Sep. 23, 1994, which issued as U.S. Pat. No. 5,431,408.
The present invention is directed to games and, more particularly, to novel games which provide a player with the opportunity to reserve a “wild” indicia from one play for use in a subsequent play.
BACKGROUND OF THE INVENTION
Games utilizing playing cards are popular throughout the world. Many people get hours of enjoyment and relaxation from playing cards. In certain parts of the world, wagering adds an additional dimension of excitement to the game. Whether in “card room” games where the players play against each other or in a traditional “casino” game environment where an employee of the house acts as a banker, wagering adds excitement to many forms of card games.
Players involved in card games with wagering often enjoy new games with relatively simple rules that can readily be learned by a beginner or casual player.
Typical card games involve a dealer providing a plurality of cards to each player. Each player then gathers the cards and tries to form the best possible hand according to some predetermined hierarchy of hand values. For example, a standard poker hierarchy is, in descending order, Royal Flush, Straight Flush, Four of a Kind, Full House, Flush, Straight, Three of a Kind, Two Pair, One Pair, and High Card. In some games, players are permitted to discard certain cards and receive new cards in an effort to form a better hand.
It is also common to designate one or more cards as “wild” cards which can have any one of a predetermined number of values at the option of the player(s) receiving such wild cards. In this manner, the designation of wild cards within a deck can significantly increase the chances of a player attaining a particular hand. In known games which utilize wild cards, players must use the wild card in the hand in which the wild card is received. Therefore, if a player has a card hand of low or no value, the wild card may not be sufficient to allow that player to form a winning hand. For example, if the payout schedule for a given game starts at a pair of jacks, and the player has the following hand: 2, 4, 5, 10 of different suits and a wild card, the best poker hand that the player could form with one wild card would be a pair of 10's. This hand would not qualify for a winning payout.
It is, therefore, desirable to provide a card game which increases the player's excitement and enjoyment, as well as the level of player participation by providing a player with an opportunity to maximize the impact of receiving a wild card.
It is also desirable to provide wagering games other than cards with an exciting, new feature which comprises a wild indicia and novel methods of using that wild indicia.
It is also desirable to provide novel games readily adaptable to wagering which are relatively simple to learn for new players.
It is also desirable to provide games which provide one or more players with opportunities to modify the player's winning payout by using such a wild indicia, received during one play, with a subsequent play.
SUMMARY OF THE INVENTION
The various embodiments of the present invention are directed to games which provide a player who has received at least one wild indicia during one play with the opportunity to reserve that wild indicia for use in a subsequent play. The advantages of the present invention are applicable to a wide variety of games including “card” games and other conventional games of chance or skill including keno, bingo, gaming devices, such as reel slots, dice games and lotto. As used herein, the term “card game” is intended to include conventional table/board type games wherein one or more persons deal actual playing cards to one or more players, as well as any type of mechanical or electronic devices which display indicia of playing cards.
According to an aspect of the invention, a gaming device is provided that includes a display screen that is capable of generating video images, and the gaming device is programmed to select a first group of indicia from a plurality of indicia in a first game, wherein the plurality of indicia include a plurality of playing indicia and at least one wild indicia. The gaming device is also programmed to cause a video image representing the first game to be displayed on the display screen, to provide a player with a winning advantage if the player receives the at least one wild indicia, and to limit the use of the at least one wild indicia.
According to another aspect of the invention, a gaming device is provided that includes a display screen that is capable of generating video images, a plurality of selection devices, and a value input device. The gaming device is programmed to determine that a player has used the value input device to make a wager, provide a first group of playing indicia to define a first game, the first group of playing indicia being selected from a plurality of playing indicia, and provide at least one wild indicia for use in other than the first game. The gaming device is also programmed to cause a video image representing the first game to be displayed on the display screen, determine that the player has used one of the plurality of selection devices to reserve the at least one wild indicia for use in a subsequent game, determine a first game outcome associated with the first group of playing indicia, and determine a first payout according to a payout schedule, the first payout being associated with the first game outcome. The gaming device is further programmed to provide a subsequent group of playing indicia to define the subsequent game, the subsequent group of playing indicia being selected from the plurality of playing indicia, determine that the player has used at least one of the plurality of selection devices to combine the at least one wild indicia with the subsequent group of playing indicia to define a modified group of playing indicia, determine a game outcome associated with the modified group of playing indicia, and determine a subsequent payout associated with the game outcome associated with the modified group of playing indicia by modifying the payout for the game outcome associated with the modified group of playing indicia.
According to a third aspect of the invention, a gaming device is provided that includes a display screen that is capable of generating video images, a value input device, and a plurality of selection devices. The gaming device is programmed to select a first group of indicia from a plurality of indicia in a first game, the plurality of indicia including a plurality of playing indicia and a wild indicia, wherein the wild indicia is not one of the plurality of playing indicia, and provide a player with the option of reserving the wild indicia in the first game for use in a subsequent game.
The wild indicia of the present invention may take any form desired by the players or the establishment conducting the game. For example, when playing a card game, the wild indicia will typically comprise a wild card. While jokers maybe utilized to indicate a wild card, it is also within the scope of the present invention to use one or more other indicia such as one of the other cards of a deck or non-conventional indicia to indicate a wild card. Similarly, in games other than card games, any form of wild indicia may be utilized. In all forms of the present invention, a player is provided with the possibility of utilizing a wild indicia when it is most advantageous for the player to do so, i.e., when the player will maximize a winning payout. When a player receives a wild indicia, the player can use that wild indicia immediately or may reserve the wild indicia for use in a subsequent play. For example, a player may use a wild card in a subsequent hand or may use a wild indicia received during the play of one game of bingo in a subsequent game.
One preferred embodiment of the present invention comprises a gaming device having an electronic touch-sensitive screen which is controlled, at least in part, by a player touching images on the screen.
Another embodiment of the present invention comprises a gaming device wherein input from a player is supplied to a device through actuation buttons.
A still further embodiment of the present invention comprises a game table designed for use by a dealer and a plurality of players. Along with conventional indicia on the game table including betting areas for each player, each player area is also provided with a reserve area wherein a player may place a wild card if that player decides not to use the wild card in the hand in which he receives the wild card and prefers to use the wild card in a later hand.
Each of the embodiments of the present invention provides one or more players with opportunities to maximize the beneficial effect of a wild indicia.
These and other embodiments are described in greater detail with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a gaming device embodiment of the present invention comprising a touch screen.
FIG. 2 illustrates a touch screen used with the embodiment of FIG. 1 .
FIG. 3 illustrates a gaming device of another embodiment of the present invention.
FIG. 4 illustrates a board game embodiment of the present invention.
DETAILED DESCRIPTION
The various embodiments of the present invention increase the level of player input, increase the likelihood of a winning payout, provide at least one player with the possibility to maximize the amount of a winning payout, and increase the overall level of enjoyment to a game which utilizes at least one wild indicia. The present invention achieves these desirable results by providing a player who receives a wild indicia during the play of one game with the option of reserving that wild indicia for use in a subsequent game.
While the various embodiments of the present invention are illustrated in conjunction with a game of five-card draw poker, the advantages of the present invention are equally applicable to a wide variety of other games of skill or chance.
According to the illustrated embodiments, five indicia of playing cards are displayed to a player. The player is provided with the opportunity to discard one or more of the cards and, if the player has received a wild card, to place that wild card in a reserve area for use with a later hand. To the extent that the player has discarded any cards or moved a wild card from his hand to a reserve area, the player is provided with replacement cards. Furthermore, a player may be provided with the option of reserving a wild card even if that player received the wild card as a draw card, i,e., as a replacement to one of the first indicia of playing cards displayed to that player. A winning payout is then provided to either the player with the highest hand or to any players which have attained a winning hand as determined by a predetermined payout schedule.
According to one preferred embodiment of the present invention, a first plurality of playing card indicia which is displayed to a player is selected from a collection which does not include a wild card. In this manner, the game can be controlled so that the first plurality of card indicia displayed to a player never contains a wild card. The cards remaining after making the first display can then be reshuffled along with one or more wild cards to form a second collection of cards from which additional cards are selected. The first plurality of playing card indicia may comprise a number of cards sufficient to form a complete hand or some lower number of cards. For example, the first three cards displayed to a player in a five-card poker hand may be selected from the first collection, which does not include any wild cards, while all remaining cards may be selected from collections to which at least one wild card indicia has been added. Similarly, wild card indicia may be placed in a first collection of cards from which the player's first card indicia are selected and then wild card indicia not displayed to one or more players as of a certain point in a hand may be removed so that no further wild cards are displayed. For example, in a five-card draw poker game, each player's first five cards may be selected from a first collection comprising one or more wild cards while draw cards may be selected from a second collection from which wild cards have been removed.
From the present description, those skilled in the art will appreciate that the odds of a player attaining a successful hand may be modified by modifying certain parameters of a game including the number of wild cards used, the number of indicia displayed from collections comprising one or more wild indicia, and the timing of when indicia are selected from collections comprising wild indicia. These and other parameters may be modified without departing from the scope of the present invention.
Further limitations can be placed upon one or more of the games of the present invention by limiting the number of plays for which a player may reserve a wild indicia. For example, in a game of bingo, a player may be provided with the opportunity of reserving a wild indicia for ten bingo games. In such instances, if the player does not use the reserved wild indicia within ten games after the wild indicia was displayed, the wild indicia would be forfeited. Similarly, in a card game, a player may be limited to utilizing a wild indicia in a certain number of hands following receipt of that wild indicia. By so limiting the use of a wild indicia, a player's chances of achieving a very high payout can be controlled. Those skilled in the art will also appreciate that the chances of displaying a wild indicia to a player can be controlled by controlling the total number of playing indicia in the collection from which cards are selected, by controlling the number of wild indicia added to the collection, as well as by keeping the wild indicia out of the collection until a predetermined number of indicia have been displayed.
FIG. 1 illustrates one embodiment of the present invention in the form of a gaming device 10 having a pressure-sensitive touch screen 20 , a coin slot 60 , a bill validator 70 , a credit card receiver/terminal 75 , flashing light 80 , payout schedule 85 , coin chute 90 and coin trough 95 . This embodiment of the present invention can be activated by a player inserting an item of monetary value including coins, paper currency, tokens, or some form of credit indicator, such as a credit card. Suitable instructions are provided in instruction window 22 to guide a player through the initial steps necessary to start the game, as well as through subsequent steps. If a player has inserted more than the amount of the minimum wager, the player will be required to designate the amount of his wager by touching the corresponding wager area 24 under the designation “SELECT WAGER.” The amount wagered will then be displayed in wager window 26 . If the player has inserted an amount greater than the amount wagered, the player's remaining credits will appear in the credits window 28 . Wagers for subsequent hands can then be automatically drawn from the player's credits in a manner which is now well known in the art.
After a player has selected an amount for an initial wager, a plurality of indicia of playing cards 30 is displayed on the screen. Following instructions and prompts provided in instruction window 22 , the player may opt to hold one or more of the cards by simply touching the image of the card on screen 20 . An actuator may also be provided for this and other player input on a button panel. If the player receives a wild card, the player may also opt to reserve the wild card for use in a subsequent hand by touching the “RESERVE WILD CARD” area 32 . When a player reserves a wild card, the player is preferably provided with an image of the wild card in reserved area 34 . In this and other embodiments of the present invention, a player may or may not be permitted to utilize a wild indicia in the same hand or game in which the player designated that the wild indicia be reserved. Such rules are preferably set by the house or other rulemaker prior to play. Furthermore, as stated above, a player may receive a wild indicia either in an initial display or in a subsequent display, such as cards drawn after a discard.
If the player has discarded any cards and/or reserved a wild card, replacement cards are provided to the player's hand and displayed in card display area 30 . If the resulting display comprises one of a predetermined plurality of winning card hands, the player is provided with a winning payout. Particularly high winning payouts may be accompanied by discernable signals such as a flashing light 80 and audible sirens from a speaker (not shown). The amount that the player has won is then preferably added to the amount shown in the “CREDITS” window 28 .
As an example, the hand shown in card display area 30 of FIG. 2 indicates a hand in which a player would want to utilize a wild card previously held in RESERVED area 34 . Those familiar with poker will appreciate that by replacing the 3 of diamonds with the wild card, the player will have attained a Royal Flush and, typically, a large payout.
Since the present invention can be played with a wide variety of games, the winning payouts for a winning hand can vary widely. As an example, with the five-card draw poker game described above, the payout schedule could be as follows:
SAMPLE TABLE PAYOUT SCHEDULE
Royal Flush
800 for 1
Straight Flush
50 for 1
Four Of A Kind
25 for 1
Full House
8 for 1
Flush
5 for 1
Straight
4 for 1
Three Of A Kind
3 for 1
Two Pair
2 for 1
Pair of Jacks or better
1 for 1
An alternative embodiment of the present invention is illustrated in FIG. 3 in the form of a gaming device. This embodiment of the present invention differs from the embodiment illustrated in FIGS. 1 and 2 in that decisions are input to the machine by the player depressing one or more buttons on a button panel 125 . Button panel 125 comprises a “DEAL/DRAW” button 126 , “BET ONE” button 128 , a “BET MAX” button 127 , a plurality of “HOLD” buttons 132 , a “RESERVE WILD CARD” button 133 , a “CASH/CREDIT” button 136 , a change button 137 and a “COLLECT WINNINGS” button 138 . According to this embodiment of the present invention, after a player has input monetary value into coin slot 160 or bill validator 170 , he can select the amount that he wants to wager on the present hand by depressing “BET ONE” button 128 the number of times needed to properly show his wager in the wager window on screen 120 or BET MAX button 127 . The remaining portion of the player's credits will be indicated in credit window 129 . The player then depresses “DEAL/DRAW” button 126 in order to receive a first plurality of cards. The player may then select which cards to hold by depressing corresponding “HOLD” buttons 132 , which are most preferably aligned with the indicia of playing cards 130 appearing on screen 120 . If the player has received a wild card that he wishes to reserve for use in a subsequent hand, the player then depresses “RESERVE” button 133 , which will move the wild card up into wild card reserve area 134 on screen 120 .
When the player has made his selection regarding which cards to hold and/or reserve, he must then again press “DEAL/DRAW” button 126 in order to receive replacement cards. According to this illustrated embodiment, after the player has received any necessary replacement cards, the gaming device 100 automatically evaluates whether the player has received a winning hand and, if he has, provides a winning payout according to payout schedule 185 , signals the winning payout with flashing light 180 and increases the player's credits shown in credit window 129 accordingly. When a player has finished playing and wishes to withdraw any credits shown in credit window 129 , the player can simply depress “COLLECT WINNINGS” button 138 in order to receive his money from coin chute 190 and coin trough 195 and/or credits. As illustrated, button panel 125 is also provided with “CHANGE” button 137 which will alert a casino attendant that a player requires change.
Another embodiment of the present invention is illustrated in FIG. 4 wherein a gaming table 200 is provided with a playing surface 210 , chip rack 220 , card shoe 230 and discard tray 240 . A plurality of player stations is located around the playing surface. According to this embodiment of the present invention, each playing area comprises a wager area 250 , a card area 260 and a wild card reserve area 270 . According to this embodiment of the present invention, when a player wishes to reserve a wild card for subsequent use, the reserved wild card is placed in a “wild card reserve area” 270 .
While the present embodiments have been described as providing a player with an option of reserving a wild card when that player receives such a wild card during the initial deal, the various embodiments of the present invention can also provide a player with the option of reserving a wild card for use in a subsequent hand even if that player receives one or more wild cards as replacement cards for those which he had originally discarded or reserved. Furthermore, a player may be provided with the option of retrieving a wild indicia from a wild indicia reserve area for use in the same game that the wild indicia was received, either between or after the player has received or seen additional playing indicia.
As a further enhancement to the excitement provided by the games of the present invention, it is also within the scope of the present invention to provide a higher or lower payout when the player uses a wild indicia.
The present invention is readily adapted for use with a wide variety of wagering games of chance or skill including blackjack, other forms of poker, keno, bingo, lotto, as well as with video slots and/or a reel slot. For example, other card games such as blackjack may be similarly played wherein one or more wild card indicia are displayed to players either in a physical form, such as in a table version, or as an image on a screen in a video version.
Those skilled in the art will appreciate that the present invention can be modified for use in other games with or without additional restrictions. For example, in a bingo game, a wild indicia received during one game may be utilized in subsequent games to cover whatever spot that a player chooses. In a lotto game, a player might utilize a wild indicia for use as any number in a subsequent play. Still further embodiments may comprise placing a wild indicia on one or more faces of a die for use in a dice game. Therefore, it is within the scope of the present invention to utilize the traveling wild indicia of the present invention in games of craps. In a keno game, the keno game could be limited to permit a player to use a reserved wild indicia in subsequent plays only if the player was using an identical wager in an identically played game. The use of the wild indicia may be restricted to a predetermined number of hands following the receipt of the wild indicia by the player. These and other restrictions may or may not be imposed on other wagering games of chance or skill.
According to further embodiments of the present invention, a wild indicia may have limitations. For example, the wild indicia may be completely wild in that it can be used as a substitute to any indicia in the game. Alternatively, the wild indicia may be restricted so that it can only be played as certain other symbols.
Furthermore, according to a further embodiment of the present invention, the mere reciept of a wild indicia can provide a player with one or more winning advantages. For example, a wild indicia may act as a multiplier in order to modify the payout schedule. Alternatively, the receipt of a wild indicia may provide or qualify the player for a super-jackpot. Still futhermore, a player may be provided with an opportunity to increase the amount of a payout by some percentage, e.g., 25% or even by a multiplier of two or three. Still furthermore, the wild indicia could also provide opportunities for a player to qualify for other opportunities. For example, in a card game if a wild card was utilized to form a royal flush, that winning player could be entered into a super-jackpot prize drawing. Those skilled in the art will appreciate that these embodiments may be achieved without departing from the scope of the present invention. | A gaming device is provided that includes a display screen that is capable of generating video images, the gaming device being programmed to select a first group of indicia from a plurality of indicia in a first game, wherein the plurality of indicia include a plurality of playing indicia and at least one wild indicia. The gaming device also being programmed to cause a video image representing the first game to be displayed on the display screen, to provide a player with a winning advantage if the player receives the at least one wild indicia, and to limit the use of the at least one wild indicia. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Division, and claims priority benefit, of now-pending application Ser. No. 11/083,885 (filed Mar. 17, 2005), which will issue as U.S. Pat. No. 7,866,443 on Jan. 11, 2011. Application Ser. No. 11/083,885, in turn, was a Continuation/Division, and claimed priority benefit, of application Ser. No. 10/095,780, filed Mar. 9, 2002, which issued as U.S. Pat. No. 6,868,944 on Mar. 22, 2005. Application Ser. No. 10/095,780, in turn, was a Continuation-In-Part, and claimed priority benefit, of application Ser. No. 09/315,809, filed May 21, 1999, which issued as U.S. Pat. No. 6,354,403 on Mar. 12, 2002. Application Ser. No. 09/315,809, in turn, claimed priority benefit of Provisional Application No. 60/085,151 for an ADJUSTABLE STAIR STRINGER AND RAILING filed May 21, 1998 by Richard Truckner and Paul Truckner.
BACKGROUND OF THE INVENTION
[0002] Numerous innovations for adjustable stairways have been provided in the prior art that are described as follows. Even though these innovations may be suitable for specific individual purposes to which they address, they differ from the present invention as hereinafter contrasted.
[0003] The prior art does not utilize a pivoted motion and does not allow an infinite amount of variable spacing when framing stairs and/or a railing. The present invention allows an infinite amount of variable spacings and use of a pivoting motion.
[0004] U.S. Pat. No. 2,245,825 to W. E. Ross teaches a folding stand that has pivoting support but is not based on vertical holes which keep treads in a horizontal position with an infinite amount of variable spacings. Furthermore, the patented invention utilizes different elements from the present invention. Some of the differences are:
1) Vertical holes are not important, 2) Stair is adjustable into one position only, 3) Not meant to be permanently fixed after moved into position on risers, 4) Risers and treads to not slide past each other, 5) Pivoting tread support is not fixed in position after adjustment and therefore not used to lock stringers.
[0010] U.S. Pat. No. 3,470,664 to J. I. Whitehead teaches an adjustable staircase. The patented invention does not have any pivoting motion and utilizes different elements from the present invention.
[0011] U.S. Pat. No. 3,885,365 to J. W. Cox teaches a self adjusting stair which utilizes a truss assemblage. In the patented invention adjustments are made using a pin and slot. The patented invention does not utilize any pivoting motion and the rails are not adjusted by stringers as with the present invention.
[0012] U.S. Pat. No. 3,962,838 to J. W. Cox teaches a self adjusting which utilizes spacers in a truss assemblage. The patented invention does not utilize a pivoting motion and the rails are not adjusted by stringers.
[0013] U.S. Pat. No. 4,406,347 to N. M. Strathopoulos teaches a modular staircase assembly. The patented invention does not utilize a pivoting motion. The rails are not adjusted by stringers and are not adjusted on vertical holes.
[0014] U.S. Pat. No. 4,959,935 to H. R. Stob teaches a prefabricated adjustable stairway. The patented invention does not utilize a pivoting motion and the rails are not adjusted by stringers. This apparatus uses a three point pivoting action so that stringers do not separate during adjustment and slide one on top of the other.
[0015] U.S. Pat. No. 5,189,854 to K. J. Nebel teaches an adjustable height staircase. The patented invention does not utilize a pivoting apparatus as described herein. The present invention utilizes a pivoting apparatus and contains different elements from the patented invention for at least the following reasons:
[0016] 1) Treads are directly connected to stringers,
[0017] 2) No risers,
[0018] 3) No sliding motion of riser past the tread.
[0019] U.S. Pat. No. 4,124,957 to Poulain shows treads that are directly connected to stringers, stringers that have special tongue and groove spacers which must be an exact size each time in order to lock stringers otherwise the stringers must be secured top and bottom of the stair only, and risers and treads do not slide past each other.
[0020] Numerous innovations for adjustable staircases have been provided in the prior art that are adapted to be used. Even though these innovations may be suitable for specific individual purposes to which they address, they would not be suitable for the purposes of the present invention as heretofore described.
SUMMARY OF THE INVENTION
[0021] The structure of the present invention can be used for forming a stair and may also be used as a support for concrete form work, as a form for a ramp, as a form for adjustable shelves, as an adjustable bleacher, and for adjustable displays.
[0022] It is an object of the present invention to provide an adjustable stringer and railing that allows users to have a quickly formed stair structure.
[0023] It is another object of the present invention to provide an adjustable stringer and railing that provides partially assembled elements that can be adjusted to a variety of applications and then securely fixed to form a stair framing and/or railing framing.
[0024] It is another object of the present invention to provide an adjustable stringer and railing that utilizes a pivoting motion.
[0025] It is another object of the present invention to provide an adjustable stringer and railing that allows an infinite amount of variable spacings when creating stairs and/or railing.
[0026] It is another object of the present invention to provide an adjustable stringer and railing that eliminates the need to calculate spacing between step treads and angle of the stairs.
[0027] It is another object of the present invention to provide an adjustable stringer and railing that provides an embodiment that includes an upper stringer arm, a lower stringer arm and at least one riser support.
[0028] It is another object of the present invention to provide an adjustable stringer and railing that provides an embodiment that includes an upper rail support and at least two railing posts pivotally attached to the upper rail support.
[0029] It is another object of the present invention to provide an adjustable stringer and railing that is easy and inexpensive to manufacture.
[0030] Another object of the present invention is the use of a bracket and setting and spacer bar that can be used with stringer elements for simplifying the formation of a stair assembly with treads, risers and rail supports.
[0031] Further objects of the present invention include a stair forming apparatus that includes a pivoting block to which treads and risers can be attached, a pivoting block to which treads only can be attached, a pivoting block which allows risers and treads to slide past each other, a pivoting block which allows risers and treads to be attached such that the risers and treads can be attached to each other after assembly to form a solid construction in which the risers become beams and the treads become lateral use of a bracing to produce great structural strength and much wider stair widths than normal with on center supports (additional stringers) as with. normal stairs, and greater stringer strength than with normal saw tooth stringers because of greater stringer depth and, when the riser/tread supports are secured to the upper and lower stringers after adjustment, the stringers are bonded together to form one solid stringer which also is capable of much greater spans without additional supports.
[0032] The structure of the present invention includes riser and tread support which allows risers and tread to slide past each other (as the stinger is adjusted) in order to utilize standard lumber and eliminate the need to cut lumber to exact widths, to use standard lumber of varying lengths according to width of the stair (i.e. 4′ to 10′ wide stairs), to use riser and tread support systems which, after pivoting and adjusting in position, allows risers to be used as beams which greatly increases the structural strength of the stair allowing much greater stair widths than normal without the need for additional center support stringers, and provides a stringer system which, when the riser/tread supports are secured, the stringer members are bonded together to form a much stronger stringer member than in normal “saw tooth” type construction giving much greater stair lengths without additional supports.
[0033] The foregoing benefits are accomplished with the simplified bracket, spacer and setting combination that permits the assembly of a stair stringer assembly without difficulty permitting the “do it yourselfer” to install a stair assembly with simple instructions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a side view of the stair embodiment of the adjustable stair stinger and railing illustrating two possible inclinations.
[0035] FIG. 2 is a side view of the railing embodiment of the adjustable stair stringer and railing.
[0036] FIG. 3 is a top view of the adjustable stair stringer and railing.
[0037] FIG. 4 is a front view showing the assembled stair and railing set in position.
[0038] FIG. 5 is a side view showing the assembled stairs.
[0039] FIG. 6 is a side view of an alternative form of the adjustable stair 10 as assembled.
[0040] FIG. 7 is a side view showing the adjustable stair in two alternative rise angles using the same elements.
[0041] FIG. 8 is a perspective view showing the nailing block and pivot attachment plate for the stair assembly of FIG. 7 .
[0042] FIG. 9 is a perspective view of an alternative riser tread support.
[0043] FIG. 10 is a perspective view of the attachment bracket as used in the present invention.
[0044] FIG. 11 is a top plan view of a stair assembly of the form of FIG. 7 with risers and without the treads.
[0045] FIG. 12 is a sectional view of a stair assembly of the form of FIG. 7 with the use of horizontal pivots.
[0046] FIG. 13 is a perspective view of the tread support bracket as used in FIG. 12 .
[0047] FIG. 14 is an alternative form of a tread support and riser support using horizontal pivots as used in FIG. 12 .
[0048] FIG. 15 is an elevation view showing alternative riser/tread supports which are individually set on a two piece stringer.
[0049] FIG. 16 is an elevation view showing the riser/tread adjusted in position.
[0050] FIG. 17 is a perspective view of the riser/tread support of FIGS. 15 & 16 .
[0051] FIG. 18 is an alternative form of the present invention using a single pivot point for a riser/tread support.
[0052] FIGS. 19 & 20 are alternative forms of tread support for the assembly of FIG. 18 .
[0053] FIG. 21 is a side elevation view with an alternative stair assembly showing riser/tread supports and setting spacing blocks.
[0054] FIG. 22 is a partial top plan view of a portion of FIG. 21 .
[0055] FIG. 23 is a side elevation view of the alternative riser/tread supports of FIG. 21 after removal of the setting/spacing blocks and as set for assembly as a stair riser and tread support.
[0056] FIGS. 24 and 25 are perspective views of the riser/tread support and setting/spacing block after separation.
[0057] FIG. 26 is a top plan view of a structure from which a bracket may be formed.
[0058] FIG. 27 is a top plan view of a setting and spacer bar for use with the bracket of FIG. 26 .
[0059] FIG. 28 is a side elevation view of FIG. 27 .
[0060] FIG. 29 is a sectional view taken along the lines 29 - 29 of FIG. 27 .
[0061] FIGS. 30 , 31 and 32 are alternative forms of bracket elements with setting/spacing bars.
[0062] FIG. 33 is a view showing alternative adjustable spacing constructions.
[0063] FIGS. 34A , 34 B, 35 A, 35 B, 36 A and 36 B illustrate the use of the brackets, setting/spacer bars and stringer elements of the present invention.
[0064] FIGS. 37 , 38 A and 38 B are side elevation views of riser formwork and locking clamp using a two piece stinger and riser/formwork supports.
[0065] FIGS. 39A , 39 B, 39 C and 39 D illustrate the forming for concrete stairway using the bracket and spacer of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
[0066] Referring to FIG. 1 which is a side view of the stair embodiment of an adjustable stair stringer and railing 110 which includes an upper stringer arm 112 , a lower stringer arm 114 and at least one riser/tread support 116 . The upper stringer arm 112 is parallel to the lower stringer arm 114 . The riser/tread support 116 is pivotally attached to the upper stringer arm 112 and pivotally attached to the lower stringer arm 114 . The riser/tread support 116 may be attached to the upper stringer arm 112 and lower stringer arm 114 by riser/tread stringer arm fasteners 118 . The riser/tread stringer arm fastener 118 can be a pin, screw, bolt, clamp, dowel or hook.
[0067] The riser/tread support 116 can be in the shape of a rectangle, square, triangle, pentangle or circle. The riser/tread support 116 may be rectangular in shape and contain a riser/tread support beveled corner 116 A. Furthermore, if there are more than one riser/tread supports 116 the riser/tread supports 116 can be positioned equally along the upper stringer arm 112 and lower stringer arm 114 . The riser/tread support 116 can be attached at horizontally positioned fixed points 116 B fastened to the upper stringer arm 112 and lower stringer arm 114 .
[0068] The stair embodiment of the adjustable stair stringer and railing 110 can include a lower stringer support 120 which can be attachable to the upper stringer arm 112 and the lower stringer arm 114 , and an upper stringer support 122 which can be attachable to the upper stringer arm 112 and the lower stringer arm 114 .
[0069] The stair embodiment of the adjustable stair stringer and railing 110 can be manufactured from wood, fiberglass, metal, metal alloys, epoxy, carbon graphite, concrete or plastic. It further can be adapted for use to pour concrete and create concrete stairs.
[0070] The railing embodiment of the adjustable stair stringer and railing 210 as shown in FIG. 2 showing risers 80 and treads 90 contains an upper rail support 212 and at least two railing posts 214 . The two railing posts 214 are pivotally attached to the upper rail support 212 . The at least two railing posts 214 are pivotally attached to the upper rail support 212 by upper rail support railing posts fasteners 218 . The upper rail support railing post fastener 218 can be a pin, screw, bolt, clamp, dowel or a hook.
[0071] The railing embodiment of the adjustable stair stringer and railing 210 can contain at least one banister 216 pivotally attachable and/or attached to the upper rail support 212 . The at least one banister 216 is parallel to the railing posts 214 . The banister 216 can be attached to the upper rail support 212 by an upper rail support banister fastener 222 . The at least one banister 216 can be positioned equally along the upper rail support 212 . The upper rail support banister fastener 222 can be a pin, screw, bolt, clamp, dowel or hook.
[0072] The rail embodiment of the adjustable stair stringer and railing 210 can contain an upper rail support railing cap 212 A which is attached to the upper rail support 212 . It can further contain a railing post attachment 220 attachable to each of the railing posts 214 .
[0073] It will be understood that each of the elements describe above, or two or more together, may also find useful application in other types of constructions differing from the type described above.
[0074] FIGS. 6-10 illustrate an alternative form of the stringer, riser and tread assembly in accord with the present invention. In this form a two piece stringer 310 A (lower) and 310 B (upper), as shown in FIGS. 6 & 7 , is first attached to a deck or wall vertical surface by an attachment bracket 312 , as shown in FIG. 10 , with the two pieces of the stringer attached to pivot holes 312 A in the bracket. Riser/tread supports 314 having pivot holes 316 spaced the same distances as the pivot holes in the attachment bracket are spaced along the risers and are fixed to the risers by suitable means at screw holes 318 to cause the riser/tread supports to be parallel to the attachment bracket and equally spaced along the risers. These vertical pivot riser/tread support 314 are unique because the supports pivot for adjustment only and are fixed in position after adjustment; the fixing of the riser/tread supports joins the two pieces of the stinger to form a one piece, permanently adjusted stringer which is structurally superior to normal stair construction; the positioning of the pivot points (opposite risers) allows the top of the stair to be attached the same distance down from the deck/floor level each time regardless of the riser height because all risers adjust equally including the first riser; the configuration of the riser/tread support allows risers 80 and treads 90 to slide against each other for adjustment; and when the risers are attached to the riser/tread supports and the treads, each riser then acts as a beam giving the stair much greater structural stability and allowing greater widths for a stair without additional supports. The riser/tread supports 314 can be constructed from metal, composites and other materials. It should be evident that the riser/tread supports 314 are now vertical if the surface of the deck where attachment was made was vertical when the attachment bracket was attached, and as illustrated in the two positions shown in FIG. 7 , the riser/tread supports are now in position to be permanently attached to the stringers at securing holes 318 and to have risers 80 and treads 90 attached to the supports.
[0075] FIGS. 12-14 illustrate an alternative form of the stringer, riser and tread assembly formed using horizontal pivoted tread support brackets and including an alternative tread support with riser support elements. FIG. 13 shows alternative pivoting tread supports using a straight bracket 412 and FIG. 14 another support 414 , which is truncated in shape which can be used with or without a riser, but allowing greater fixing to the stringer. Riser 80 and treads 90 can still slide past each other to form beams. There are three steps shown on the drawing which illustrates how this system would be installed with pivot points that are horizontal.
[0076] The feature of the riser/tread support in either the vertical or horizontal pivoted form is that it is a one piece apparatus which attaches to the two piece stringer using two pivot points which normally are vertical or horizontal but can be at any common angle. The riser/tread supports pivots to adjust for a required height to form the correct stair profile.
[0077] The riser/tread support is then fixed in position (using nails, screws, bolts, glue, etc.) against the two piece stringer to form one solid, non-moving stringer which is capable of supporting both risers and treads or treads alone or risers alone (when being used for concrete formwork). The two piece stringer is then cut (at the dotted lines shown) to conform to the deck or wall at the top and the base at ground level at the bottom. The riser/tread support allows risers and treads to slide past each other so that the risers can be adjusted for height sliding up or down past the back of the tread. The back of the tread is pushed against the face of the riser to form an enclosed stair. The position of the risers and treads can vary infinitely in respect to each other depending on the stair adjustment.
[0078] FIGS. 15-17 illustrate a further alternative form for riser/tread supports 512 which are individually set on a two piece stringer 310 A and 310 B using removable setting blocks 514 and setting pins 516 . In this form the removable setting blocks 514 are used to space the riser/tread supports equally along the two piece stringer by being placed on a reference surface of a support and as their ends abut along the stringer. The stringer pieces are separated from each other by the removable setting pin 516 and the riser/tread supports 512 are attached at their pivot points 518 A and 518 B to the stringer 112 and to the stringer 114 . When the setting blocks 514 and the setting pins 516 are removed, the two parts of the stringer can be slid with respect to each other to adjust the riser/tread supports 512 in the desired vertical position and the riser/tread supports can then be secured to the stringers by screws, nails, or other fasteners at securing holes 520 . The riser/tread supports are then in position for the attachment of equally spaced treads and risers.
[0079] FIGS. 18-20 illustrate a stair section showing pivoting riser/tread supports using a single pivot point allowing the tread to be set level after stringer installation. Equally spaced support brackets 612 are pivoted at a single pivot 614 position off the stringer with those pivot positions being located the same distance below the deck/floor when the stringer is attached with the pivot position a desired distance below the level of the deck or floor to which the stair is to be attached. With a single pivot point for each of the equally spaced riser/tread supports, the supports can be attached to the second stringer by suitable means and the treads will always be equally spaced and will have equal rising distances. The single pivot point can be at any common point (shown as alternatives 614 B) along the riser/tread support brackets 612 and the brackets can be just a tread support or a tread and riser support. FIG. 20 illustrates an alternative form 612 B for the bracket in a truncated form.
[0080] FIGS. 21-25 illustrate another alternative form for riser/tread supports for use in the present invention. In this form the riser/tread supports 712 are individually set on a two piece stringer 112 - 114 using removable setting/spacing blocks 714 . This form of two piece stringer/riser/tread support assembly can be assembled with the stringers 112 - 114 and the riser/tread supports 712 in place by attachment means at the pivots 712 A and with the riser/tread supports spaced by the body 716 of setting/spacing blocks 714 mating and cooperating extensions 718 A and 718 B with centering slots 720 A and 720 B in the riser/tread supports. When the assembly is to be used, the setting/spacing blocks can then be removed from the riser/tread supports and the stringers can then slid with respect to each other to rotate the riser/tread supports about their pivot points. The stringer can then be attached to the face of the deck or wall where the stair is to be attached and the stringers can be cut (at possible cut lines shown) to face against the deck or wall. The riser/tread supports will then be equally spaced both vertically and horizontally, can be attached by suitable fastening means to the stringers, and are in position for installation of risers and treads.
[0081] FIGS. 26-33 illustrate another alternative form for a riser/tread support bracket 812 . This form may be formed from a metal or other suitable material blank 812 A with stamped holes, slots and side portions to from the bracket. The side portions 813 and 814 form the tread and riser support surfaces (respectively) with stamped holes 815 for attaching means for the treads and risers. Pivot holes 816 are used for connecting the bracket to the stringers and holes 817 are for fixing the bracket in place when a stringer assembly is completed. The bracket 812 is provided with stamped alignment guide holes at 819 and a guide slot at 820 .
[0082] FIGS. 27-30 illustrate a setting and spacing bar 822 . The setting and spacing bar may be formed of metal or other suitable material and includes a central body portion 823 with folded ears 824 at each with a guide tab 825 formed at each end of the body portion.
[0083] The setting and spacing bar 822 is adapted to cooperate with and space two brackets 812 by aligning the guide tab 825 with the guide hole 819 at one bracket and with guide slot 820 in the next bracket and serves to establish the spacing between brackets. The folded ears 824 separate two stringers and thus to allow for the space for relative movement between stringers.
[0084] With at least a pair of brackets 812 spaced by setting and spacing bars 822 and an upper and lower stringer the brackets may be attached by suitable means to the stringers at the pivot holes 816 to provide aligned and spaced riser/tread brackets for a stair assembly as will be described with reference to FIGS. 34-38 .
[0085] FIGS. 30-33 illustrate alternative forms for riser/tread brackets similar to that shown in FIGS. 26-29 . FIG. 31 illustrates a bracket 812 with a setting and spacing bar 822 integrally formed with the bracket. The bar 822 has a length designed to space adjacent brackets and a near central folded ear portion 824 for spacing stringers. The bar 822 would be detachable after it has functioned in setting and spacing. FIG. 31 illustrates another alternative of an integrally formed bracket 812 with a removable spacing bar 822 and a central setting body 824 . FIG. 32 is another alternative bracket similar to FIG. 31 with a removable spacing bar 822 and a central plug 826 for spacing the stringers. FIG. 33 illustrates alternative forms for the end of a spacing bar 822 to adapt the bracket to different spacings of brackets along a stringer assembly. The spacing bar may include holes or pins at 822 A or notches at 822 B. Spacing bars of the type shown here can be used with the brackets 116 shown in FIG. 5 by cooperating with the spacer slots 115 in positioning brackets 116 before stringers 112 and 114 are moved relative to each other in setting the brackets 116 for receiving treads and/or risers.
[0086] FIGS. 34-36 illustrate the use of the brackets with stringers in the formation of a stair assembly. FIGS. 34A and 34B illustrate the opposite sides of a stair stringer assembly, each side having an upper 112 and lower 114 stringer with a plurality of brackets 812 of the type illustrated in FIGS. 26-29 (or of the types shown in FIGS. 1-25 ) and employing setting and spacing bars 822 to position the brackets along the stringers. The two stringer assemblies mirror each other to be left and right sides of a stairway. When assembled, spaced and guided, the brackets are attached to the stringers by suitable means through pivot holes 316 . FIGS. 35A and 35B illustrate the moved portion of the stringers 812 - 814 and the rotation of the brackets 812 to the desired position for attachment to a deck or wall and for tread and riser attachment after cutting the stingers for attachment to the deck or wall. At this stage in the formation of the stringer assembly the brackets 812 can be permanently attached to the stringers at the provided attachment holes.
[0087] FIGS. 36A and 36B illustrate the completed stair using the brackets and movable stringers of the present invention. It should be noted that the forward holes 815 along the tread side portions 813 of the bracket of FIG. 26 permit the location for pre-drilling guide holes into a tread from below. By knocking the tread against the bracket, the raised holes will mark the underside of the tread. Pre-drilling guide holes will permit ease of assembly of the tread from below before a riser is added to the face of the stair.
[0088] FIGS. 37 and 38A illustrate the use of the principle of the present invention for the positioning of formwork for poured concrete stairs. The use of two part parallel stingers with pivoted riser/formwork supports permits the setting of equally spaced horizontal riser forms and equally spaced vertical spaces between poured stairs. The two piece stringer is first set at the desired angle and the separated stinger parts are fixed with respect to the top and bottom of the desired stair. Equally spaced riser/formwork supports are positioned along the risers by attachment at pivot points with the support elements having adjustment slots ( FIG. 37 ) or by the use of locking holders ( FIG. 38B ). Riser formwork elements are attached to the free end of each of the supports. Concrete aggregate can then be poured behind each of the riser formworks to the desired level for the stairs and allowed to set. It should be evident that the face of the riser formwork elements can be adjusted to a desired angle other than vertical by adjusting the relative positions of the two stringer elements. The riser height adjustment can be achieved by setting the first and last support and their riser formworks in position and then raising or lowering intermediate supported riser formworks to a string line drawn from the first to the last support. Equally spaced horizontal supports will then result in equally spaced vertical riser formworks.
[0089] An additional use for the parallel stringers, brackets and spacers is illustrated in FIGS. 39A , 39 B, 39 C and 39 D for the setting of forms for pouring concrete in the formation of a concrete stair. Previous forming systems have required that stingers be set at each side of the stairs to be poured along with form boards for the vertical forms off the stair. With the use of the parallel stringers, brackets and spacers of the present invention, the form work for a stair is easily position and aligned. As with the case of the riser/tread setting of a stairway, the brackets are placed and spaced on the parallel stringers so that all brackets move parallel with each other and provide a surface for the mounting of riser forms.
[0090] As illustrated in FIG. 39A , the parallel stringers 112 and 114 (as shown in FIG. 1 ) are set with brackets 812 and spacers 814 (as shown in FIGS. 26 through 35B ) so that the brackets are equally spaced and pivoted about mounting fasteners 118 ( FIG. 1 ) in each of the parallel stringers 112 and 114 . Note that the brackets are mounted in a reverse position from that shown in the previous figures because the only surface that will be needed in the form work is the vertical surface 814 ( FIG. 26 ) where a riser form 390 is to be attached. When set in place, the spacers are removed as shown in FIG. 39B so that the brackets are free to be rotated with the movement of the parallel stringers. As illustrated in FIG. 39C , when the parallel stringers are moved with respect to each other, the brackets are rotated parallel to each other. The vertical surfaces 814 of the brackets 812 are then parallel to each other and spaced equally along the formwork. With the stringer assembly set and fixed in place for the desired angle of rise for the stairway, the vertical surfaces are positioned for the mounting of a riser form 390 at each bracket. It should be understood that the surface 814 need not be exactly vertical if it is desired that the riser part of a stair be tilted slightly from vertical.
[0091] FIG. 39D illustrates in perspective one side of a poured concrete stairway with aggregate 392 poured along the desired stairway and finished against the riser forms 390 and leveled between riser forms. The parallel stringers, riser forms and brackets may then be removed for reuse after the concrete aggregate has become set. The tread width and riser heights will all be equal in the finished stairway.
[0092] While certain preferred embodiments of the invention have been specifically disclosed, it should be understood that the invention is not limited thereto as many variations will be readily apparent to those skilled in the art and the invention is to be given its broadest possible interpretation within the terms of the following claims. | An adjustable stair stringer and railing construction assembly. The assembly is adapted to use a pair of parallel stringer arms for each stair side, a riser/tread support bracket for each stair, and alignment and spacing elements for spacing the support brackets along the stringers. The brackets include formations for spacing the stringers apart and for spacing adjacent brackets along the stringers. The brackets are initially pivotally attached to each of the stringers so as to be rotatably movable about their pivotal attachment as the stringers are moved axially. Axial movement of the stringers with respect to each other establishes the angle of rise. Treads and risers are attached to the brackets to form stairs, and railings are attachable to the stringer and bracket assembly. The parallel stringers, brackets and spacers are also used in the preparation of formwork for pouring aggregate stairs, with the stringers, brackets and spacers being reusable. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The invention relates to the field of modified rosins which contain a chemically bonded polymeric compound and methods of making such compounds. The rosin compounds can be used as sizing agents in the paper industry.
[0003] 2. Description of the Background Art
[0004] Most grades of paper used for writing, printing, packaging and other uses are treated with a sizing agent. Sizing agents (sizes) increase the fluid resistance of paper or paperboard, usually to wetting by aqueous liquids such as water, inks, and the like.
[0005] Rosin is a complex mixture of natural products that has been known since ancient times. It remains a low-cost organic acid and is used today in paints, printing inks, toners, rubber chemicals, and as a paper size, among other uses. In general, rosin is purified from natural sources (for example, coniferous trees) and from products formed in the paper industry by fractionation or other means. Rosin is composed of tricyclic rosin acids (such as abietic acid, palustric acid, and neoabietic acid), fatty acids and unsaponifiables.
[0006] Paper has been sized using rosin and alum for about two hundred years now. For most of this time, rosin has been saponified, i.e., reacted with an alkali, to render it partly or completely soluble in water, although rosin in its free acid form is a more effective paper size. The rosin soap or rosin in free acid form then can be mixed with paper fibers and alum (aluminum sulfate), which acts to precipitate the rosin onto the fibers. Rosin modification to improve sizing compounds has been performed. For example, the rosin can be reacted with a dienophile to produce a tricarboxylic acid. An example of this type of reaction with maleic anhydride is shown in FIG. 1 . The dienophiles most often employed in this process are fumaric acid and maleic anhydride, but other substances such as itaconic acid or maleic acid also can be used. The reaction products are known as fortified or reinforced rosins, which perform as paper sizes with more efficiency. See Casey, James P. (Ed.) Pulp and Paper Chemistry and Chemical Technology, 3rd. edition, vol. III, Wiley-Interscience, John Wiley & Sons, New
York, 1983.
[0000]
[0008] Today, dispersed rosin sizes, also called rosin size emulsions, are very important commercial products. Many in the industry divide rosin size emulsions into anionic and cationic types. Anionic rosin size emulsions have been described in for example, U.S. Pat. Nos. 1,882,680 and 3,865,769. Most anionic dispersions are stabilized with rosin alkali soaps and/or with casein. Casein, a milk protein, is amphoteric and has an isoelectric point of pH 4.6. Thus, casein is cationic at pH values below pH 4.6 and anionic above pH 4.6. Therefore, it is reasonable to assume rosin size emulsions stabilized with casein likewise are cationic at low pH and anionic at higher pH values. Techniques such as streaming potential measurements or zeta potential measurements measure net effect of charges on substances, and are commonly used to assess overall charge and to determine isoelectric points.
[0009] Cationic rosin size emulsions have been described in U.S. Pat. Nos. 3,966,654; 5,846,308 and 6,042,691. In this type of rosin emulsion, usually a cationic resin or combination of resins is mixed with rosin and emulsified. The cationic resins are cationic because of the presence of amine groups, which are believed to form salts with the carboxylic acid groups on the rosin. Attachment between the rosin and cationic resins also occurs because of hydrogen bonds and coordination bonds.
[0010] Modified rosin products also have been chemically modified by attaching nitrogen-containing compounds, such as by forming imides or various amines or amides with rosin and, for example, maleopimaric acid or oligomeric amines for use as paper sizes. U.S. Pat. No. 3,135,749 also describes imides of maleated rosin. None of the described compounds are imides of polymers and maleated rosin, however, and therefore they are distinct from the compounds of this invention. These compounds were designed for pharmacological uses such as to lower blood pressure and alleviate cardiac work load rather than paper sizing. Rosins modified with the addition of amines for paper sizing purposes have been prepared by reacting maleic anhydride and triethanolamine with rosin, which results in the attachment of the triethanolamine by ester bonds to maleated rosin. The resulting product can be emulsified with casein or with a special surfactant. U.S. Pat. Nos. 4,540,635 and 5,201,944 provide additional information on this subject.
[0011] Conventional rosin sizing of paper is, with a few exceptions, limited to acidic pH conditions due to the acidic characteristics of alum and the tendency of conventional sizes to perform poorly above a pH of about 6.5. The paper industry, however, has shifted to conditions closer to neutral pH because of the better permanence of paper under these conditions and the widespread use of calcium carbonate in paper-making. Conventional rosin sizes, however, have significantly decreased performance at these neutral pH conditions, so increasing amounts of size composition are needed to achieve the same result. This causes higher costs and may reduce paper quality and plant efficiency.
[0012] Most sizing performed under neutral pH conditions is achieved by synthetic sizes based on alkyl ketene dimers (AKD) or alkenyl succinic anhydride (ASA). These sizes generally are not compatible with aluminum sulfate and are more difficult to use. Rosin has been modified by esterification to protect it from saponification and render it more useful at pH values above 6.5, but sizes based on esterified rosin have met with very limited commercial success. Therefore, there remains a need in the art for affordable and convenient rosin size compositions which are effective under harsh conditions, i.e. pH above 6.5, and/or higher temperatures, i.e. temperatures above 50° C.
SUMMARY OF THE INVENTION
[0013] Accordingly, embodiments of the invention provide a polymer-rosin compound of Formula I:
[0000]
[0000] wherein R 1 is a hydrogen, carboxylic acid or a carbonyl which forms a 5-member hetero ring structure by covalent attachment to the nitrogen, wherein R 2 is a straight or branched C1-C3 alkyl group or is a single bond between the nitrogen and (R 3 ) n , wherein R 3 is selected from the group consisting of alkane, alkene, aminoalkane, diaminoalkene, aminoalkene, diaminoalkene, arene (aromatic hydrocarbon), aminoarene, polyamine and a mixture thereof, wherein R 4 is absent or is selected from the group consisting of hydrogen, alkane and polyamine, and wherein n is an integer of at least 9. Preferably n is 9 to about 2500.
[0014] Preferred embodiments of the invention provide such polymer-rosin compounds wherein R 1 is a carbonyl which forms a 5-membered hetero ring structure by covalent attachment to the nitrogen (in which case R 4 is absent) or wherein R 1 is a carboxylic acid, and wherein n is about 400 to about 700, or about 500 to about 600. Additional preferred embodiments include such compounds wherein R 2 is a bond or a straight or branched C1-C3 alkyl group. Further preferred embodiments include such compounds wherein the polymer is straight or branched and is a homopolymer or a co-polymer. Most preferably, R 3 is polyethylenimine.
[0015] Preferred embodiments include polymer-rosin compounds wherein R 3 is present on about 1 to about 17% of the molecules of Formula I, more preferably about 1.5% to about 8% of the molecules of Formula I. In some embodiments, the polymer-rosin compounds include those wherein R 3 is present on about 3 to about 16% of the molecules of Formula I or about 3 to about 14% of the molecules of Formula I. Most preferred polymer-rosin compounds have about 2% to about 5% of the molecules of Formula I. Embodiments most preferred for use as a paper size generally have less than about 6% of the molecules of Formula I.
[0016] Most preferred compounds include Formula II:
[0000]
[0017] or Formula III:
[0000]
[0018] Additional embodiments of the invention include methods of making the polymer-rosin compounds described above which comprise reacting an at least partially fortified rosin compound, for example tall oil rosin or gum rosin, with a polyamine compound. The partially fortified rosins preferably are about 3% to about 16% or about 3% to about 14% fortified. Preferred fortified rosin compounds may be rosins selected from the group consisting of maleated rosin, fumarated rosin, itaconicated rosin, citraconicated rosin, acrylated rosin, methacrylated rosin and any combination thereof and preferred polyamine compounds are selected from the group consisting of polyethylenimine, polyaniline, poly(allyl amine), poly(oxyethylene/oxypropylene)diamine, O,O′-bis(2-aminopropyl) polypropylene glycol, and any combination thereof. In some preferred methods, the ratio of polyamine to rosin is about 1% to about 17% by weight, or more preferably about 1.5% to about 8% by weight and most preferably about 2% to about 5% by weight. For paper sizes the ratio of polyamine to rosin is less than 6%.
[0019] Additional embodiments of the invention include methods of making the polymer-rosin compounds as discussed above by (a) melting an at least partially fortified rosin in a reversibly sealable vessel that is equipped with an inlet attached to an inert gas source to allow entry of an inert gas atmosphere into said vessel and an outlet to allow exit of gases and water vapor from said vessel; (b) agitating said fortified rosin and maintaining said fortified rosin at a temperature of about 100° C. to about 300° C.; (c) providing a flowable polyamine compound; (d) dispensing said flowable polyamine compound into said fortified rosin; (e) reacting said polyamine and said fortified rosin by agitating said polyamine/fortified rosin mixture at a temperature of about 100° C. to about 300° C. to form an amide- or imide-linked polymer-rosin compound; (f) cooling said polymer-rosin compound; and (g) optionally storing said polymer-rosin compound in a sealed container. Preferably, at least the reaction is conducted in an inert atmosphere and is conducted at a temperature of about 125° C. to about 250° C., about 150° C. to about 240° C. or about 170° C. to about 230° C., and preferably in the absence of solvent. Preferably, the at least partially fortified rosin is about 3% to about 16% fortified or about 3% to about 14% fortified.
[0020] In some embodiments of the methods, the polyamine compound is selected from the group consisting of polyaniline, poly(allyl amine), poly(oxyethylene/oxypropylene) diamine, O,O′-bis(2-aminopropyl)polypropylene glycol, polyethylenimine, and any combination thereof, most preferably polyethylenimine. The ratio of polyamine to rosin advantageously is about 1% to about 17% by weight, preferably about 1.5% to about 8% by weight and most preferably about 2% to about 5% by weight. The reaction preferably is conducted for about 2 hours.
[0021] Embodiments of the invention also include polymer-rosin compounds made by any of the methods discussed above.
[0022] Further embodiments of the invention include a polymer-rosin dispersion composition comprising a polymer-rosin compound as discussed above, water and a surfactant. and a paper or paperboard product which has been treated with this polymer-rosin dispersion composition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 shows an example of a chemical reaction suitable for producing a fortified rosin (maleic anhydride tall oil rosin (MATOR)).
[0024] FIG. 2 is an infrared spectrum of the modified rosin product of Example 1, and shows the formation of an imide linkage.
[0025] FIG. 3 is an infrared spectrum showing amide formation in an exemplary fumarated rosin adduct with polyethylenimine.
[0026] FIG. 4 is a graph showing the variation of softening point with addition of alpha olefin wax to MATOR modified with 10% LupasolWF™.
[0027] FIG. 5 is a graph showing the acid number of modified rosin compositions made by reacting varying amounts of PEI with 13.6% MATOR.
[0028] FIG. 6 is a graph showing the softening point of modified rosin compositions made by reacting varying amounts of PEI with 13.6% MATOR.
[0029] FIG. 7 is an exemplary IR spectrum of 13.6% MATOR.
[0030] FIG. 8 is an IR spectrum of 12% PEI on 11% MATOR.
[0031] FIG. 9 shows the chemical reaction of MATOR with PEI to form a modified rosin product. n=an integer of at least 9.
[0032] FIG. 10 shows the chemical structure of the reacted product of FTOR (fumarated tall oil rosin) with PEI. n=an integer of at least 9.
[0033] FIG. 11 shows the chemical structures of exemplary acidic compounds useful for making the fortified rosin compounds for reaction with the inventive methods and the resulting fortified rosin compounds as indicated. 11 A (maleic anhydride); 11 B (fumaric acid); 11 C (itaconic anhydride); 11 D (methacrylic acid); 11 E (itaconic anhydride rosin adduct with PEI); 11 F (methacrylic acid rosin adduct with PEI).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] In accordance with embodiments of the present invention, this specification discloses modified rosin products, which are useful in the paper industry and for other purposes, and a method of making such products. Methods of using the products to size paper also are disclosed. Other uses for the products of the invention include inks, toners, adhesives, and the like. See for example U.S. Pat. Nos. 6,200,372; 7,671,144, 7,501,468 and 4,612,273 and U.S. Patent Publication No. 2005-0143488, the disclosures of which are incorporated by reference, for discussion and examples of uses for rosin products which are suitable for the present invention.
[0035] Preferred embodiments of the invention involve a rosin-based sizing agent where fortified rosin is modified by chemical attachment of a cationic resin (polymer). The chemical attachment results in an imide or amide linkage between carboxylic acid groups on the rosin and amine groups on the polymer resin which are stable with respect to temperature so that the rosin will not become saponified under conditions found in paper-making in a paper mill. Preferred compounds are the products of fumarated or maleated rosin and polyethylenimine (PEI).
[0036] Embodiments of the invention involve compounds with an attachment of a polymer amine via imide and/or amide linkages to acid groups on rosin, as well as compositions, including emulsions and dispersions, containing these compounds and methods of making the compositions. Products made with these compounds and compositions also form part of the invention. Preferred compounds have about 1% to about 17% or about 1.5% to about 8% polymer relative to the weight of rosin, and most preferably about 2% to about 5% polymer. Preferred compounds which are to be used as sizes in the paper industry contain less than about 6% polymer to avoid rendering the composition too hydrophilic for effective paper sizing, because the polymer is hydrophilic, and most preferably about 2% to about 5%.
[0037] Rosin is derived from natural sources and is a complex material. Rosins (also known as colophony) useful in this invention include tall oil rosin (TOR), gum rosin, wood rosin or any other convenient form of colophony or mixture thereof, in a crude or refined state. Modified rosins such as disproportionated and dimerized rosins also may be employed. Partially hydrogenated or polymerized rosins also may be used, as well as rosins that have been treated to inhibit crystallization, such as with formaldehyde.
[0038] The preferred rosin useful in the invention is fortified tall oil or gum rosin, or a mixture thereof, optionally mixed with additional unfortified rosin(s). However, any convenient commercially available type of rosin may be used. Most preferably, the fortified rosin is the adduct reaction product of appropriate structures (abietic, palustric and neoabietic acids, for example) on the tall oil rosin and an alpha-beta-unsaturated organic acid or anhydride such as fumaric acid, maleic acid, acrylic acid, methacrylic acid, itaconic acid, citraconic acid, maleic anhydride, itaconic anhydride, citraconic anhydride and mixtures of these compounds or any known method of rosin fortification. These compounds are referred to herein as “acidic compounds.” Preferred acidic compounds for reaction with the rosin are fumaric acid and/or maleic anhydride. It is understood that in a fortified rosin product not every rosin molecule is reacted, resulting in a mixture of reacted and non-reacted rosin molecules.
[0039] The fortified rosin products useful for the invention preferably are produced with about 3% to about 16% acidic compound by weight of rosin, or about 3% to about 14% acidic compound by weight of rosin, however any convenient commercially available fortified rosin also may be used. Preferred ranges are 3%-16% when the acidic compound is fumaric acid and 3%-14% when the acidic compound is maleic anhydride.
[0040] Suitable polymer amines for use with the invention include any polymer amine compound which can react as described below with acidic groups on rosin or fortified rosin to result in an imide or amide linkage, for example polyaniline, poly(allyl amine), poly(oxyethylene/oxypropylene) diamine (CAS no. 65605-36-9), O,O′-bis(2-aminopropyl)polypropylene glycol (CAS no. 9046-10-0), or polyethylenimine. Preferred polymers contain little or no water. The most preferred polyamine is polyethyleneimine (PEI), such as Lupasol WF™ (water-free PEI).
[0041] As used herein, the term “polymer” and its cognates, with reference to polyamine compounds useful with the invention, indicates a compound with more than 8 monomers, whereas the term “oligomer” refers to compounds having 8 or fewer monomer units. The polymeric amine compounds useful in the invention include polymers having more than 8 monomer units or at least 9 monomer units, at least 10 monomer units, at least 12 monomer units, at least 20 monomer units, at least 25 monomer units or at least 30-50 monomer units. Preferred polyamines are compounds with 9 monomer units to about 2500 monomer units, or more preferably about 50 monomer units to about 1000 monomer units. Most preferred polyamines have at least about 400 monomer units to about 750 monomer units or about 500-600 monomer units. Depending on the molecular weight of the monomer unit, the preferred molecular weight of the polyamine compound generally is about 300 or more atomic mass units (amu) or about 350 amu to about 90,000 amu. Most preferred polyamines have a molecular weight of at least about 16,000 amu to about 37,000 amu or about 40,000 amu, for example about 20,000 amu to about 30,000 amu or about 25,000 amu. As is known in the art, polymers generally are characterized by average molecular weight rather than a precise molecular weight. Therefore, the monomer unit number and the molecular weight ranges discussed above are estimates of the averages of the polymer compounds, and variations from these ranges are contemplated for use with the invention.
[0042] Polymers useful with the invention for paper sizes or other uses in general have a molecular weight and size which allow them to melt or flow at the temperatures normally found in manufacturing, i.e. at the temperature of use. Therefore, depending on the particular process being used, the person of skill in the art can choose a polymer size/molecular weight suitable for the conditions. Thus, any suitable polymer having this functional characteristic are contemplated for use with the invention. In paper manufacturing, conditions can range, but generally are near about 105° C., for example, therefore the polymer compounds used should be able to melt and flow at this temperature.
[0043] Amine polymers containing primary and secondary amines may be used in the invention, however primary amines in general are more reactive and only primary amines can form imides. Tertiary amines are not suitable to provide amide or imide linkages but may be included in the reaction mixture.
[0044] Polyethylenimine at an average molecular weight of about 25,000 is the preferred polyamine. It preferably is used in the reaction as discussed below at about 1% to about 17% by weight relative to the rosin, most preferably about 2% to about 5%.
[0045] This invention also relates to rosin compositions such as emulsions and dispersions of rosin, including such compositions that are highly effective sizing agents for paper. The dispersions can either be anionic or cationic in charge, and are more stable and more effective paper size agents compared to conventional dispersed sizes made with just fortified rosin or with other commonly modified rosins such as rosin esters.
[0046] To make embodiments of the products of this invention, cationic materials are chemically attached to rosin, forming imides and/or amides which are thermally stable and otherwise resistant to decomposition under all application conditions used in paper mills. The size compositions are particularly suited to use under harsh conditions, for example neutral pH (above pH 6.5) and at higher than normal temperatures.
[0047] Commerically available fortified rosins containing added acid groups may be purchased or prepared. Fortified rosins also may be mixed with non-fortified rosins for use with the invention. Esterified rosin also may be used as part of the mixture. The preferred rosin is a maleated tall oil or gum rosin or a fumarated tall oil or gum rosin, or mixtures thereof. Fortified rosin can be made by any convenient method as known in the art. In general, any method known in the art is suitable, including any method referenced here. The formation of Diels-Alder adducts of rosin is known per se. Heating abietic acid, for example, causes the conjugated bonds to change places; maleation then occurs through a Diels-Alder mechanism. See the reaction, which is shown in FIG. 1 , for example.
[0048] To produce rosin compounds according to embodiments of the invention, fortified rosin or a mixture of fortified rosin and unfortified rosin is melted at a temperature of about 100° C. to about 300° C. as is suitable for the rosin being used, or preferably at a temperature of about 170° C. to about 220° C. or about 200° C. and held with agitation to ensure uniformity and complete melting. Approximately 2 hours, for example, generally is sufficient. The container for conducting the reaction preferably is equipped with a nitrogen flow system which can maintain an inert atmosphere in the container and assist in venting undesired gases, such as water vapor (steam) which is produced during the reaction or oxygen, however any suitable inert gas can be used for this purpose. A scrubber system also may be included and is preferred. Preferably, the reaction is carried out at a temperature of about 100° C. to about 300° C. or any convenient temperature depending on the melting points of the reactants. More preferably, the reaction is conducted at about 125° C. to about 250° C. or about 150° C. to about 240° C. and most preferably about 170° C. to about 220° C. No solvent is used, and in particular addition of water preferably is avoided as far as possible.
[0049] The reaction preferably is carried out in an inert atmosphere or any non- or limited-oxygen-containing gas, to prevent oxygen from becoming involved in the reaction. Any inert gas can be used, such as argon, helium or nitrogen, however nitrogen generally is more convenient and less expensive. Water also preferably is avoided during the reaction. Therefore, the reaction should be carried out in a vessel equipped with a mechanism for venting gases such as oxygen and water vapor prior to and during the reaction. Most preferably the flow of inert gas is fast enough to remove oxygen and water as it is formed by the reaction.
[0050] Once the rosin has been melted and the atmosphere of the vessel inerted, the polyamine compound is added to the rosin, having been melted, if necessary. The compound preferably is added in small batches or very gradually, since water is produced by the reaction and preferably is not allowed to build up in the reaction vessel, but is vented from the system as the reaction proceeds, with sufficient agitation to mix the rosin and amine, but not so violent an agitation to increase bubble formation and foaming.
[0051] The polyamine compound can be added over a period of about 15 minutes up to about 7 hours. In most cases a period of about 30 minutes to about 120 minutes, preferably about 30 to about 90 minutes, and most preferably about 60 minutes. The reaction is allowed to proceed, with agitation, while maintaining the reaction vessel at the desired reaction temperature until the reaction has proceeded to the degree necessary, for example for about 30 minutes or more, preferably for about 45 minutes to about 6 hours, or about 60 minutes to 4 hours. The reaction mixture is cooled to stop the reaction, and the product then may be used or stored in a sealed container for later use. The length of the total reaction time depends on the formulation, with times ranging in most cases from about 30 minutes to more than 3 hours. Persons of skill will be able to determine the appropriate time to allow the reaction to go to completion by observation, for example of evolution of water vapor (steam), from the reaction mixture. Infrared spectrum analysis can be used to characterize the rosin adducts to confirm that the reaction has taken place and the degree of reaction that has occurred by detecting the loss of the anhydride carbonyl signal and the appearance of imide carbonyl stretches.
[0052] The stoichiometry of the reaction can be important in some embodiments of the inventive method of reaction. For example, an excess of anhydride groups is preferred if only imides are desired in reactions involving the polyamine compound(s) or, for example, polyethylenimine (PEI). When using PEI, amide bonds also can form even though anhydride groups are not in large excess. The chemical reaction between the maleated or fumarated rosin and the polyamine(s) optionally may be carried out with the use of an acid catalyst.
[0053] As discussed above, compounds, such as PEI, which contain primary, secondary, and tertiary amines (in the approximate ratio of 1:1:0.75 in the case of some commercial preparations of PEI) will react primarily on the primary amines in the formation of imides and amides, and tertiary amines will not react at all. These considerations will affect the ratios of compounds used in the reaction.
[0054] The process used to produce dispersions in this patent preferably is the inversion process, also referred to as the Bewoid process. Several different emulsification methods may be used, however, or any convenient method known in the art. If appropriate, the inversion process may be used, either batch or continuous processes. One distinct advantage of the continuous process is that materials with very high softening points can be emulsified. Other common techniques involve the use of a homogenizer. Either a solvent may be used with a homogenizer or higher temperatures and pressures using only water. Because of cost and environmental concerns, a nonsolvent process is preferred for commercial purposes, but a solvent process is convenient for the laboratory.
[0055] Dispersed rosin compositions according to embodiments of the invention generally contain about 40% to about 80% water and about 58% to about 17% rosin compound, and are emulsified using known emulsifying agents such as casein, cationic starch, alkali salts of sulfonated nonylphenol ethoxylates, sodium lauryl sulfate, or any appropriate emulsifying agent, preferably in amounts of about 0.3% to about 8% of the total composition. Preferred rosin size dispersions contain approximately 60% water, approximately 37% rosin size compound according to the invention and approximately 3% emulsifying agents. Small amounts of defoamer (up to about 800 ppm of a 20% solution of silicon polymers, for example) and/or biocide (about 600 ppm dazomet, for example) optionally also may be added. The person of skill is aware of compounds which may be added to benefit the final product. Such products also are contemplated as part of the invention. In addition, any carrier or other product can be added depending on the use to which the product is to be put, as is known in the art.
[0056] Preferred compounds and compositions according to embodiments of the invention are used as sizing agents for paper and paperboard. The sizes can be used according to known methods in the industry. In general the rosin composition is an aqueous dispersion which is mixed with paper pulp, and the pulp is thereafter formed into paper. Two factors important in judging the quality of a size product are the sizing effect and size stability. The Hercules Size Test can be used to measure size performance. This test measures the change in reflectance of the paper surface during penetration of a standard aqueous solution of dye from the opposite face of the paper sheet. The end point of the test is the time to reach a convenient degree of reduction in reflectance, for example 10% or 20%. Longer times indicate better sizing performance for the paper product.
[0057] The preferred compounds of the invention are useful as a paper size that can be used conveniently at neutral pH ranges, yet be effective as a size. The compositions can be used as internal or external (surface) sizes. Very high quality dispersions of the products, the preferred dispersions for use as paper sizes, were made with about 1% to about 5% PEI on about 3% to about 16% MATOR. Additional compounds include about 1% to about 17% PEI on about 83% to about 99% maleated or fumarated rosin. The modified rosin compounds of the invention may be blended with additives to adjust the softening point as is convenient. Suitable additives include wax, mineral oil and the like. Reactive materials such as ASA may also be used as additives. The inventive products also may be mixed with esterified rosin compounds for use as paper sizing compositions.
[0058] Considering the widespread use of rosin amines, rosin imides and the like in inks and toners, and in adhesives, the products discussed in this patent also have utility in these other application fields.
[0059] The following non-limiting examples provide illustrations of the manufacture and use of compounds according to the invention.
EXAMPLES
Examples 1-19
Preparation of Rosin Reaction Products
[0060] A one liter resin kettle was equipped with a nitrogen feed and outlet, a temperature control probe, an agitator, a water-cooled condenser and receiver, and a stopper which could be removed for addition of ingredients. The agitator was outfitted with two blades: a radial blade on top and an axial blade on bottom. The agitator shaft was fixed so that the bottom blade was in the middle of the mixture, and the top blade was only halfway immersed. A heating mantle with attached temperature control was used to heat the mixture. The nitrogen flow was maintained at a level sufficient to reduce oxygen levels in the reaction vessel so that oxidation of the MATOR was minimal and the water produced in the reaction was carried out of the resin kettle.
[0061] Six hundred grams of solid MATOR chunks (made with 11.8% maleic anhydride by weight relative to the weight of rosin) were added to the resin kettle. The MATOR was melted and brought to a temperature of 200° C., with agitation. Polyethyleneimine homopolymer (Lupasol WF™, BASF Corp., CAS No. 9002-98-6), also referred to as aziridine homopolymer, was heated in a large syringe and kept in an oven at 70° C. to maintain the polymer as a liquid. A total amount of 18 g PEI was dispensed from the syringe in a thin stream to the molten MATOR, in portions. The final ratio of PEI/MATOR was 3% by weight. After approximately 3 g of PEI (Lupasol WF™ (Lutensol™), average molecular weight 25,000) was added, the amount dispensed, temperature, and appearance of the mixture were noted and agitation continued. Another portion of PEI was added and observations again were noted. Periodically, the syringe was returned to the oven briefly to keep the PEI free-flowing. The temperature of the reaction vessel was held at approximately 200° C., and the mixture was agitated until it appeared completely translucent, homogeneous, and bubble and foam free. Total reaction time was about 1 hour. The mixture was poured from the kettle into an aluminum tray for cooling, sealed in a plastic bag, and stored.
[0062] In order to confirm that the reaction had occurred and an imide was produced, the product was subjected to infrared (IR) spectrum analysis. The loss of the anhydride carbonyl signal and the appearance of the imide carbonyl stretches in the infrared spectrum indicated a successful reaction. The IR spectrum of the finished product is shown in FIG. 2 . Changes in the softening point and acid numbers also confirmed a successful reaction. Final properties of the product formed are listed in Table I, below. The acid number was determined by ASTM Method D465-96, using toluene and ethyl alcohol. Note that this method underestimates anhydride groups in known ways.
[0063] This synthetic method was repeated successfully on a large scale in plant production equipment. The rosin reaction was repeated according to Example 1, above, in Examples 2-19, with changes in the ratio of maleic anhydride to rosin used in the production of the MATOR and the ratios of PEI:MATOR. The specifics are listed below in Table I, with properties of the final products.
[0064] The tall oil resin used to make the MATOR in Examples 16-18 was analyzed by gas chromatography to quantitate the amount of palustric, neoabietic and abietic acids in the starting compound. The results showed that there were sufficient amounts of these acids (which are conjugated) to allow as much as 16% maleic anhydride to be adducted in the Diels-Alder reaction. Lupasol G20™ (CAS no. 25987-06-8) is a copolymer of 1,2-ethanediamine with aziridine and is a more linear polymer than Lupasol WF™ (Example 19).
[0000]
TABLE I
Properties of Modified Rosins.
wt %
wt %
Soften-
Exam-
Acidic
Amine
ing
Acid
ple
Com-
Com-
Point
Number
Number
Rosin
Amine
pound
pound
(° C.)
(mg/g)
1
MATOR
Lupasol
11.8
3
114.9
195.1
WF ™
2
MATOR
Lupasol
13.6
1
110.4
209.9
WF ™
3
MATOR
Lupasol
13.6
2
114.1
204.4
WF ™
4
MATOR
Lupasol
13.6
3
117.1
198.8
WF ™
5
MATOR
Lupasol
13.6
4
126.8
194.5
WF ™
6
MATOR
Lupasol
13.6
6
130.9
174.6
WF ™
7
MATOR
Lupasol
13.6
10
146.2
138.2
WF ™
8
MATOR
Lupasol
13.6
12
150.5
127
WF ™
9
MATOR
Lupasol
13.6
14
156.6
ND*
WF ™
10
MATOR
Lupasol
13.6
15
147.2
127
WF ™
11
MATOR
Lupasol
3
3
98
166.4
WF ™
12
MATOR
Lupasol
3
4
117.5
177.9
WF ™
13
MATOR
Lupasol
6
3
101.6
168.9
WF ™
14
MATOR
Lupasol
6
6
111.5
145.3
WF ™
15
MATOR
Lupasol
11
4
118.9
172.7
WF ™
16
MATOR
Lupasol
16
4
125.9
173.4
WF ™
17
MATOR
Lupasol
16
10
153.1
132
WF ™
18
MATOR
Lupasol
16
17
147.2
130.7
WF ™
19
MATOR
Lupasol
13.6
6
133.5
172.8
G20 ™
*ND = could not determine
Examples 20-31
Preparation of Rosin Reaction Products
[0065] The rosin reaction was repeated as described in the Examples above, with the specifics indicated in Table II, below, using the liquid (non-polymer) amines as indicated. Because the amines were liquid, there was no need to heat the syringe used to add the amine. The ratios of amine to MATOR and characteristics of the final products are as listed below.
[0000]
TABLE II
Properties of Modified Rosins.
wt %
wt %
Soften-
Exam-
Acidic
Amine
ing
Acid
ple
Com-
Com-
Point
Number
Number
Rosin
Amine
pound
pound
(° C.)
(mg/g)
20
MATOR
tert-butyl
13.6
14
105.6
156.3
amine
21
MATOR
3-dimethyl
13.6
14
105.5
136.2
aminopropyl
amine
22
MATOR
n-butyl
13.6
13.6
76
135.9
amine
23
MATOR
n-butyl
13.6
14
84.6
136.9
amine
24
MATOR
ethanol
13.6
13.6
76.5
133.1
amine
25
MATOR
diethyl
13.6
14
101.8
207.7
amine
26
MATOR
dibutyl
13.6
14
82.9
165
amine
27
MATOR
1,6-diamino
13.6
14
124.3
121.7
hexane
28
MATOR
propylamine
13.6
13.6
81.8
137.2
29
MATOR
aniline
13.6
14
ND*
ND*
*ND = could not determine
Example 30
Rosin Adducts with Triethanolamine
[0066] In Example 30, rosin resin was prepared as described for Examples 21-30, but following the disclosures of U.S. Pat. No. 4,540,653, using triethanolamine as the amine. Triethanolamine is a tertiary amine, and the reaction produces an ester linkage, and therefore not an imide or an amide. The ratio of triethanolamine:MATOR was 8%.
[0000]
TABLE III
Properties of Triethanolamine Rosin Adduct.
wt %
wt %
Soften-
Exam-
Acidic
Amine
ing
Acid
ple
Com-
Com-
Point
Number
Number
Rosin
Amine
pound
pound
(° C.)
(mg/g)
30
MATOR
trietha-
11.8
8
112.5
142.6
nolamine
Example 31
Fumarated Rosin Adduct with Polyethylenimine
[0067] The rosin reaction again was repeated, using the method described in Example 1 above, except that fumarated rosin (prepared with 8% fumaric acid relative to rosin) was used in place of maleated rosin and the reaction temperature was 220° C. The ratio of PEI:fumarated rosin was 2%. Amides are formed in this reaction; imides cannot form. An IR spectrum of this product is shown in FIG. 3 .
[0000]
TABLE IV
Properties of Fumarated Tall Oil Rosin-PEI Adduct.
wt %
wt %
Soften-
Exam-
Acidic
Amine
ing
Acid
ple
Com-
Com-
Point
Number
Number
Rosin
Amine
pound
pound
(° C.)
(mg/g)
31
FTOR
Lupasol
8
2
108.1
193
WF ™
Example 32
Emulsification of Rosin Adducts
[0068] The modified rosin product of Example 1 was emulsified using an inversion process. The modified rosin resin (187 g) was placed in a round bottom flask fitted with a stirrer and heated well above its softening point (i.e., above 115° C.). The melted resin was agitated, and an aqueous solution of potassium hydroxide (2.5 g of 45% KOH) was added slowly to the flask. The amount of the base was sufficient to saponify a few percent of the rosin.
[0069] Casein dispersion was prepared separately by dispersing 7.4 g casein in 72.5 g of water with agitation and heat, and by raising the pH with 1.3 g potassium hydroxide to about pH 10.5. Then, 13.5 g of a 22% aqueous solution of a cationic polyacrylamide (Nalsize™ 7541) was mixed into the casein dispersion to result in 5.7% casein-polyacrylamide on rosin. This casein-polyacrylamide dispersion was added to the resin slowly. Then, 52.1 g water at 65° C. was added to this mixture, which inverts from a water-in-oil type emulsion to an oil-in-water emulsion during this water addition. Additional water, about 156.4 g (at room temperature) was added until the final desired concentration was reached (final concentration 40%). The process by which the emulsion was formed is described in U.S. Patent Publication 2009/0298975, and in particular example 6 of that patent application. Biocides and defoamers may be added as desired to the emulsion. See Table VI below for emulsion properties of the rosin dispersions.
Example 33
Emulsion of Rosin Adducts
[0070] Emulsions were prepared as described in Example 32 using the rosin products of Examples 4, 6, 12, 14, 15, 30 and 31, with different amounts of KOH added. See Table V, below.
[0000]
TABLE V
Emulsion Preparations.
Example
45% KOH
Amine
Number
(g)
Rosin
Compound
4
2.9
13.6%
3% PEI
MATOR
6
1.8
13.6%
6% PEI
MATOR
12
0.1
3%
4% PEI
MATOR
14
1.8
6%
6% PEI
MATOR
15
1.4
11%
4% PEI
MATOR
30
2.1
13.6%
8% TEA
MATOR
31
1.0
8%
2% PEI
FTOR
[0071] The compound of Example 6 was modified from this description as follows. One part alpha olefin wax was added to nine parts rosin to lower the softening point from 130.9° C., which generally is considered too high for good paper sizing under standard conditions of paper manufacturing. Products that had melting points so high that simultaneous stirring and water addition was not possible could not be emulsified using this method. Also, compounds that had so few acid groups that casein (which preferentially operates as a surfactant at a pH close to 6.20) did not effectively act as a surfactant or compounds for which KOH addition resulted in salt formation, or both, could not be emulsified with this method. These compounds were not considered suitable for use as paper sizing agents in an anionic dispersion of this type without further processing or blending, but can be used in other industries.
Example 34
Effect of Addition of Wax to Rosin Emulsion
[0072] The effect of addition of wax to the rosin product of Example 7 is shown in FIG. 4 . Wax lowers the softening point.
Example 35
Emulsification of Rosin Adducts by Homogenization
[0073] The modified rosin compounds of Examples 1 and 20 were emulsified by homogenization. The modified rosin (208.7 parts) was dissolved in 139.1 parts methylene chloride solvent. Separately, an aqueous phase was prepared by adding 27.8 parts of Sta-lok™ 140 starch (an cationic waxy corn starch) and 3.5 parts of Ufoxane™ 2 sodium lignosulphonate (a lignin-based surfactant) to 650 parts water and cooking for 90 minutes at 93 to 95° C., and then cooling to room temperature. The aqueous and solvent phases then were blended together in a blender at low speed for two minutes. The mixture was homogenized in two passes in a Manton Gaulin™ homogenizer, model 15MR, at 7000 psig. The solvent then was stripped off at atmospheric pressure, and the dispersion cooled. See Table VI, below, for results.
Example 36
Emulsification of Rosin Adduct by Homogenization without an Exogenous Emulsifying Agent
[0074] The modified rosin prepared in Example 18 (220.6 parts) was dissolved in 147.1 parts methylene chloride solvent. Separately, an aqueous phase was prepared by adding 8.9 parts of 88% aqueous formic acid to 505.9 parts water. The aqueous and solvent phases were blended together in a blender at low speed for two minutes. The mixture then was homogenized in two passes in a Manton Gaulin™ homogenizer, model 15MR, at 7000 psig. The solvent then was stripped off at atmospheric pressure, and the dispersion cooled. As shown in Table VI, this process resulted in a stable emulsion without using any other exogenous emulsifying agent. Without wishing to be bound by theory, it is believed that the hydrophilic amine groups in the PEI/MATOR stabilized the emulsion, but that the high level of PEI produced a highly hydrophilic product that could produce light sizing. It is possible that changes in pH might cause the product to be more attracted to the paper fibers, resulting in a greater level of size.
[0000]
TABLE VI
Emulsion Properties of Selected Examples.
Total Solids
Viscosity
Particle Size
Examples
(%)
Fall Out (%)
(cp)
(μm)
pH
1, 32
40.1
3.1
13
0.774
5.9
4, 33
39.9
2.0
ND
0.588
6.4
6, 33
40.2
8.9
ND
ND
6.8
12, 33
37.2
8.9
ND
1.134
6.6
14, 33
39.1
20
ND
ND
7.5
15, 33
40.7
3.2
ND
1.078
6.7
30, 33
40.7
5.3
37
0.432
6.3
31, 33
42.2
5.6
91
1.070
6.2
1, 35
27.7
1.6
20
0.664
4.7
20, 35
26.7
1.6
19.4
0.974
6.3
18, 36
29.0
2.8
7.6
0.514
3.4
ND = not done
[0075] Emulsion properties reported in Table VI include total solids, fall out, viscosity, particle size and pH. Fall out is the amount of sediment accumulated on the bottom of a centrifuge tube after spinning a 50 g sample at approximately 1000×g for one half hour, pouring off the supernatant, rinsing the residue lightly with water and drying the residue at 105° C. for three hours. The fall out is reported as a percentage of the dispersion solids. Viscosity measurements were made using a Brookfield™ model DV-I+, using spindle LV 1. Particle sizes were measured on a Coulter™ LS 13 320, Laser Diffraction Particle Size Analyzer, Beckman Coulter™, Inc. Median values were tabulated.
Example 37
Testing Results on Modified Rosin Compositions
[0076] Modified rosin compounds made using 13.6% MATOR and varying amounts of PEI were tested by infrared spectroscopy, nuclear magnetic resonance, melting point, softening point (ball and ring method), acid number (the value in mg KOH/g sample that measures acid groups present in a compound), and mass spectroscopy. The test results showed that softening point increases with the amount of PEI fortification and with the amount of maleic fortification. The acid number of MATOR decreases as it reacts with PEI because the reaction consumes carboxylic acid groups in fortified abietic acid. The acid number values were determined by dissolving the compound in a mixture of toluene and ethanol, titrating the solution with NaOH, and calculating the number of acid groups present in the compound from the titration end point. The data are shown in FIG. 5 . This acid number underestimates the true number of acid groups because the maleic anhydride groups of the compound react with ethanol, forming an ester. As a consequence, the slope of the line representing the data should be steeper. See FIG. 5 for data relating to acid number and FIG. 6 for data relating to softening point.
[0077] Infrared (IR) spectra were taken of the starting MATOR and the final reacted product to verify that the procedures did cause the reaction to go to completion. An exemplary IR spectrum of 13.6% MATOR is shown in FIG. 7 . Comparing this Figure to FIGS. 8 and 2 , which show the IR spectra of 12% PEI reacted with 11% MATOR and 3% PEI on 11.8% MATOR, respectively, one can see that the peak at 1780 cm −1 (the anhydride carbonyl) disappears as the reaction proceeds. When equimolar amounts of PEI and MATOR are reacted (approximately 12% PEI on 11% MATOR, for example), the peak should be gone entirely. In FIG. 2 , the anhydride carbonyl peak is present, but smaller than in FIG. 7 . In FIG. 8 , the anhydride carbonyl peak has completely disappeared.
Example 38
Confirmation of Diels-Alder Adduct Formation Using a Model Compound
[0078] Pure abietic acid was used as a model for rosin to test the feasibility of the reaction. Abietic acid was reacted with maleic anhydride in a Diels-Alder reaction to form the anhydride product. Formation of the product was confirmed by the loss of one of the alkene protons in the proton Nuclear Magnetic Resonance spectrum ( 1 H-NMR) (the peak at approximately 5.4 ppm disappears), an increase in M+H peak (401 m/z) in the mass spectrum, and the addition of new C═O peaks in the IR spectrum (1750-1770 cm-1). The resulting Diels-Alder adduct then was reacted with a stoichiometric amount of 4-bromoaniline, a solid amine, to give the imide product.
[0079] The imide was characterized by the M+H peak at 554 m/z by mass spectrometry, addition of the aryl CH protons (7.0 and 7.8 ppm) in the 1H-NMR, and the loss of the anhydride C═O peaks in the IR spectrum. New imide C═O peaks appear in the 1700-1780 cm-1 region. No amide peak was seen in the mass spectroscopy results. The IR spectrum of the model compound was essentially identical to the PEI-maleated rosin adduct in the C═O region which confirmed this as the product in the PEI-rosin reaction. The IR spectrum also was well comparable to the IR spectrum of a similar imide, 2,5-pyrrolidinedione, CAS number 123-56-8.
[0080] These tests show that an imide linkage is formed by the reaction. See FIG. 9 for the chemical reaction of MATOR and PEI. FIG. 10 provides the structure of the analogous product made using fumarated tall oil rosin (FTOR). The imide group is less acidic than the carboxylic acid group it replaces, and is more stable. Because the imide is more stable, the rosin products made in this way are more stable, for example in use as a paper size under conditions found in paper manufacture, even at high temperatures and high pH. This results in an effective size that forms fewer depositions under manufacturing conditions. See FIG. 11 for structures of additional exemplary acidic compounds and fortified rosin compositions which are useful with the inventive methods.
Example 39
Paper Sizing
[0081] Hand sheets were prepared for testing of sizing. Procedures for their production generally conform to Tappi test method T 205 with some exceptions. Briefly, pulp (a mixture of 85% bleached, kraft hardwood and 15% bleached, kraft softwood, with a Canadian Standard Freeness (CSF) of 350 mL) was added to a cup. Water was maintained at 55° C. and adjusted to 135 ppm hardness using CaCl 2 . The water was added to the pulp and agitation begun. Within seconds, the pH was adjusted with dilute NaOH. After one minute, alum (8 lb/ton of pulp) and the size composition (5 lb/ton of pulp) were added. The alum basis (defined according to the common practice in the paper industry as “dry” alum) was Al 2 (SO 4 ) 3 .14H 2 O (average 14 waters of hydration). At the 90 second mark, 3 lb/ton cationic starch (UltraCharge™ 340) was added. At 2 minutes, 0.5 lb/ton colloidal silica (Eka™ NP442) was added. At 3 minutes, the sheet was formed, then pressed once for one minute at 60 psig. Drying was performed in a laboratory drum drier for 2.5 minutes at approximately 115° C.
[0082] Results of a Hercules Sizing Test (HST), using Naphthol Green B dye with 1% formic acid ink at 80% reflectance, for four different sizes, are shown in Table VII. A commercially available size composition was used as a control. The data show that Example 1,32 is a highly efficient size at the near-neutral pH of 6.7. Example 1, 35 is less efficient, but significantly better than the standard commercially available size NeuRoz™ 426. Example 20,35 was produced with a non-polymer amine, tert-butyl amine.
[0000]
TABLE VII
Sizing Results, bleached pulp.
Example Number
HST (sec)
1, 32
40.5
1, 35
19.5
20, 35
2.4
NeuRoz ™ 426
7.6
Example 40
Paper Sizing
[0083] The method described in Example 39 was repeated except that the starch used was cationic starch Cato™ 232. Results of the Hercules Sizing Test for the indicated examples and commercially available sizes are shown in Table VIII.
[0000]
TABLE VIII
Sizing Results, bleached pulp.
Example Number
HST (sec)
1, 32
61.4
31, 33
102.9
NeuRoz ™ 426
31.5
NeuRoz ™ 540
41.7
Example 41
Paper Sizing Tests
[0084] Example 40 was repeated with the products indicated in Table IX. These data show that the most efficient size is Example 4,33. Examples 12,33 and 15,33 also perform well compared to the commercial products. Examples 6,33 and 14,33 appear to contain too many hydrophilic groups for optimal and efficient paper sizing.
[0000]
TABLE IX
Sizing Results, bleached pulp.
Example Number
HST (sec)
4, 33
138.7
6, 33
0.3
12, 33
63.8
14, 33
1.4
15, 33
96.0
NeuRoz ™ 426
26.0
NeuRoz ™ 540
43.0
Example 42
Paper Sizing
[0085] This example shows sizing of paper with unbleached instead of bleached pulp. The method described in Example 39 was repeated except that the starch used was cationic starch Cato™ 232 and no colloidal silica was added. In addition, alum was used at 6 lb/ton and 4 lb/ton size was added. The pulp was virgin unbleached kraft (UBK) softwood with a CSF of 380 ml. The results of the Hercules Sizing Test are shown in Table X. The size produced in Example 1, emulsified according to Example 32 was most efficient. The least efficient is Example 30,33, which comprises rosin prepared by prior art methods.
[0000]
TABLE X
Paper Sizing, UBK Pulp.
Example Number
HST (sec)
1, 32
430
30, 33
33
1, 35
119
NeuRoz ™ 426
87
NeuRoz ™ 540
158
Example 43
Deposition Testing
[0086] A lower tendency to deposit on surfaces in paper mills is an important attribute in paper sizes for use in commercial paper mills. Deposition tests were performed in order to compare the amount of rosin size depositing on the pulp for selected rosin size products according to the invention compared to a current commercial product. This test was modified from a test developed by Allen and Filion, Tappi J. 79:226, 1996. Mill pulp was adjusted in solids to 15% and raised to pH 7, a level that promotes deposition. The pulp was heated, and kept at a constant temperature of 60° C., with stirring, in a heavy duty mixer for 1 hour. Plates attached to the stirring element were weighed before and after the test. Eight pounds of size per dry pound of pulp was added. The average weight increases are reported in Table XI, and show a lower deposition for the inventive product than either of the commercially available sizes. Without wishing to be bound by theory, it is possible that this result is due to a stronger attachment of the inventive product to the fiber and/or better protection of acid groups from saponification in the inventive product.
[0000]
TABLE XI
Deposition Testing Results.
Example
Average Weight
Number
Gain (mg)
1, 32
4.8
NeuRoz ™ 426
6.5
NeuRoz ™ 540
5.5
Example 44
Testing of Electrokinetic Properties
[0087] The zeta potential is a measure the potential difference between a dispersion medium and the stationary layer of fluid attached to the dispersed particle. In the paper industry, the zeta potential is used to measure the electrokinetic potential in the colloidal system of a sizing product. The zeta potentials of a rosin product according to the invention was tested at the indicated pHs for comparison to two commercially available dispersed rosin sizes manufactured by Plasmine Technology™, Inc. At the pH values normally encountered in paper mills using dispersed rosin sizes (about pH 4.5 to pH 6.5), NeuRoz 540 is an anionic size, prepared from fortified rosin; NeuRoz 426 is a cationic size, also prepared from fortified rosin. However, as the data in Table XII show, when the pH is raised, the sizes change character. The testing was performed using a Zeta-potential and Particle Size Analyzer ELSZ-2 (Photal Otsuka Electronics™ Co., Ltd.).
[0000]
TABLE XII
Zeta Potentials of Dispersed Rosin Sizes.
Zeta Potential (mV)
pH
Example 32
NeuRoz ™ 540
NeuRoz ™ 426
4.1
+27.4
+12.7
+25.5
5.9
−12.7
−25.2
+30.5
7.9
−37.2
−37.2
−18.9
9.9
−34.2
−39.2
−36.6 | Rosin is modified by maleation and then by imidization resulting in attaching a cationic polymer or cationic material upon the rosin. Alternatively, rosin can be fumarated and then cationic material attached by amide links. The products may be used for an efficient paper size and other applications of rosin products. | 2 |
TECHNICAL FIELD
[0001] The present invention relates to a particle analyzer which obtains information relating to the dimension and shape of a particle by analyzing an image of the particle, and a storage medium storing a computer program which imparts a function to display the information of the particle dimension and shape based on the particle image to a computer.
BACKGROUND
[0002] There is a known conventional particle analyzer in which a particle suspension is poured into a sheath flow cell, and an image of a particle included in the particle suspension flowing in the sheath flow cell is captured and analyzed so that an analysis result is displayed (see U.S. Pat. No. 5,721,433 and Japanese Laid-Open Patent Publication 10-318904). The particle analyzer recited in U.S. Pat. No. 5,721,433 displays a two-dimensional scattergram based on two parameters representing particle characteristics (equivalent circle diameter and circularity). The analyzer recited in Japanese Laid-Open Patent Publication 10-318904 displays a three-dimensional scattergram based on three parameters representing particle characteristics (equivalent circle diameter, circularity, aspect ratio). The equivalent circle diameter is a parameter relating to particle diameter, and the circularity and the aspect ratio are parameters relating to particle shape.
[0003] To analyze particles, useful information may be obtained from comparing at least three parameters relating to particle diameter. Two particles determined as having a substantially equal size by comparing two parameters relating to particle diameter, for example, may turn out to be very different in their sizes and shapes when a third parameter relating to particle diameter is added to the two parameters. To more accurately perform the particle analysis, therefore, it is desirable to compare at least three parameters relating to particle diameter, and it is similarly desirable to compare at least three parameters relating to particle shape for the same purpose.
[0004] The particle analyzers recited in U.S. Pat. No. 5,721,433 and Japanese Laid-Open Patent Publication 10-318904, however, could not compare three or more parameters relating to particle diameter or particle shape.
SUMMARY
[0005] The scope of the present invention is defined solely by the appended claims, and is not affected to any degree by the statements within this summary.
[0006] A first particle analyzer embodying features of this invention comprises:
[0007] a flow cell through which a specimen passes, the specimen including a plurality of particles to be captured;
[0008] an imaging device for capturing an image of a particle in the specimen passing through the flow cell;
[0009] an image processor for obtaining a first characteristic value of a first parameter relating to particle diameter, a second characteristic value of a second parameter relating to particle diameter, and a third characteristic value of a third parameter relating to particle diameter based on the particle image obtained by the imaging device; and a controller for generating and outputting a screen on which the first, second and third characteristic values can be displayed at a time.
[0010] A second particle analyzer embodying features of this invention comprises:
[0011] a flow cell through which a specimen passes, the specimen including a plurality of particles to be captured;
[0012] an imaging device for capturing an image of a particle in the specimen passing through the flow cell;
[0013] an image processor for obtaining a first characteristic value of a first parameter relating to particle shape, a second characteristic value of a second parameter relating to particle shape, and a third characteristic value of a third parameter relating to particle shape based on the particle image obtained by the imaging device; and
[0014] a controller for generating and outputting a screen on which the first, second and third characteristic values can be displayed at a time.
[0015] A first storage medium, embodying features of the invention, stores a computer program which imparts a function to display information of a particle by processing an image of the particle to a computer, the computer program executes steps of:
[0016] obtaining first, second and third characteristic values of first, second and third parameters relating to particle diameter from the particle image; and
[0017] generating and outputting a screen on which the first, second and third characteristic values can be displayed at a time.
[0018] A second storage medium, embodying the features of the invention, stores a computer program which imparts a function to display information of a particle by processing an image of the particle to a computer, the computer program executes steps of:
[0019] obtaining first, second and third characteristic values of first, second and third parameters relating to particle shape from the particle image; and
[0020] generating and outputting a screen on which the first, second and third characteristic values can be displayed at a time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is an illustration of a structure of a particle analyzer according to an embodiment of the present invention;
[0022] FIG. 2 is an illustration of a screen showing a record list displayed on a display unit of an information processing device according to the embodiment;
[0023] FIG. 3 is an illustration of a screen showing an analysis result displayed on the display unit of the information processing device according to the embodiment;
[0024] FIG. 4 is an illustration of a screen showing an analysis result displayed on the display unit of the information processing device according to the embodiment;
[0025] FIG. 5 is an illustration of a screen showing a display parameter setting view displayed on the display unit of the information processing device according to the embodiment;
[0026] FIG. 6A illustrates a table representing specimens and parameter values thereof according to the embodiment;
[0027] FIG. 6B illustrates a table representing specimens and parameter values thereof according to the embodiment;
[0028] FIG. 6C illustrates a table representing specimens and parameter values thereof according to the embodiment;
[0029] FIG. 7A is a radar chart according to the embodiment;
[0030] FIG. 7B is a radar chart according to the embodiment;
[0031] FIG. 8A is a radar chart according to the embodiment;
[0032] FIG. 8B is a radar chart according to the embodiment;
[0033] FIG. 9A is a radar chart according to the embodiment;
[0034] FIG. 9B is a radar chart according to the embodiment;
[0035] FIG. 9C is a radar chart according to the embodiment;
[0036] FIG. 10A is a radar chart according to the embodiment;
[0037] FIG. 10B is a radar chart according to the embodiment;
[0038] FIG. 10C is a radar chart according to the embodiment;
[0039] FIG. 11A is a radar chart according to the embodiment;
[0040] FIG. 11B is a radar chart according to the embodiment;
[0041] FIG. 11C is a radar chart according to the embodiment;
[0042] FIG. 11D is a radar chart according to the embodiment;
[0043] FIG. 12 is an illustration of a screen showing a particle image list displayed on the display unit of the information processing device according to the embodiment;
[0044] FIG. 13 is an illustration of a screen showing a display screen for individual particle displayed on the display unit of the information processing device according to the embodiment;
[0045] FIG. 14A illustrates a table representing particles and parameter values thereof according to the embodiment;
[0046] FIG. 14B illustrates a table representing particles and parameter values thereof according to the embodiment;
[0047] FIG. 15A is a radar chart according to the embodiment;
[0048] FIG. 15B is a radar chart according to the embodiment;
[0049] FIG. 15C is a radar chart according to the embodiment;
[0050] FIG. 16A is a radar chart according to the embodiment;
[0051] FIG. 16B is a radar chart according to the embodiment;
[0052] FIG. 16C is a radar chart according to the embodiment;
[0053] FIG. 17A is a radar chart according to the embodiment;
[0054] FIG. 17B is a radar chart according to the embodiment;
[0055] FIG. 17C is a radar chart according to the embodiment;
[0056] FIG. 18A is a radar chart according to the embodiment;
[0057] FIG. 18B is a radar chart according to the embodiment;
[0058] FIG. 18C is a radar chart according to the embodiment;
[0059] FIG. 19A is a radar chart according to the embodiment;
[0060] FIG. 19B is a radar chart according to the embodiment;
[0061] FIG. 19C is a radar chart according to the embodiment;
[0062] FIG. 20 is a block diagram illustrating a structure of the information processing device according to the embodiment;
[0063] FIG. 21A is a flow chart illustrating steps of a particle imaging process according to the embodiment;
[0064] FIG. 21B is a flow chart illustrating steps of an analysis result 1 display process according to the embodiment;
[0065] FIG. 22A is a flow chart illustrating steps of an analysis result 2 display process according to the embodiment;
[0066] FIG. 22B is a flow chart illustrating steps of a analysis and display process for individual particle according to the embodiment;
[0067] FIG. 23A illustrates a modified example of the radar chart according to the embodiment; and
[0068] FIG. 23B illustrates a modified example of the radar chart according to the embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0069] The description of an embodiment given below will clearly articulate the effect and significance of the present invention. The embodiment described below, however, only suggests an example of embodying the present invention, and the present invention is not necessarily limited thereto.
[0070] Hereinafter, a particle analyzer according to an embodiment of the present invention is described referring to the accompanied drawings.
[0071] FIG. 1 is an illustration of a structure of a particle analyzer according to an embodiment of the present invention. The particle analyzer has a measurement device 1 and an information processing device 2 . The measurement device 1 pours a specimen into a flow cell and captures an image of a particle in the specimen flowing in the flow cell. The information processing device 2 analyzes the captured particle image and displays an analysis result thereby obtained.
[0072] First, the specimen is suctioned through a suctioning pipette 11 by a suctioning device such as a diaphragm pump (not illustrated in the drawing) and passes through a sample filter 12 to be drawn into a specimen charging line 13 provided at an upper section of a flow cell 15 . The sample filter 12 removes coarse particles and dust included in the specimen as the specimen passes therethrough, thereby eliminating the risk of blocking the flow cell 15 having a narrow flow path. Another effect exerted by the sample filter 12 is to crumble coarse agglomerates.
[0073] A sheath syringe 14 is turned on, so that the specimen sucked in the specimen charging line 13 is guided into the flow cell 15 . The specimen guided into the flow cell 15 extruded through a lower end of a sample nozzle 15 a . At the same time, a sheath liquid is poured into the flow cell 15 from a sheath liquid bottle 16 through a sheath liquid chamber 17 . The specimen in the flow cell 15 is surrounded by the sheath liquid and then formed into a flat specimen flow.
[0074] The specimen flow thus flattened is irradiated with a pulsed light from a strobo light 18 at time intervals of 1/60 second, and a still image of a particle included in the specimen is captured every approximately 2μ second by a camera 20 via an object lens 19 . An image signal outputted from the camera 20 is inputted to the information processing device 2 .
[0075] The information processing device 2 obtains an image of each particle based on the inputted image signal in parallel with reception of the image signal. The information processing device 2 obtains parameter values representing particle characteristics based on each of the obtained particle images, and displays an analysis result of the specimen on a display unit. The structure of the information processing device 2 will be described later referring to FIG. 20 .
[0076] A description is given below to the parameters representing the particle characteristics obtained by the information processing device 2 based on the particle image.
[0077] The parameters representing the particle characteristics obtained by the information processing device 2 are classified into parameters in which a particle diameter is quantitatively determined and parameters in which a particle shape is quantitatively determined. The parameters in which a particle diameter is quantitatively determined include: equivalent circle diameter; maximum length; vertical length of maximum length; long-axis diameter; short-axis diameter; Feret diameter (horizontal); Feret diameter (vertical); perimeter equivalent circle diameter; particle perimeter; particle area; envelope perimeter; envelope area; and area equivalent circle diameter. The parameters in which a particle shape is quantitatively determined includes: circularity; aspect ratio; aspect ratio of horizontally circumscribed rectangle; average luminance value, luminance dispersion value; degree of envelope (perimeter); degree of envelope (area); and circularity (area). The parameters are described in detail below.
[0000]
TABLE 1
<Particle diameter>
Equivalent circle
Diameter of circle having circumference
diameter
equal to particle perimeter
(area equivalent
(diameter of circle having area equal to
circle diameter):
particle area)
Maximum length
Maximum length between two points on
contour of particle image
Vertical length of
When particle is sandwiched between two
maximum length
straight lines in parallel with straight
line which connects two points
representing maximum length, shortest
length which vertically connects the two
straight lines
Long-axis diameter
Length of long axis when particle is
sandwiched between two pairs of parallel
lines
Short-axis diameter
Length of short axis when particle is
sandwiched between two pairs of parallel
lines
Feret diameter
Horizontal tangent diameter defined by
(horizontal)
distance between two pairs of parallel
lines sandwiching particle
Feret diameter
Vertical tangent diameter defined by
(vertical)
distance between two pairs of parallel
lines sandwiching particle
Perimeter equivalent
Diameter of circle equal to particle
circle diameter
perimeter
Particle perimeter
Peripheral length of particle
Particle area
Area of particle
Envelope perimeter
Perimeter of shape connecting
protruding portions of particle
Envelope area
Area of shape connecting protruding
portions of particle
[0000]
TABLE 2
<Particle shape>
Circularity
Ratio between particle perimeter and
perimeter of circle corresponding to
projected area of particle image
Aspect ratio
Ratio between long-axis diameter and
short-axis diameter
Aspect ratio of
When particle is surrounded by
horizontally
horizontally circumscribed rectangle,
circumscribed
aspect ratio of the rectangle
rectangle
Average luminance
Average of pixel luminance values in
value
particle region
Luminance dispersion
Standard deviation of pixel luminance
value
values in particle region
Degree of envelope
Ratio between envelope perimeter and
(perimeter)
particle perimeter
Degree of envelope
Ratio between particle area and envelope
(area)
area
Circularity (area)
ratio between projected area of particle
image and area of circle equal to
particle perimeter
[0078] FIG. 2 is an illustration of a screen showing a record list displayed on the display unit of the information processing device 2 . The illustrated screen is displayed when a record list tab 110 is pressed.
[0079] As illustrated in the drawing, the display unit includes a menu 100 , a record list 111 , and a select-cancel button 112 . The menu 100 includes a record list tab 110 , analysis result tabs 120 and 130 , and a particle image list tab 140 . When these tabs are pressed, screens corresponding to the pressed tabs are displayed.
[0080] The record list 111 displays thereon records of specimens measured by the measurement device 1 . The record is a measurement result obtained by a measuring operation carried out under given measurement conditions. For example, when a user commands to end the measuring operation already started and the measuring operation is ended, the measurement result obtained during the measuring operation is created as one record. In the event that the analyzer is set to end the measuring operation as soon as the number of measured particles after the measurement started reaches a given number, the measurement result obtained during the measuring operation is created as one record.
[0081] As illustrated in the drawing, record items include: record number; measurement date and time; specimen number; statistical values (for example, average, SD, CV) of the parameters (equivalent circle diameter, circularity). The record number is a specific number used to identify each record. The measurement date and time is a date and time when the measurement relevant to the record ended. The specimen number is a number used to identify each specimen. The specimen number is associated with the specimen name.
[0082] The statistical values (for example, average, SD, CV) are obtained through statistics of parameter values of whole particles in one record. For example, average in the section of equivalent circle diameter in a record shows an average value of equivalent circle diameter values of all of particles measured to obtain the record. SD shows a standard deviation of the parameter values, and CV shows a coefficient of variation (degree of variability) calculated from the average and SD.
[0083] When a cell in the record list 111 is pressed, a record including the cell is highlighted to be selectable. When the select-cancel button 112 is pressed, selection of any record on the table is cancelled. On the record list 111 , a plurality of records can be selected.
[0084] At the right and left ends of the record list 111 , scroll bars respectively used to shift its display region side to side and up and down are provided. All of the records can be viewed when the up-down scroll bar is scrolled, and all of the record items can be viewed when the side-to-side scroll bar is scrolled.
[0085] FIG. 3 is an illustration of a screen showing an analysis result 1 displayed on the display unit of the information processing device 2 . The illustrated screen is displayed when the analysis result tab 120 is pressed in a state where one record is selected on the record list 111 of FIG. 2 .
[0086] As illustrated in the drawing, the display unit includes, in addition to a menu 100 similar to that of FIG. 2 , a record information list 121 , a particle diameter histogram 122 , a particle diameter parameter selection box 123 , a particle shape histogram 124 , a particle shape parameter selection box 125 , and a scattergram 126 .
[0087] The record information list 121 displays information associated with one record selected on the record list 111 illustrated in FIG. 2 .
[0088] The particle diameter histogram 122 displays, in the form of histogram, distribution of the particle diameter parameters of different particles measured in the record displayed on the record information list 121 . The particle diameter parameter displayed on the particle diameter histogram 122 is selected from a list of selectable particle diameter parameters when the particle diameter parameter selection box 123 is pressed. A lateral axis of the particle diameter histogram 122 is set in a range corresponding to the particle diameter parameter currently displayed, and right and left sides of a longitudinal axis respectively represent accumulation and frequency.
[0089] The particle shape histogram 124 displays, in the form of histogram, distribution of the particle shape parameters of different particles measured to in the record displayed on the record information list 121 . The particle shape parameter displayed on the particle shape histogram 124 is selected from a list of selectable particle shape parameters when the particle shape parameter selection box 125 is pressed. A longitudinal axis of the particle shape histogram 123 is set in a range corresponding to the particle shape parameter currently displayed, and upper and lower sides of a lateral axis respectively represent accumulation and frequency.
[0090] When the particle diameter histogram 122 and the particle shape histogram 124 are displayed, a user can know values of the particle diameter parameters and particle shape parameters in different particles measured in the record displayed on the record information list 121 .
[0091] The scattergram 126 is a graph two-dimensionally or three-dimensionally expressing the combined contents of the particle diameter histogram 122 and the particle shape histogram 124 . A lateral axis and a longitudinal axis of the scattergram 126 are set in the same manner as the lateral axis of the particle diameter histogram 122 and the longitudinal axis of the particle shape histogram 124 .
[0092] When the scattergram 126 is displayed, a user can know distribution of values of the particle diameter parameters and particle shape parameters in different particles measured in the record displayed on the record information list 121 .
[0093] FIG. 4 is an illustration of a screen showing an analysis result 2 displayed on the display unit of the information processing device 2 . The illustrated screen is displayed when the analysis result tab 130 is pressed in a state where at least one record is selected on the record list 111 illustrated in FIG. 2 .
[0094] As illustrated in the drawing, the display unit includes, in addition to a menu 100 similar to that of FIG. 2 , a parameter value list 131 , a chart 132 , and a display parameter setting button 133 .
[0095] The parameter value list 131 displays statistical values of the parameters associated with the specimen in at least one record selected on the record list 111 illustrated in FIG. 2 . Items laterally shown display names of specimens corresponding to the records selected on the record list 111 , and items longitudinally shown displays the parameters. The parameters are defaulted in six items illustrated in the same drawing (equivalent circle diameter, long-axis diameter, short-axis diameter, circularity, aspect ratio, degree of envelope (area). As described later, the parameters can be changed by pressing the display parameter setting button 133 and then displaying a display parameter setting screen. At the right and left ends of the parameter value list 131 , scroll bars respectively used to shift its display region side to side and up and down are provided. In the case where contents to be displayed cannot be displayed within the display region of the parameter value list 131 , these scroll bars can be used to display the specimen names and parameters in all of the records.
[0096] The chart 132 displays a radar chart based on the parameter values displayed on the parameter value list 131 . FIG. 4 illustrates a radar chart showing on one screen three specimens displayed on the parameter value list 131 , and statistical values of three parameters relating to particle diameter and statistical values of three parameters relating to particle shape based on statistical values of six parameters of these specimens. When the chart 132 is thus displayed, a plurality of parameters of a plurality of specimens can be compared at a time.
[0097] The display parameter setting button 133 is used to set the parameters to be displayed on the parameter value list 131 and the chart 132 . When the display parameter setting button 133 is pressed, a display parameter setting screen illustrated in FIG. 5 is displayed.
[0098] Referring to FIG. 5 , a display parameter setting screen 200 includes setting regions 201 to 205 , and an OK button 206 .
[0099] On the setting region 201 , the particle diameter parameters to be displayed on the parameter value list 131 and the chart 132 illustrated in FIG. 4 are selected. When the particle diameter parameters displayed on the setting region 201 are pressed, relevant check boxes are checked as illustrated in the drawing, and it is known that the parameters with the checked boxes are selected. On the setting region 202 , the particle shape parameters displayed on the parameter value list 131 and the chart 132 illustrated in FIG. 4 are selected. When the particle shape parameters displayed on the setting region 202 are pressed, relevant check boxes are checked as illustrated in the drawing, and it is known that the parameters with the checked boxes are selected.
[0100] On the setting region 203 , types of the parameter statistical values displayed on the parameter value list 131 and the chart 132 illustrated in FIG. 4 are selected. The selectable types of the statistical values include the statistical values of parameters illustrated in FIG. 2 (for example, average, SD, and CV).
[0101] On the setting region 204 , a reference parameter for normalizing the parameter values displayed on the parameter value list 131 and the chart 132 illustrated in FIG. 4 is set. For example, when the long-axis diameter is selected as the reference parameter for normalization as illustrated in the drawing, the other parameter values are set so that the long-axis diameter shows the value of 1. The values thus set are displayed in FIG. 4 . The average luminance value is normalized in the range of 0 to 1.0. In the case where the average luminance value is included in a range of specific thresholds previously set, the average luminance value is normalized in the range of 0-1.0 depending on the threshold value. The average luminance value exceeding the threshold value is always normalized to “1.0”. In the event that the reference parameter for normalization is not set, actually measured values are used as the statistical values.
[0102] On the setting region 205 , a display range of axes displayed on the chart 132 illustrated in FIG. 4 is set. When the display range is set to 0-1 as illustrated in the drawing, for example, the center of the axes expresses 0, and the outermost end thereof expresses 1 as illustrated in FIG. 4 .
[0103] When the OK button 206 is pressed, the parameters set in the display parameter setting screen 200 are reflected on the screen of the analysis result 2 illustrated in FIG. 4 . Then, the parameter value list 131 and the chart 132 illustrated in FIG. 4 are accordingly updated.
[0104] Various examples of the radar chart displayed on the chart 132 of FIG. 4 are illustrated in FIGS. 7 to 11 .
[0105] FIG. 6 illustrates names of specimens of the records referenced when the radar chart is created, and parameter values relevant to the specimen names of the records. FIG. 6A illustrates the parameter values obtained by normalizing average values of actually measured values in different particles, in which the parameter values are normalized based on the long-axis diameter. As described earlier, the average luminance value is normalized in the range of 0 to 1.0. The parameter values of FIG. 6B represent CV (degree of variability). The parameter values of FIG. 6C represent the average values of actually measured values in different particles. To simplify the illustration, the Feret diameter illustrated in FIG. 6C is one of average Feret diameter (horizontal) and average Feret diameter (vertical) larger than the other.
[0106] FIGS. 7A and 7B are radar charts when three specimens and six parameters are selected from the specimens and the parameters illustrated in FIG. 6A . The six parameters are defaulted. “LATEX” generally called standard sample particles is a specimen containing particles having nearly spherical shapes.
[0107] As illustrated in FIG. 7A , the radar charts of “LATEX 4204A”, “Tonar”, and “Almina” have shapes closer to regular hexagon in the mentioned order. It is known from the illustration that “LATEX 4204A”, “Tonar”, and “Almina” contain particles having shapes closer to spherical shape in the mentioned order.
[0108] As illustrated in FIG. 7B , the radar charts of “LATEX 4203A”, “LATEX 4204A”, and “LATEX 4202A” have shapes closer to regular hexagon in the mentioned order. It is known from the illustration that “LATEX 4203A”, “LATEX 4204A”, and “LATEX 4202A”, contain particles having shapes closer to spherical shape in the mentioned order. The display range of the axes in FIG. 7B is set to 0.6 to 1. The display region is thus set based on display range of the setting region 205 on the display parameter setting screen illustrated in FIG. 5 .
[0109] FIGS. 8A and 8B are radar charts when three specimens and six parameters are selected from FIG. 6B . The six parameters are defaulted.
[0110] According to the radar charts illustrated in FIG. 8A , it is known that “LATEX 4204A”, “LATEX 4203A”, and “LATEX 4202A” have smaller degrees of variability in the mentioned order. According to the radar charts of FIG. 8B , “LATEX 4204A”, “Tonar”, and “Almina” have smaller degrees of variability in the mentioned order. It is also known that the degree of variability is largely different from one specimen to another.
[0111] FIGS. 9A-9C are radar charts when three specimens and five, three, and four parameters are selected from FIG. 6C . The default of the parameters is changed using the display parameter setting screen illustrated in FIG. 5 . Likewise, it is determined whether or not the radar charts of FIGS. 9A to 9C have shapes close to regular pentagon, regular triangle, or square to know whether or not the particles of the specimens are nearly circular. Because the parameter values of these radar charts are the average values of actually measured values, it can be confirmed whether or not the different specimens have different values in a particular parameter.
[0112] All of the parameters displayed on the radar charts of FIGS. 9A to 9C are the particle diameter parameters. When the particle diameter parameters alone are selected, it is desirable to include three of the particle diameter parameters, equivalent circle diameter, long-axis diameter and short-axis diameter. Referring to these three parameters, an outer shape of the particle, as well as its dimension, can be easily grasped.
[0113] FIGS. 10A to 10C are radar charts when three specimens and three parameters are selected from FIG. 6A . The state of the parameters is already changed from their default state using the display parameter setting screen illustrated in FIG. 5 . Likewise, it is determined whether or not the radar charts have shapes close to regular triangle to know whether or not the particles of the specimens are nearly circular.
[0114] FIG. 10B illustrates the radar chart in which the parameter display range of FIG. 10A is set to 0.5 to 1. FIG. 10B , therefore, makes it easier to grasp the shape of the radar chart rather than FIG. 10A . In FIG. 10C , it is difficult to differentiate the shapes of the radar charts of three specimens, the parameter display range is set to 0.8 to 1. This helps to readily know that the particles of “LATEX 4203A” are more spherical than any other specimens.
[0115] All of the parameters displayed on the radar charts of FIGS. 10A to 10C are the particle shape parameters. When the particle shape parameters alone are selected, it is desirable to include three of the particle shape parameters, which are circularity, aspect ratio, and degree of envelope. Referring to these three parameters, the particle shape can be accurately grasped.
[0116] FIGS. 11A to 11D are radar charts when three specimens and 4 to 5 parameters are selected from FIG. 6A . The state of the parameters is already changed from their default state using the display parameter setting screen illustrated in FIG. 5 . Likewise, it is determined whether or not the radar charts have shapes close to regular pentagon or square to know whether or not the particles of the specimens are nearly spherical.
[0117] FIG. 11B illustrates the radar chart in which the parameter display range of FIG. 11A is set to 0.5 to 1. FIG. 11D illustrates the radar chart in which the parameter display range of FIG. 11C is set to 0.5 to 1. Therefore, FIG. 11B makes it easier to grasp the shape of the radar chart rather than FIG. 11A , and FIG. 11D makes it easier to grasp the shape of the radar chart rather than FIG. 11C .
[0118] FIG. 12 is an illustration of a screen showing a particle image list displayed on the display unit of the information processing device 2 . The illustrated screen is displayed when the particle image list tab 140 is pressed in a state where at least two records are selected on the record list 111 illustrated in FIG. 2 .
[0119] As illustrated in the drawing, the display unit includes, in addition to a menu 100 similar to that of FIG. 2 , record information lists 141 and 143 , and particle image lists 142 and 144 .
[0120] The record information lists 141 and 143 display information of the records selected on the record list 111 illustrated in FIG. 2 .
[0121] The particle image lists 142 and 144 respectively display the images of all of particles measured in the records displayed on the record lists 141 and 143 . At the right ends of the particle image lists 142 and 144 , scroll bars respectively used to shift their display regions up and down are provided. Accordingly, all of the particle images on the particle image lists 142 and 144 can be viewed.
[0122] In the example illustrated in FIG. 12 , two records are displayed. When one record is selected on the record list 111 illustrated in FIG. 2 , the record contents are displayed on the record information list 141 and the particle image list 142 alone. In the event that at least three records are selected on the record list 111 illustrated in FIG. 2 , the record information lists and the particle image lists are suitably arranged on the screen depending on the number of selected records. In such a case, the display regions of the record information lists and the particle image lists that correspondent to the respective records are suitably adjusted on the screen.
[0123] When the particle images of the particle image lists 142 and 144 are selected, a particle selection range 145 is set. In response to an operation to display a submenu on the particle selection range 145 , a selection display menu 146 is displayed. In the drawing, the particle selection range 145 is set for the particle images continuously displayed, however, can also be set for an arbitrary number of any particle images displayed on the particle image lists 142 and 144 .
[0124] The selection display menu 146 is provided with an “analysis and display for individual particle” window. When the “analysis and display for individual particle” window is pressed, a display screen for individual particle illustrated in FIG. 13 is displayed.
[0125] Referring to FIG. 13 , a display screen for individual particle 150 includes a parameter value list 151 , a particle image list 152 , a chart 153 , and a display parameter setting button 154 .
[0126] The parameter value list 151 displays information of particles selected by the particle selection range 145 on the particle image list illustrated in FIG. 12 . Items laterally shown displays names of specimens corresponding to the particles selected by the particle selection range 145 , and items longitudinally shown displays the parameters of the particles. The six parameters are defaulted. The parameters can be changed by pressing the display parameter setting button 154 and then displaying parameter setting screen, which will be described later.
[0127] The particle image list 152 displays the images of the particles displayed on the parameter value list 151 . Along with the particle images, particles names are displayed, which are the specimen names with serial numbers appended thereto.
[0128] The chart 153 displays a radar chart based on the parameter values displayed on the parameter value list 151 . The illustration of FIG. 13 displays a radar chart showing on one screen two particles displayed on the parameter value list 151 , and three parameter values relating to particle diameter and three parameter values relating to particle shape based on six parameters of these particles. When the chart 153 is thus displayed, a plurality of parameters of a plurality of particles can be compared at a time.
[0129] The display parameter setting button 154 is used to set the parameters to be displayed on the parameter value list 151 and the chart 153 . When the display parameter setting button 154 is pressed, a setting screen similar to the display parameter setting screen 200 illustrated in FIG. 5 is displayed. In the display parameter setting screen thus displayed, a region corresponding to the setting region 203 is omitted.
[0130] When the parameters are changed on the setting screen, any changes made then are reflected on the display screen for individual particle 150 illustrated in FIG. 13 , and the display contents of the parameter value list 151 and the chart 153 illustrated in FIG. 13 are updated.
[0131] Various examples of the radar chart displayed on the chart 151 of FIG. 13 are illustrated in FIGS. 15 to 19 .
[0132] FIG. 14 illustrate names of particles in the records referenced when the radar chart is created, and the parameter values of the particles. FIG. 14A illustrates the parameter values obtained by normalizing actually measured values of different particles, in which the values are normalized based on the long-axis diameter. As described earlier, the average luminance value is normalized in the range of 0 to 1.0. The parameter values illustrated in FIG. 14B represent actually measured values of the respective particles. To simplify the illustration, the Feret diameter illustrated in FIG. 14C is one of Feret diameter (horizontal) and Feret diameter (vertical) larger than the other.
[0133] FIG. 15A is a radar chart when two particles of one specimen and six parameters thereof are selected from FIG. 14A . The six parameters are defaulted. By determining whether or not the radar chart of FIG. 15A has a shape close to regular hexagon, it is known whether or not the particle image is nearly circular.
[0134] FIG. 15B is a radar chart when two particles of one specimen and three parameters thereof are selected from FIG. 14B . The state of the parameters is already changed from their default state using the display parameter setting screen. Likewise, it is determined whether or not the radar chart of FIG. 15B has a shape close to regular triangle to know whether or not the particle image is nearly circular. The display range of the axes in FIG. 15B is set to 10 to 20.
[0135] FIG. 15C is a radar chart when two particles of one specimen and three parameters thereof are selected from FIG. 14A . The state of the parameters is already changed from their default state using the display parameter setting screen. Likewise, it is determined whether or not the radar chart of FIG. 15C has a shape close to regular pentagon to know whether or not the particle image is nearly circular.
[0136] In FIGS. 16 and 17 , the shapes of the radar charts are determined to know whether or not the particle images are nearly circular in a manner similar to FIG. 15 . FIGS. 18 and 19 are radar charts when two particles of different specimens are selected. Likewise, the shapes of the radar charts are determined to know whether or not the particle images are nearly circular.
[0137] FIG. 20 is a block diagram illustrating the structure of the information processing device 2 .
[0138] The information processing device 2 is made of a personal computer, and includes a main body 300 , an input unit 310 , and a display unit 320 . The main body 300 has a CPU 301 , a ROM 302 , a RAM 303 , a hard disc 304 , a read out device 305 , an input/output interface 306 , an image output interface 307 , and a communication interface 308 .
[0139] The CPU 301 runs a computer program stored in the ROM 302 and a computer program loaded into the RAM 303 . The RAM 303 is used to read out the computer programs recorded on the ROM 302 and the hard disc 304 . The RAM 303 is also used as a working region of the CPU 301 when the computer programs are run.
[0140] The hard disc 304 is installed with various computer programs to be run by the CPU 301 such as operating system and application program, as well as data used to run the computer programs. More specifically, the hard disc 304 is installed with a program for receiving an image signal outputted from a camera 20 , creating an image of each particle based on the received image signal, and analyzing a specimen based on the particle image, and a display program for displaying an analysis result on the display unit 320 . By installing these programs, the analyzing process and the display process illustrated in FIGS. 2 to 19 are carried out.
[0141] The read out device 305 includes a CD drive or a DVD drive. The read out device 305 can read a computer program and data recorded on an external storage such as a recording medium. Therefore, the programs executed by the information processing device 2 can be updated via the external storage, for example, recording medium.
[0142] The input unit 310 including a keyboard and a mouse is connected to the input/output interface 306 so that a user can input a command to the information processing device 2 using the input unit 310 . The image output interface 307 is connected to the display unit 320 including, for example, a display screen so that a video signal based on image data is displayed on the display unit 320 . The display unit 320 displays an image based on the inputted video signal. The image signal outputted from the camera 20 can be inputted through the communication interface 308 .
[0143] FIG. 21A is a flow chart illustrating steps of the particle imaging process carried out in the information processing device 2 .
[0144] When the particle image is captured by the camera 20 , the image signal outputted from the camera 20 is received by the information processing device 2 through the communication interface 308 (S 1 ). After a predetermined image processing is applied to the received image signals, the resulting image signals are separated from one another by each particle, and the particle image is generated therefrom for individual particle. The generated particle images are stored in the hard disc 304 (S 2 ). Based on the particle images, all of the parameter values relating to particle diameter and particle shape described so far are calculated (S 3 ). The calculated parameters are stored in the hard disc 304 in association with the particle image. Then, statistical values of equivalent circle diameter and circularity (average, SD, CV) are calculated based on the actually measured values of equivalent circle diameter and circularity of each particle, and then stored in the hard disc 304 (S 4 ). Then, the particle imaging process ends.
[0145] When the record list screen illustrated in FIG. 2 is thereafter displayed, record information of the specimen most recently measured is added to the list, and the statistical values obtained in S 4 (average, SD, CV) are included in the record information.
[0146] FIG. 21B is a flow chart illustrating steps of a display process of an analysis result 1 .
[0147] The process is carried out when the analysis result tab 120 is pressed in a state where one record is selected on the record list 111 of FIG. 2 .
[0148] First, all of the parameter values relating to particle diameter and particle shape are obtained from the hard disc 304 for the record selected on the record list 111 of FIG. 2 (S 11 ). An initial screen of the analysis result 1 is generated and displayed based on the obtained parameter values (S 12 ). In this description, the record information list 121 of FIG. 3 displays the record information selected on the record list 111 of FIG. 2 . Further, the particle diameter histogram 122 , particle shape histogram 124 , and scattergram 126 are generated based on the parameters (equivalent circle diameter, circularity) defaulted in the particle diameter parameter selection box 123 and the particle shape parameter selection box 125 , and then displayed in the corresponding regions of FIG. 3 .
[0149] When the initial screen of the analysis result 1 is thus displayed, it is determined whether or not the parameters in the particle diameter parameter selection box 123 and the particle shape parameter selection box 125 have been changed (S 13 ). When any of the parameters is changed (S 13 : YES), the particle diameter histogram 122 , particle shape histogram 124 , and scattergram 126 are generated based on the changed parameters, and then displayed in the corresponding region of FIG. 3 (S 14 ). The process then returns to S 13 to determine again whether or not any of the parameters is changed. When any tab other than the analysis result tab 120 is selected via the menu 100 of FIG. 3 during the determination, the display process of the analysis result 1 ends.
[0150] FIG. 22A is a flow chart illustrating steps of a display process of an analysis result 2 .
[0151] The process is carried out when the analysis result tab 130 is pressed in a state where at least one record is selected on the record list 111 of FIG. 2 .
[0152] First, all of the parameter values relating to particle diameter and particle shape are obtained from the hard disc 304 for the record selected on the record list 111 of FIG. 2 (S 21 ). An initial screen of the analysis result 1 is generated and displayed based on the obtained parameter values (S 22 ). The parameter values are obtained from the default values of the set parameters of FIG. 5 . Then, based on the defaulted parameters and the obtained parameter values, the parameter value list 131 and the chart 132 of FIG. 4 are displayed. An example of the initial screen of the analysis result 1 is illustrated in FIG. 4 .
[0153] When the initial screen of the analysis result 2 is thus displayed, it is determined whether or not any of the parameters (setting region 201 , 202 ), type of statistical value (setting region 203 ), reference parameter for normalization (setting region 204 ), and display range (setting region 205 ) is changed based on the display parameter setting screen of FIG. 5 (S 23 ). Having determined that any of the parameters, type of statistical value, reference parameter for normalization, and display range is changed (S 23 : YES), the parameter value list 131 and the chart 132 are reconfigured based on the changed contents, and then displayed on the corresponding region of FIG. 4 (S 24 ). Then, the process returns to S 23 to determine again whether or not any of the parameters, type of statistical value, reference parameter for normalization, and display range is changed. When any tab other than the analysis result tab 130 is selected via the menu 100 of FIG. 3 during the determination, the display process of the analysis result 2 ends.
[0154] FIG. 22B is a flow chart illustrating steps of an analysis and display process for individual particle.
[0155] This process is carried out when an “analysis and display for individual particle” window on the selection display menu 146 based on the particle selection range 145 set on the particle image lists 142 and 144 of FIG. 12 is pressed. When the particle image list screen illustrated in FIG. 12 is displayed, all of the parameter values relating to particle diameter and particle shape for the records to be displayed on the list screen are obtained from the hard disc 304 .
[0156] First, all of the parameter values relating to the diameters and shapes of particles included in the particle selection range 145 set on the particle image lists 142 and 144 of FIG. 12 are obtained (S 31 ). Based on the obtained parameter values, an initial screen of the “analysis and display for individual particle” is generated and displayed (S 32 ). The parameter values are obtained from the default values of the set parameters of FIG. 5 . Then, based on the defaulted parameters and the obtained parameter values, the parameter value list 151 and the chart 153 of FIG. 4 are displayed. An example of the initial screen of the “analysis and display for individual particle” is illustrated in FIG. 13 .
[0157] When the initial screen of the “analysis and display for individual particle” is thus displayed, the display parameter setting button 154 illustrated in FIG. 13 is pressed to determine whether or not the set parameters have been changed (S 33 ). As described earlier, when the display parameter setting button 154 is pressed, the screen in which the setting region 203 is deleted from the display parameter setting screen of FIG. 5 is displayed so that the set parameters can be changed. When the screen is operated to change any of the parameters (setting region 201 , 202 ), reference parameter for normalization (setting region 204 ) and display range (setting region 205 ) (S 33 : YES), the parameter value list 151 and the chart 153 are reconfigured based on the changed contents and displayed on the corresponding regions illustrated in FIG. 13 (S 34 ). Then, the process returns to S 33 to determine again whether or not any of the parameters, reference parameter for normalization and display range is changed. When an operation to end the “analysis and display for individual particle” is done during the determination, the display process of the “analysis and display for individual particle” ends.
[0158] Processes in FIGS. 21 and 22 are carried out by the CPU 301 in accordance with the program installed in the hard disc 304 illustrated in FIG. 20 . The analysis and display processes described referring to FIGS. 2 to 19 are carried out based on the processes using the program.
[0159] According to the present embodiment, the chart 132 of FIG. 4 displays the radar chart where arbitrary particle diameter parameters and arbitrary particle shape parameters of one specimen can be subjected to comparison. Accordingly, characteristics of one specimen can be visually grasped based on a plurality of parameters.
[0160] Because the radar charts of a plurality of specimens can be displayed as well, characteristics of the different specimens can be visually compared.
[0161] According to the present embodiment, the chart 153 of FIG. 13 displays the radar chart where arbitrary particle diameter parameters and arbitrary particle shape parameters of one particle can be subjected to comparison. Accordingly, characteristics of one particle can be visually grasped based on a plurality of parameters.
[0162] Because the radar charts of a plurality of particles can be displayed as well, characteristics of the different particles can be visually compared.
[0163] The embodiment of the present invention was described so far. The present invention, however, is not necessarily limited to the embodiment, and the embodiment can be variously modified.
[0164] According to the present embodiment, the chart 132 of FIG. 4 and the chart 153 of FIG. 13 display the radar charts. As far as a plurality of parameter values can be compared in a plurality of specimens or particles, any charts other than the radar chart may be displayed.
[0165] FIG. 23 illustrate charts which can be used in place of the radar charts.
[0166] FIGS. 23A and 23B are respectively a polygonal line graph and a bar graph when three specimens and six parameters are selected. When these charts are displayed, a plurality of parameters can be compared in a plurality of specimens in a manner similar to the radar charts. The charts of FIGS. 23A and 23B can display a plurality of parameters of a plurality of particles, in which case a plurality of parameters can be similarly compared in a plurality of particles.
[0167] According to the present embodiment, the chart 153 displays the radar chart of each particle as illustrated in FIGS. 12 and 13 . The radar chart of FIG. 13 may be displayed based on a comparison unit in which the particle selection range including a plurality of particles in FIG. 12 is set as the unit.
[0168] More specifically, after the particle selection range including a plurality of particles is set in FIG. 12 , particles included in the selection range are used as the comparison unit. Then, another comparison unit including different particles is set. FIG. 13 illustrates the radar chart showing statistical values of the parameters of the particles included in the comparison units. Instead of comparing different particles, the units each including a plurality of particles can be used as the basis of comparison. The display parameter setting screen is provided with a region corresponding to the setting region 203 of FIG. 5 , in which types of statistical values of the displayed parameters are selectable.
[0169] According to the present embodiment, the statistical values of equivalent circle diameter and circularity are calculated during the measuring operation. Instead, the statistical values of these parameters may be calculated during the display of the analysis result 1 of FIG. 3 or the analysis result 2 of FIG. 4 , or the statistical values of all of the parameters may be calculated during the measuring operation.
[0170] According to the present embodiment, equivalent circle diameter, long-axis diameter, and short-axis diameter are used as the particle diameter parameters, and circularity, aspect ratio, and degree of envelope (area) are used as the particle shape parameters on the initial screen (default) of the analysis result 2 and the initial screen (default) of the “analysis and display for individual particle”. On these initial screens, combination of any other parameters may be set, and at least four particle diameter parameters or at least four particle shape parameters may be set. However, the particle diameter parameters preferably include equivalent circle diameter, long-axis diameter, and short-axis diameter, and the particle shape parameters preferably include circularity, aspect ratio, and degree of envelope (perimeter or area).
[0171] The selectable parameters are not necessarily limited to the parameters illustrated in FIG. 5 , and other parameters may be included as the particle diameter parameters and particle shape parameters.
[0172] The embodiment of the present invention can be variously modified within the scope of the technical idea disclosed in the appended claims. | A particle analyzer is disclosed that comprises:
a flow cell through which a specimen passes, the specimen including a plurality of particles to be captured; an imaging device for capturing an image of a particle in the specimen passing through the flow cell; an image processor for obtaining a first characteristic value of a first parameter relating to particle diameter, a second characteristic value of a second parameter relating to particle diameter, and a third characteristic value of a third parameter relating to particle diameter based on the particle image obtained by the imaging device; and a controller for generating and outputting a screen on which the first, second and third characteristic values can be displayed at a time. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to alternating current power distribution systems and more specifically to an automatic power factor control device for such systems.
2. Description of the Prior Art
When inductive loads are added or subtracted to a power distribution system, they can have an adverse effect on the power factor which results in excess consumption of electrical energy. Due to the relatively high costs of electrical energy, this excess consumption can substantially increase the cost of operating inductive equipment such as electrical motors or inductive heaters.
It is well known to those skilled in the art that banks of capacitors can be added or subtracted to the power distribution system in order to improve the power factor. These prior art devices typically include mechanical contactors for switching the capacitor banks into or out of the system. These mechanical contactors cause undesirable electrical interference and electrical transients.
One attempt to solve the problems associated with power factor control is described in U.S. Pat. No. 4,356,440 by Curtis et al., assigned to the Charles Stark Draper Laboratory, Inc. and entitled, "Power Factor Correction System". The '440 patent discloses a discrete-time, closed loop power factor corrector system that controls the coupling of a delta-connected switched capacitor array to a 3- or 4-wire power line which may have time-varying, unbalanced, inductive loads. For inductive loads that cannot be exactly compensated with a delta-connected capacitance, the corrector system minimizes the total RMS reactive current drawn from the power line.
Another attempt to solve the power factor problem is disclosed in U.S. Pat. No. 4,348,631, Gyugyi et al., assigned to Westinghouse Electric Corp., and entitled, "Static VAR Generator". The '631 patent discloses a device for inserting capacitance into an AC network for power factor correction or voltage regulation that minimizes transient disturbances to the system. Current surges and voltage transients that are normally associated with connection of capacitors into an AC network are minimized by predetermining an amount of inductance that must be inserted to suppress these transients and simultaneously inserting the inductance into the network with the capacitance.
SUMMARY OF THE INVENTION
The apparatus of the present invention provides an automatic power factor control device for an alternating current power distribution system having inductive loads coupled thereto. The automatic power factor control device is connected to each line of the multiphase power distribution system and generates signals indicative of the voltage and current associated with each line. The current and voltage signals of each phase are compared to one another to determine the phase lag therebetween and to generate signals indicative of a time associated with the phase lag. The time dependent signals are applied to a microprocessor controlled circuit that converts the time dependent signals into a degree value and determines the cosine of the degree value. The cosine is then multiplied by 100 to provide a power factor which can be displayed on a digital readout. The microprocessor controlled circuit also controls a switching network that is capable of adding or removing banks of delta connected capacitors to or from the power lines. As the power factor decreases, the banks of the delta connected capacitors are connected to the power lines to improve the power factor. The switching network includes only two SCR switches per bank of capacitors. The banks of capacitors can be connected at any time regardless of the voltage potential residing on the capacitors without creating any current surges or electrical transients.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block description of the automatic power factor control device of the present invention;
FIG. 2 is a block diagram of the firing control circuits, power lines and a delta connected capacitor bank of the present invention.
FIG. 3 is a schematic block diagram of the firing control circuit of FIG. 2; and
FIGS. 4-7 are flow charts of the software associated with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a block diagram illustrates the automatic power factor control device of the present invention. The automatic power factor control device is connected to a power distribution system which includes the high voltage power lines 11, 12, 13 which are connected to a distribution transformer 14. The distribution transformer 14 distributes the high voltage electrical energy to a plant which places a load on the power distribution system. When the plant load includes a number of inductive devices such as electrical motors or inductive heaters, the power factor of the electrical energy is adversely affected. This change in power factor can increase the consumption of electricity and increase the cost of operating the plant.
The automatic power factor control device includes a potential transformer 15 having three small single phase transformers that provide three output signals, V A , V B V C , which are indicative of the voltage associated with the power lines 11, 12, 13. A plurality of transformers 17, 18, 19 are also connected to the power lines 11, 12, 13 and provide output signals I A , I B , I C which are indicative of the current associated with the power lines.
The output signals V A , V B , V C are applied to comparators 21-26. In FIG. 1 the sinusoidal waveforms V A and I A are illustrated as being representative waveforms applied to comparators 21-26. It can be appreciated that there is a phase lag between the waveforms V A and I A of FIG. 1. When these two waveforms are applied to comparators 21, 22, they generate two rectangular signals 27, 28. Likewise, comparators 23-26 also generate signals which for the sake of simplicity are not illustrated. The output of comparators 21-26 is applied to a programmable three section timer 30. The output signals of the timer 30 are applied as input to a data bus 31 and an address bus 32. The output signals of the timer 30 are time dependent signals indicative of the phase lag between the voltage and current of the power lines 11, 12, 13.
The address bus 31 and the data bus 32 are also connected to an analog section 30 which is comprised of an analog switch 33, a RMS/DC converter 34, and an analog-to-digital converter 35. The inputs to the analog switch 33 are the waveforms I A , I B , I C . If the waveforms I A , I B , I C fall below a set level, the analog section 30 provides the automatic power factor control device with a signal that causes it to remove any correction and to generate an error code.
The data bus 31 and address bus 32 are connected to an eight bit microprocessor 36 which is preferably a Motorola 6802 microprocessor. The microprocessor is responsive to a program stored in a programmable read only memory (PROM) 37. The microprocessor 36 is also connected to a chip select 38 and a buffer 40 which couples the microprocessor to a display panel 50.
The output of the microprocessor 36 is applied to a peripheral interface adapter (PIA) 41 which is used to control banks of wye connected capacitors, which are hereinafter described in greater detail. The PIA 41 is connected to a buffer 42, a plurality of optocouplers 43, and a plurality of firing control circuits 44 in order to add or remove the banks of delta connected capacitors to or from the power lines 11, 12, 13. In the preferred embodiment of the present invention there are eight optocouplers 43, sixteen firing control circuits 44, and eight banks of delta connected capacitors.
The display panel 50 includes a plurality of light emitting diodes (L.E.D.'s) 51 labeled #1-#8 that indicate which of the eight banks of delta connected capacitors are presently coupled to the power lines 11, 12, 13. The display panel also includes display L.E.D's 52 labeled A, B, C and lead indicating L.E.D.'s 53 labeled A, B, C which provide information regarding the status of phases A, B, C, associated with the power lines 11, 12, 13. The display panel 50 further includes a digital readout 54 which provides a percentage value for the power factor.
Referring now to FIG. 2, a block diagram illustrates a single bank 60 of the delta connected capacitors. The bank 60 is comprised of three delta connected capacitors 61, 62, 63 which have bleeder resistors 64, 65, 66 that are connected in parallel thereto. In the preferred embodiment of the present invention there are eight banks 60 of delta connected capacitors. Capacitors 61, 62, 63, are connected to SCR switches 71, 72 by inductors 67, 68. Preferably, the SCR switches include two oppositely poled SCR devices. The SCR switches 71, 72 are controlled by firing control circuit 44a, 44b, respectively. There is a firing control circuits 44a and firing control circuit 44b, for each bank 60 of delta connected capacitors. The bank 60 of delta connected capacitors is coupled to the three phase power lines 11, 12, 13 at a terminal block 73. Preferably, there are fuses 74, 75, 76 disposed between the automatic power factor control device and the terminal block 73.
Referring now to FIG. 3, a schematic block diagram illustrates the details of the firing control circuit 44a. The firing control circuit 44b is substantially identical to firing control 44a except that it is connected within the automatic power factor control device in a different fashion as illustrated in FIG. 2. For purposes of simplicity only firing control 44a will be described.
The firing control 44a is connected to the optocoupler 43, the SCR switch 71, and the firing control 44b. A first input to the firing control 44a from the buffer 42 is provided by the optocoupler 43. A second input to firing control 44a is provided by the optocoupler 80 which is connected to the SCR switch 71. The input from the optocoupler 43 is applied to an auto-reset circuit 81 and a 0.5 second timer 82 and then to an AND circuit 83. The input from the optocoupler 80 is applied to an auto-reset circuit 84 and a 50 microsecond timer 85 and then to the AND circuit 83. The output of the optocoupler 80 is a rectangular waveform 88 which is a zero cross indication between the voltage of the power lines 11, 12, or 13 and the voltage across the capacitors 61, 62, or 63.
It should be noted that it is not necessary to wait for the voltages of capacitors 61, 62, 63 to discharge. The firing control 44a can reapply the switch 71 at any point where the voltage across the switch is zero.
The purpose of the auto reset circuits 81, 84 is to insure that noise does not initiate a fire command to the SCR switch 71 which is applied through the d.c. hard gate firing circuits 86, 87. The signal to the microprocessor control and the zero cross signal must be on continuously until the timers 82, 85 "time out". Any noise situation will reset the timers 82, 85. It should also be pointed out that the "on" signal to firing control 44b is delayed 0.5 seconds so that the "on" command is staggered.
Referring now to FIGS. 4-7, flow charts illustrate the software stored in the PROM 37. The program in PROM 37 controls the hardware described above in FIGS. 1-3 and also allows the microprocessor 36 to calculate the power factor which is displayed in readout 54. The power factor is calculated by converting the phase lag between signals V A , V B , V C and I A , I B , I C to a time dependent signal. The time dependent signal is converted to degrees and the degrees are then converted to cosine values using a look up table which may be located in the PROM 37. The cosine values are then multiplied by one hundred to arrive at the power factor value, which is displayed in the readout 54.
Depending on the computed value the microprocessor 36 places on line at least one bank 60 of delta connected capacitors. The microprocessor 36 then recomputes the power factor and looks for a leading condition or a factor that is slightly greater than a "target" value, e.g. 96% (target=95%). If no "lead" is detected at that point, no more banks 60 of capacitors are added. The arrangement of banks 60 of capacitors is such that a smooth progression of capacitance values may be manipulated. Preferably, the values are arranged in a binary progression. Thus, if there are eight banks 60 of capacitors, 256 separate combinations can be connected to the power lines 11, 12, 13.
The flow charts of FIGS. 4-7 include a number of routines. In order to appreciate the functions of these routines, Table I below lists the names of these routines and describes their functions.
TABLE I______________________________________Routine Address Description______________________________________DABBD FC4D Part of the CKILD routine. Handles the case of a power factor reading out of allowable dead band area.CKILD FB99 Main routine for incrementing capacitor bank 60. Reads current power factor, checks for phase lead, checks for power factor within target values, sets status bits.CKLEAD F906 Part of main OPERATE loop. Checks for power factor lead following a capacitor bank 60 in cumulative pattern.CUMULA FB8B Part of INTERR routine. If user has requested a STEP operation in CUMULATIVE mode, this routine increments capacitor bank 60 in cumulative pattern.FARDEC FE12 Main routine for decrementing capacitor bank 60. It reads the power factor and checks for a leading condition. If power factor is leading, this routine determines which capacitor bank 60 to remove and then removes it. This procedure is repeated until power factor no longer leads.FARINC FDC2 Main routine for incrementing capacitor bank 60. It determines which capacitor bank 60 to add and then adds it. Unlike FARDEC, it does not read current power factor, nor does it do more than one increment.FRSTDB FC43 Part of CKILD routine. This routine handles the first occurrence of a power factor reading within the specified dead band area.ILEAD FC57 Part of CKILD routine. If the power factor is leading, this routine removes capacitor banks 60 until there is no longer a lead.INTERR FAE7 Main interrupt handler. Determines source of interrupt and, based on this, either updates display or increments capacitor bank 60.INTEST F93E Main test loop. In this loop, user can increment capacitor bank 60 under manual control.ISBELO FE86 Part of FARDEC routine. It handles case of power factor leading in excess of maximum allowable value. It waits 20 milliseconds and then repeats a capacitor bank 60 decrement, greatly speeding up normal decrement cycle.MAXFAR FDE4 Part of FARINC routine. It outputs calculated capacitor bank 60 configuration to the port controlling the capacitor banks 60.NOTARG FBB3 Part of CKILD routine. This section checks for power factor within specified deadband area. If within deadband, it sets a flag value to prevent further updates until power factor moves out of deadband.NTBELO FE5F Part of FARDEC routine. This section calculated the new capacitor bank 60 configuration when a decrement is required.OPERAT F8CF Main program loop. Checks for setting of switches 71, reads unit status, checks power factor, and calls routines to increment or decrement capacitor bank 60.OUTEST F988 Exit code for INTEST. Clears capacitor banks 60, zeroes variables, and reinitializes unit in preparation for automatic mode.RMS1 FA94 Part of RMSAMP routine. Gets the appropriate status bit if all three phase currents A, B, C are above the minimum level.RMS2 FAAD Part of RMSAMP routine. Checks to see if any capacitors banks 60 are on-line if current is below minimum value. If there are some online, it turns them off, one at a time.RMS3 FABD Part of RMSAMP routine. Gets various status bits based upon current system conditions.RMSAMP FA60 Reads RMS current, checks to see if current is above minimum specified value. Sets status bits.TARGET FD5D Part of CKILD routine. If a target power factor has been specified, this routine checks to see if last read power factor is within this range.TESTOP F936 Part of main OPERATE routine. Test status of OPERATE/TEST switch.UPDATE F90F Part of main OPERATE routine. Reads current power factor, formats result and updates displays.ZEROVO FEB7 Part of FARDEC routine. Sets the appropriate status bits and capacitor configuration for case where all capacitor banks 60 are removed from power lines 11, 12, 13.______________________________________
For a greater appreciation of the operation of the software and hardware reference may be had to Appendix A. Appendix A is the assembly language program stored in PROM 37. The assembly language program includes source code as well as explanatory comments which would enable those skilled in the art to generate the software of PROM 37. However, the description in the specification is believed to be sufficient for those skilled in the art to understand the instant invention, therefore, Appendix A is to be retained in the file and not be printed.
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, rather than limitation, and that changes may be made within the purview of the appended claims without departing from the true scope and spirit of the invention in its broader aspects. | In an apparatus for controlling the power factor of a power distribution system connected to inductive loads, banks of delta connected capacitors are added to or removed from the power lines of the power distribution system by a plurality of solid state switching devices which are under the control of a microprocessor. The solid state switching devices include optically isolated SCR devices that do not generate electrical interference and provide transient free operation. The microprocessor is also capable of calculating the power factor and displaying it on a digital readout. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of and claims the benefit of U.S. patent application Ser. No. 11/934,396 entitled Encapsulated Stator Assembly and Process For Making, filed on Nov. 2, 2007 which in turn claims the benefit of U.S. Provisional Patent Application No. 60/905,710, filed on Mar. 8, 2007, and entitled Magnetic Bearings For Use In Corrosive Environments.
BACKGROUND OF THE INVENTION
[0002] This disclosure relates to rotor and stator assemblies that utilize magnetic bearings and can be used in corrosive environments and processes of assembling the magnetic bearings. The rotor and stator assemblies can be used in turboexpanders, pumps, compressors, electric motors and generators, and similar turbo-machinery for the oil and gas industry.
[0003] A turboexpander is an apparatus that reduces the pressure of a feed gas stream. In so doing, useful work may be extracted during the pressure reduction. Furthermore, an effluent stream may also be produced from the turboexpander. This effluent stream may then be passed through a separator or a distillation column to separate the effluent into a heavy liquid stream. Turboexpanders utilize rotating equipment, which is relatively expensive and typically includes a radial inflow turbine rotor mounted within a housing having a radial inlet and an axial outlet. The turbine rotor is rotatably mounted within bearings through a shaft fixed to the rotor. Such turboexpanders may be used with a wide variety of different gas streams for such things as air separation, natural gas processing and transmission, recovery of pressure letdown energy from an expansion process, thermal energy recovery from the waste heat of associated processes, and the like. Compressors can be associated with turboexpanders as a means to derive work or simply dissipate energy from the turboexpander.
[0004] There are three primary types of bearings that may be used to support the rotor shaft in turbomachinery such as the turboexpander or compressor noted above. The various types of bearings include magnetic bearings, roller-element bearings, and fluid-film bearings. A magnetic bearing positions and supports a moving shaft using electromagnetic forces. The shaft may be spinning (rotation) or reciprocating (linear translation). In contrast, fluid-film and roller-element bearings are in direct contact with the rotor shaft and typically require a fluid based lubricant, such as oil.
[0005] Magnetic bearings provide superior performance over fluid film bearings and roller-element bearings. Magnetic bearings generally have lower drag losses, higher stiffness and damping properties, and moderate load capacity. In addition, unlike other types of bearings, magnetic bearings do not require lubrication, thus eliminating oil, valves, pumps, filters, coolers, and the like, that add complexity and includes the risk of process contamination.
[0006] In a typical magnetic bearing arrangement for rotor and stator assemblies, a stator comprising a plurality of electromagnetic coils surrounds a rotor shaft formed of a ferromagnetic material. Each of the electromagnetic coils, referred to as magnetic radial bearings because they radially surround the rotor, produce a magnetic field that tends to attract the rotor shaft. The rotor shaft assembly is supported by these active magnetic radial bearings inside the stator at appropriate positions about the rotor shaft. By varying the amount of current in the coils of a particular magnet, the attractive forces may be controlled so that the rotor remains centered between the magnets. Sensors in the stator surround the rotor and measure the deviation of the rotor from the centered position. A digital processor uses the signals from the sensors to determine how to adjust the currents in the magnets to center the rotor between the magnets. The cycle of detecting the shaft position, processing the data, and adjusting the currents in the coils, can occur at a rate of up to 25,000 times per second. Because the rotor “floats” in space without contact with the magnets, there is no need for lubrication of any kind.
[0007] Anti-friction bearings as well as seals may be installed at each end of the rotor shaft to support the shaft when the magnetic bearings are not energized. This avoids any contact between the rotor shaft and the stator's radial magnetic bearings. These auxiliary or “back-up” bearings are generally dry, lubricated, and remain unloaded during normal operation.
[0008] In the oil and gas industry, the rotor and stator assemblies can operate in a process gas, which can also serve as a cooling agent. The process gas typically is natural gas at pressures of about 10 bar to about 200 bar. Unfortunately, natural gas can have a high degree of contaminants. These contaminants can include corrosive agents such as hydrogen sulfide (H 2 S), water, CO 2 , oil, and others. In the worst case, the combination of water and H 2 S leads to what is called wet sour gas, a more corrosive gas. Magnetic bearings typically require cooling so as to maintain an acceptable temperature in the bearing components. Utilizing the process gas directly as the coolant provides a significant advantage in enabling a seal-less system, which eliminates the need for buffer gases (which are not generally available in upstream oil and gas applications) and enhancing safety and operability of the turbo-machinery installed. However, the cooling of the magnetic bearing assembly, and hence its use, in a process gas environment that contains the above contaminants poses a significant risk to the vulnerable components of the magnetic bearing.
[0009] The National Association of Corrosion Engineers (NACE) Standard MR0175, “Sulfide Stress Corrosion Cracking Resistant Metallic Materials for Oil Field Equipment” is a widely used standard in the oil and gas industry that specifies the proper materials, heat treat conditions, and hardness levels required to provide good service life of machinery used in sour gas environments. A NACE compliant material or component is substantially resistant to corrosion such as may occur upon exposure of a non-NACE compliant material to sour gas and/or wet sour gas. For example, NACE compliant welds generally require a post-weld heat treatment process to relieve any weld stresses that would normally contribute to the susceptibility for corrosion. Currently, there are no magnetic bearing systems used in the oil and gas industry that are fully NACE compliant.
[0010] NACE compliance is desirable because the rotor shaft assembly includes several components that could be exposed to a sour gas environment during operation. These include, among others, the rotor shaft itself, the magnetic rotor laminations about the rotor shaft, and the rotor-landing sleeves. As an example of the sensitivity to corrosive agents, it has been found that if the rotor laminations are exposed to wet sour gas they typically fail due to hydrogen embrittlement and stress related corrosion cracking. Stress related corrosion cracking is an issue since the magnetic rotor laminations are typically manufactured as punchings that are shrunk-fit onto the rotor shaft. During operation at working speeds, these components experience relatively high mechanical stresses due to the shrink-fit stresses and radial forces imparted thereon.
[0011] Another drawback of current magnetic bearing systems used in rotor and stator assemblies relates to the steel alloys typically used in the construction of the rotor shaft and/or rotor laminations. The selection of steel compositions that are most resistant to sour gas generally have poor magnetic properties. Because of this, high electromagnetic losses on the rotor shaft occur resulting in heat loads exceeding 1.00 W/cm 2 (6.45 W/in 2 ). The exposure to the high temperatures from the heat loads can lower resistance of the steels to sour gas corrosion. Increasing the size of the components to minimize the heat loads is not practical in view of the costs, and foot prints associated with the larger components.
[0012] In addition to the rotor shaft and laminations, the rotor shaft assembly typically includes a rotor landing sleeve shrunk-fit onto each end of the rotor shaft. This landing sleeve engages an inner race of a roller-element backup bearing in the event of a rotor landing, during which the magnetic bearing fails and the backup bearing has to support the rotor during the subsequent shut-down procedure. Currently, the rotor landing sleeve is formed of a material that is not NACE compliant and is therefore subject to corrosion in a sour gas environment.
[0013] The magnetic bearing stator is a stationary component that provides the source of the magnetic field for levitating the rotor assembly. An air gap separates the stator from the rotor shaft. In order to maximize the magnetic field strength and the levitation force this air gap is made as small as possible while still meeting mechanical clearance requirements between the rotor shaft and the stator. The gap size is typically on the order of millimeter fractions. If the gap is increased, the coils in the stator require more current to levitate the rotor, or the diameter or axial length of the stator has to be increased, all of which increase the overall stator size. If the stator size is limited and cannot be increased, then the levitation force is reduced if the air gap is larger than required by mechanical clearances.
[0014] Current stators are either encapsulated or non-encapsulated. In the case of encapsulated stators, a stator “can” protects the stator components from the process environment. Current stator cans are generally comprised of two concentric tubes of the same material joined at the ends. This tubular can section is located in the gap between the stator and the rotor shaft. If the can material is non-magnetic then it adds an additional magnetic gap on top of the required mechanical clearance, which reduces bearing capacity. In order to maintain bearing capacity, the material of the tubular can section can be selected to be magnetic.
[0015] In current practice, the stator can sections are assembled from magnetic NACE compliant alloys (typical examples are chromium-nickel alloys with a 15-18 wt % chromium 3-5 wt % nickel and 3-5 wt % copper content such as 17-4 precipitation hardened (PH) stainless steel) and are welded together. The welds would normally require a post-weld heat treatment at temperatures in excess of 600° C. in order to be fully NACE compliant. However, due to the temperature limits of the encapsulated electric stator components and the method of current manufacture, no heat treatment is possible. Therefore, the welds are not currently NACE compliant and are subject to corrosion and failure such as from exposure to sour gas. Moreover, some components of the stator, such as sensors, as well as power and instrumentation wires, cannot be encapsulated and are exposed to the process gas environment.
[0016] Referring now to prior art FIG. 1 , there is shown an exemplary turbo expander-compressor system generally designated by reference numeral 10 that includes a rotor and stator assembly having multiple magnetic bearings for supporting a rotor shaft. The system 10 includes a turbo expander 12 and compressor 14 at opposite ends of a housing 16 that encloses multiple magnetic bearings 18 for supporting rotor shaft 20 .
[0017] Each magnetic bearing 18 includes a stator 22 disposed about the rotor shaft 20 . The stator 22 includes stator poles, stator laminations, stator windings (not shown) arranged to provide the magnetic field. Fixed on the rotor shaft 20 are rotor laminations 24 , each rotor lamination aligned with and disposed in magnetic communication with each stator 22 . When appropriately energized, the stator 22 is effective to attract the rotor lamination 24 so as to provide levitation and radial placement of the rotor shaft 20 . The illustrated system 10 further includes additional axial magnetic bearings 26 and 28 so as to align the rotor shaft 20 in an axial direction by acting against a magnetic rotor thrust disk 30 . Roller-element backup bearings 32 are disposed at about each end of the rotor shaft and positioned to engage a rotor landing sleeve 34 disposed on the rotor shaft 16 when the magnetic bearings fail or when system 10 is in an off state. When the system 10 is configured to accommodate axial or thrust loads, the width of the sleeve 34 is increased to accommodate any axial movement.
[0018] The backup bearings 32 are typically made of roller-element bearings. In such bearings, the inner and outer races require steel alloys of high hardness (typically in excess of HRC 40 (Rockwell C-Scale Hardness)) to accomplish low wear and long bearing life. However, in steel alloys, the properties of high hardness and corrosion resistance are contradicting requirements. As a result, current races are made of high-hardness steel alloys that do not meet NACE corrosion requirements.
[0019] The system 10 further includes a plurality of sensors represented by 36 as well as power and instrumentation wires 38 in electrical communication with controller units (not shown). The sensors 36 are typically employed to sense the axial and radial discontinuities on the rotor shaft 20 such that radial and axial displacement along the shaft can be monitored via the controller unit so as to produce a desirable magnetic levitation force on the rotor shaft 20 .
[0020] Prior art FIG. 2 illustrates a partial cross-sectional view of an exemplary rotor and stator assembly 50 . The rotor and stator assembly 50 includes a rotor shaft assembly 52 that includes rotor laminations 54 attached to a rotor shaft 56 . An encapsulated stator assembly 60 surrounds the rotor shaft assembly 50 and includes a stator frame 62 , magnetic stator laminations 64 wrapped in conductive windings 66 , and a stator sleeve 68 . The stator sleeve 68 generally has a thickness ranging from 0.05 to 5.0 millimeters (mm). The encapsulated stator assembly 60 includes a hermetically sealed can defined by walls 70 and the stator sleeve 68 , the walls 70 having a thickness of about one centimeter. The can is formed from multiple sections that are welded at various interfaces 72 . These welds are not NACE compliant. Other stator components not shown are stator slots, poles, sensors, and power and instrumentation wires. An air gap 80 separates the rotor shaft assembly 52 from the stator assembly 60 . In operation, the rotor shaft 56 levitates in a magnetic field produced by the stator assembly 60 .
[0021] Given the increasing use of rotor and stator assembly that utilize magnetic bearing systems in corrosive environments, a growing need exists to overcome the above-described deficiencies of current magnetic bearings.
BRIEF DESCRIPTION OF THE INVENTION
[0022] Disclosed herein are corrosion resistant stator assemblies and processes for fabricating the same. In one embodiment, a stator assembly comprises a stator sleeve formed of a magnetic material; a sleeve extender coaxial to the stator sleeve formed of a non-magnetic material fixedly attached to each end of the stator sleeve, wherein a point of attachment is heat treated; and a wall formed of the non-magnetic material fixedly attached to the sleeve extender configured to hermetically house a stator and form the encapsulated stator assembly.
[0023] In another embodiment, the stator assembly comprises a stator sleeve; magnetic stator laminations wrapped in conductive windings in magnetic communication with the sleeve; and a barrier layer formed on the stator sleeve, the magnetic stator laminations, and combinations thereof.
[0024] A process for forming an encapsulated stator assembly comprises welding a stator sleeve extender formed of a non-magnetic material to a stator sleeve formed of a magnetic material and subsequently heat-treating the welded stator sleeve extender and the stator sleeve at a temperature effective to relieve weld stress; attaching stator electromagnetic components to the stator sleeve; and welding a housing formed of the non-magnetic material to the stator sleeve extender, wherein the housing is configured to encapsulate and hermetically seal the stator electromagnetic components.
[0025] The features and advantages of the components and processes disclosed herein may be more readily understood by reference to the following drawings and detailed description, and the examples included therein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The figures below, wherein like elements are numbered alike, are for illustrative purposes.
[0027] FIG. 1 is a prior art schematic of a magnetic bearing system illustrating a magnetic bearing rotor assembly and stator used for example, in an expander-compressor.
[0028] FIG. 2 is a prior art schematic of an encapsulated stator showing the stator can with NACE non-compliant welds, arranged relative to a rotor assembly.
[0029] FIG. 3 is a schematic showing a rotor assembly coated with a polymer barrier layer.
[0030] FIG. 4 is a schematic showing the steps of building a stator can with NACE compliant welds.
[0031] FIG. 5 is a schematic of the roller-element backup bearing disposed relative to a rotor shaft and rotor landing sleeve.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The present disclosure provides rotor and stator assemblies that include magnetic bearings and processes for assembling the magnetic bearings that are suitable for use in corrosive environments. The magnetic bearing assemblies can be made to be fully NACE compliant as may be desired for some applications. For example, NACE compliant rotor shaft assemblies were achieved by coating the magnetic steel rotor shaft and rotor laminations with a barrier film. For magnetic bearing systems employing an encapsulated stator assembly, NACE compliant stator cans were achieved using a combination of magnetic and non-magnetic materials for the encapsulation, that when welded together required heat treatment only in joints between different materials. Similarly, rotor landing sleeves, inner and outer races of backup bearings, as well as power and instrumentation wires can be made NACE compliant by the use of specific materials, which will be described in greater detail below.
[0033] A turboexpander is used as an illustrative example, but the magnetic bearings for corrosive environments disclosed herein are useful in axial bearings and other implementations of magnetic bearings; for example, pumps, compressors, motors, generators, and other turbomachinery.
[0034] FIG. 3 illustrates one embodiment for rendering the rotor assembly of magnetic bearings suitable for use in corrosive environments, such as in sour gas and wet sour gas environments. The rotor shaft assembly 100 includes a rotor shaft 102 , rotor laminations 104 disposed about the shaft, and rotor landing sleeve 108 . A barrier layer 106 is shown disposed on all of the exposed surfaces of the rotor shaft assembly. In an optional embodiment, the barrier layer is formed on selected surfaces of the rotor shaft assembly. For example, the barrier layer could be formed on selected areas of the rotor assembly most prone to corrosion. These include selected areas of the rotor shaft, the rotor laminations, or the punchings used to collectively form the rotor laminations. In one embodiment, the barrier layer is applied to rotors comprising laminations made from iron-silicon (FeSi) that are known to have no or only a low corrosion resistance. NACE compliant alloys such as 17-4 PH stainless steel generally do not require the polymeric surface coating because they are inherently corrosion resistant.
[0035] Optionally, a primer coat can be applied prior to application of the barrier layer. The particular thickness of the primer layer will depend on the type of barrier material selected but in general should be selected to be effective for use in the particular environment in which the magnetic bearing is disposed. It is well within the ordinary skill of those in the art to optimize the thickness of the layer based on the polymer composition and the intended application.
[0036] Suitable materials for forming the barrier layer 106 for protecting the rotor shaft assembly 100 in corrosive environments include, but are not intended to be limited to, various fully (i.e., perfluorinated) and partially fluorinated polymers. Suitable fully fluorinated polymers include polytetrafluoroethylene (PTFE), and perfluoroalkoxy-tetrafluoroethylene copolymer (PFA), fluorinated ethylene-propylene copolymer (FEP) and the like. PFA is a copolymer of tetrafluoroethylene [CF 2 ═CF 2 ] with a perfluoralkyl vinyl ether [F(CF 2 ) n CF 2 OCF═CF 2 ]. The resultant polymer contains the carbon-fluorine backbone chain typical of PTFE with perfluoroalkoxy side chains. One particular form of PFA suitable for the barrier layer is tetrafluoroethylene-perfluoromethylvinylether copolymer (MFA). Partially fluorinated polymers include ethylene-chlorotrifluoroethylene copolymer (ECTFE), ethylene-tetrafluoroethylene copolymer (ETFE) and polyvinylidene fluoride (PVDF).
[0037] Combinations of fluoropolymers sold under the tradenames Xylan™ by Whitford Corporation, and Teflon™ and Teflon-S™ by Dupont are also useful barrier layer materials. Xylan™ coatings comprise in part PTFE, PFA, and FEP. Teflon™ coatings comprise in part PTFE, PFA, FEP, and ETFE fluorocarbon resins. Teflon-S™ is another related family of fluorocarbon coatings containing binding resins, which provide increased hardness and abrasion resistance or other desirable properties.
[0038] Other organic materials useful in forming the barrier layers include powdered epoxies, filled epoxies, filled silicones, and filled PPS (polyphenylene sulfide). Representative thermosetting epoxy powder coatings include, but are not intended to be limited to, Scotchkote™ 134 and Scotchkote™ 6258 from 3M Corporation.
[0039] Scotchkote™ 134 fusion bonded epoxy coating (FBEC) is a one part, heat-curable, thermosetting epoxy coating comprising in part di(4-hydroxyphenol) isopropylidene diglycidyl ether-di(4-hydroxyphenol) isopropylidene copolymer. Scotchkote™ 6258 fusion bonded epoxy coating (FBEC) is a one part, heat-curable, thermosetting epoxy coating comprising in part a mixture of di(4-hydroxyphenol)isopropylidene diglcycidyl ether-di(4-hydroxyphenol)isopropylidene copolymer, and epichlorohydrin-o-cresol-formaldehyde polymer. Scotchkote™ 134 and Scotchkote™ 6258 are applied as a dry powder optionally over a 25.4 micrometer (1 mil) phenolic primer coat and heat cured to a thickness of 254 to 381 micrometers (10 to 15 mil) at a temperature of 150° C. to 250° C. for up to 30 minutes.
[0040] Still other materials useful for forming the barrier layer 106 in FIG. 3 include conversion coatings of oxides, phosphates, and chromates, and more specifically, conversion materials sold under the trade names Sermalon™, Sermaloy™, Sermagard™ and Sermatel™ by Sermatech.
[0041] The Sermalon™ coating system comprises an aluminum-filled chromate/phosphate bond coat, an intermediate high temperature polymeric inhibitive coating, and a PTFE impregnated topcoat. Coating thickness ranges from 100 to 150 micrometers. SermaLoy™ is an intermetallic nickel aluminide with a silicon-enriched outer layer. Sermatel™ is a family of inorganic coatings that bond to metal creating a metal-ceramic composite. Sermagard™ is a water based aluminized coating with ceramic binder.
[0042] Thicknesses of the polymer barrier layer 106 can range from 2 micrometers to 600 micrometers (0.079 mil to 23.6 mil).
[0043] The polymer barrier layer 106 can be applied to the substrate (i.e., on all or selected surfaces of rotor assembly) in the form of a liquid dispersion or a powder, optionally over a primer layer. Liquid dispersions, comprising polymeric material in a water or solvent suspension, can be applied in a spray and bake coating process in which the liquid dispersion is sprayed onto the substrate for subsequent heating above the melting temperature of the polymeric material contained in the dispersion. Known methods of applying polymeric material in powdered form include spraying of the powder onto the substrate using an electrostatic gun, electrostatic fluidized bed, or a flocking gun, for example. In another example, the powder can be sprayed onto a substrate that has been heated above the melt temperature of the polymeric material to form a coating, also referred to as thermal spraying. It is also known to apply coatings in a process known as “rotolining” in which the substrate and powder is heated, in an oven for example, above the melt temperature of the polymeric material while the substrate is rotated to form a seamless coating on the substrate.
[0044] As previously discussed, the barrier layer 106 is applied to at least one exposed selected surface of the rotor shaft assembly 100 , which can include one or more surfaces defined by the rotor laminations 104 , the rotor shaft 102 , the rotor landing sleeve 108 , other rotor assembly surfaces or the fully assembled rotor 100 . The purpose is to encapsulate portions of or the entire rotor assembly in a protective coating that inhibits corrosion, such as may occur upon exposure to sour gas.
[0045] The components of the rotor shaft assembly are typically formed of magnetic steel. In one embodiment, the rotor laminations are made of iron-silicon (FeSi) material and the polymeric barrier coating is disposed thereon.
[0046] In another embodiment, the rotor laminations are clad with a barrier layer comprising a hydrogen resistant nickel based alloy comprising 40-90 wt % (weight percent) nickel based on the total weight of the nickel based alloy. Herein, “X-Y wt %” means “X wt % to Y wt %” where X and Y are numbers. In particular, the hydrogen resistant nickel based alloy is HASTELLOY® C22® from Haynes International, comprising about 56 wt % nickel, about 2.5 wt % cobalt, about 22 wt % chromium, about 13 wt % molybdenum, about 3 wt % tungsten, about 3 wt % iron, about 0.5 wt % manganese, about 0.08 wt % silicon, about 0.35 wt % vanadium and about 0.010 wt % carbon based on total weight of the nickel based alloy.
[0047] In another embodiment, the rotor shaft is formed of a magnetic steel of type 17-4PH stainless steel alloy, a precipitation hardened martensitic stainless steel comprising 10-20 wt % chromium based on total weight of the precipitation hardened martensitic stainless steel, and further comprising copper and niobium additions. More specifically the precipitation hardened martensitic stainless steel comprises about 16.5 wt % chromium, about 4.5 wt % nickel, about 3.3 wt % copper and about 0.3 wt % niobium based on total weight of the precipitation hardened martensitic stainless steel. The use of the magnetic steel permits construction of a rotor shaft assembly having compact dimensions. The polymeric barrier layer or the optional HASTELLOY® C22® coating on the rotor laminations provides for additional resistance to corrosion such as from exposure to sour gas. However, the usage of sour gas resistant alloys such as the type 17-4PH alloy impacts the magnetic properties of the rotor compared to, for example, iron-silicon alloys (FeSi), thus increasing the electromagnetic losses. This poses a significant challenge particularly during ambient air testing of the assembled machine as required by the American Petroleum Institute. Ambient air has significantly lower pressure and therefore lower cooling capacity than a pressurized process gas. In addition, its thermal and transport properties are inferior to many process gases, further reducing its cooling capacity compared to pressurized process gas. One way to compensate for this is to increase the rotor size so as to increase the exposed area, thus reducing the rotor surface heat flux and increasing the cooling capability. However, this reduces the attractiveness of the magnetic bearing in the intended application. If the rotor dimensions are not increased, the resulting rotor could have a rotor surface heat flux in excess of 1 W/cm 2 (6.45 W/in 2 ). If tested in ambient air, this can easily result in excessive heat rise beyond the laminated rotor insulation material capabilities. All of these disadvantages can be avoided by testing the assembled machine in air or other gases (such as Nitrogen) at a pressure elevated enough and/or at temperature lowered enough to maintain an acceptable temperature of the bearing components. The exact combination of needed pressure and temperature is design dependent and requires knowledge of the expected rotor losses at test conditions to be properly selected. Alloys other than the 17-4PH alloy such as PERMALLOY™ of Western Electric Company and MOLY PERMALLOY™ alloy from Allegheny Ludlum Corporation, low-carbon martensitic stainless steels, or similar materials, can also be used to fabricate the rotor laminations. PERMALLOY™ and MOLY PERMALLOY™ comprise about 80 wt % nickel, about 14 wt % iron, about 4.8 wt % molybdenum, about 0.5 wt % manganese, and about 0.3 wt % silicon based on total weight of the alloy. Low carbon martensitic stainless steels comprise about 11.5-17.0 wt % chromium, about 3.5-6.0 wt % nickel, and no more than 0.060 wt % carbon based on total weight of the low carbon martensitic stainless steel.
[0048] In another embodiment, the rotor landing sleeve 108 as shown in FIG. 3 is formed of a cobalt based superalloy steel comprising 40-70 wt % cobalt based on total weight of the cobalt based superalloy steel. The use of cobalt based superalloy steels advantageously makes the rotor landing sleeve NACE compliant. More specifically, suitable cobalt based superalloy steels include, but are not intended to be limited to, cobalt based superalloy steels sold by Haynes International Corp. under the trade names ULTIMET®, comprising about 54 wt % cobalt, about 26 wt % chromium, about 9 wt % nickel, about 5 wt % molybdenum, about 3 wt % iron, about 2 wt % tungsten, about 0.8 wt % manganese, about 0.3 wt % silicon, about 0.8 wt % nitrogen, and about 0.06 wt % carbon based on the total weight of the cobalt based superalloy steel. Other suitable cobalt based superalloy steels include HAYNES™ 6B, comprising about 51 wt % cobalt, about 10 wt % nickel, about 20 wt % chromium, about 15 wt % tungsten, about 3 wt % iron, about 1.5 wt % manganese, about 0.4 wt % silicon, and about 0.10 wt % carbon based on total weight of the cobalt based superalloy steel, and chrome coatings sold by Armoloy Corporation under the trade name Armoloy®. ULTIMET® and HAYNES™ 6B alloys comprise primarily cobalt, chromium, and nickel. These cobalt based superalloys exhibit outstanding tribological characteristics that are necessary to prevent damage to the rotor shaft surface during a magnetic bearing failure when the rotor shaft is dropped onto the roller-element backup bearings, while at the same time meeting corrosion resistance requirements. In addition, there are nickel-cobalt based alloys (such as the MP35N alloy) that can be work hardened and aged to increase their hardness and thus strength and still remain NACE compliant.
[0049] FIG. 5 shows a general schematic of a roller-element backup bearing 200 comprising inner races 208 and outer races 206 relative to rotor shaft 202 and landing sleeve 204 . In another embodiment, the inner and outer races of the roller-element backup bearing are made of a martensitic nitrogen stainless steel comprising 10-20 wt % chromium and 0.1-1.0 wt % nitrogen based on total weight of the martensitic nitrogen stainless steel. Typical compositions are about 0.25 to 0.35 wt % carbon, about 0.35 to 0.45 wt % nitrogen, about 0.5 to 0.6 wt % silicon, about 14.5 to 15.5 wt % chromium, and about 0.95 to 1.05 wt % molybdenum based on the total weight of the composition. These martensitic nitrogen stainless steels are commercially available from the Barden Corporation as Cronidur-30™ or SKF Bearings USA as VC444. These martensitic nitrogen stainless steels are available in hardnesses sufficiently high for the application in roller-element backup bearing races (HRC of higher than 55) and also provide excellent corrosion resistance.
[0050] In yet another embodiment, the various stator components can be protected from corrosive gas environments by applying a barrier material to selected surfaces. These include the stator can surfaces, power and instrumentation wires, stator sensors, and stator sleeve. This is advantageous for non-encapsulated stator assemblies.
[0051] In another embodiment, test methods disclosed herein permit testing a compact magnetic bearing with a rotor surface heat flux in excess of 1 W/cm 2 (6.45 W/in2) in a factory environment prior to installation on site. This entails operating the bearing in the factory in a pressurized atmosphere of air or other inert gas as opposed to methane or natural gas used at an oil production site. The air or the other inert gas is pre-cooled by chillers or heat exchangers, or is optionally a cryogenic fluid that expands to a selected temperature and pressure prior to being supplied to the magnetic bearing. The temperature of the atmosphere ranges from −260° C. to 40° C. The atmosphere is pressurized to at least 2 bar to increase its heat removal capability while maintaining the rotor temperature within engineering limitations.
[0052] As previously discussed, the rotor and stator assembly can include an encapsulated stator assembly, also referred to herein as a stator can. In one embodiment, the stator can is constructed with NACE compliant materials and welds using a combination of magnetic and non-magnetic steel alloys. Magnetic steel alloys are placed in areas of the stator can where the magnetic steel provides an electro-magnetic advantage, e.g., the stator sleeve. Non-magnetic steel (such as Inconel) has better corrosion resistance and does not require post-weld heat treatment and therefore it is placed in areas where magnetic steel properties are not required.
[0053] In one embodiment, the magnetic steel alloy of the encapsulated stator comprises a precipitation hardened martensitic stainless steel comprising 10-20 wt % chromium based on total weight of the precipitation hardened martensitic stainless steel. More specifically, the precipitation hardened martensitic stainless steel comprises about 16.5 wt % chromium, about 4.5 wt % nickel, about 3.3 wt % copper, and about 0.3 wt % niobium based on total weight of the precipitation hardened martensitic stainless steel.
[0054] In one embodiment, the non-magnetic material of the encapsulated stator comprises a nickel based alloy comprising 40-70% nickel based on total weight of the nickel based alloy. More specifically, the nickel based alloy comprises about 58 wt % nickel, about 21.5 wt % chromium, about 9 wt % molybdenum, and about 5 wt % iron based on total weight of the nickel based alloy.
[0055] FIG. 4 schematically illustrates a process for fabricating a NACE compliant stator can. The process 150 includes welding non-magnetic stator sleeve extender portions 152 to a stator sleeve 154 at interface 156 . By forming a composite of the sleeve without any stator components disposed thereon, a NACE compliant weld can be formed by exposing the welded composite to post-weld heat treatment that ensures low hardness (below HRC 33) of the weld area and all heat affected zones. The welds are formed by any welding process in the art that allows post-weld heat treatment such that the weld stresses resulting from the welding of dissimilar materials are relieved and that a hardness of less than HRC 33 is accomplished. Exemplary welding processes include autogenous electron beam and electron-beam with filler, laser weld, TIG weld, MIG weld, arc weld, torch weld and combinations comprising at least one of the foregoing processes. By way of example, the stator sleeve extender sections 152 can comprise a non-magnetic superalloy steel welded to each end of the stator sleeve 154 that comprises a type 17-4PH magnetic steel. More specifically, the non-magnetic superalloy steel can comprise a nickel based alloy comprising 40-70% nickel based on total weight of the nickel based alloy. Even more specifically, the nickel based alloy can comprise Inconel 625® commercially available from Inco Alloys International, comprising about 58 wt % nickel, about 21.5 wt % chromium, and about 9 wt % molybdenum, and about 5 wt % iron. The resulting unit is then heat-treated to form the NACE compliant welds at interface 156 .
[0056] A suitable post-weld heat-treatment process is a double age hardening process as per NACE MR0175 to one of the following heat cycles: 1.) solution anneal at 1040±14° C. and air cool or liquid quench to below 32° C.; followed by a first precipitation-hardening cycle at 620±14° C. for a minimum of 4 hours at temperature and air cool or liquid quench to below 32° C.; and followed by a second precipitation-hardening cycle 620±14° C. for a minimum of 4 hours at temperature and air cool or liquid quench to below 32° C.; or 2.) solution anneal at 1040±14° C. and air cool or liquid quench to below 32° C.; followed by a first precipitation-hardening cycle at 760±14° C. for a minimum of 4 hours at temperature and air cool or liquid quench to below 32° C.; followed by a second precipitation-hardening cycle 620±14° C. for a minimum of 2 hours at temperature and air cool or liquid quench to below 32° C.
[0057] Next, the stator components such as a stator frame 160 comprising magnetic stator laminations 158 wrapped in conductive windings 162 are attached. The remaining stator can sections 164 are then welded at interfaces 166 to complete the stator can. The can sections 164 are formed of the same or similar non-magnetic steel previously used, such as the Inconel™ 625 superalloy steel noted above. Because similar materials are welded, the welds at the interfaces 166 are NACE compliant and do not need a post-weld heat treatment. Thus, a NACE compliant encapsulated stator can be assembled without subjecting the internal stator electric components to damaging levels of heat.
[0058] Next, the power and instrumentation wires are attached to the stator components. To provide maximum corrosion protection, the external power and instrumentation wires can be made NACE compliant, wherein the wires comprise a wire sleeve comprising a non-magnetic corrosion-resistant alloy surrounding an electrically conductive material. An example of such a NACE compliant wire is the use of NACE compliant materials such as Inconel alloys as a wire sleeve material. The wire sleeve encapsulates the electrical conductor which is insulated with, for example, ceramics such as magnesium oxide (MgO) which provide excellent electric insulation under pressurized conditions
[0059] The following examples fall within the scope of, and serve to exemplify, the more generally described methods set forth above. The examples are presented for illustrative purposes only, and are not intended to limit the scope of the invention.
Example 1
[0060] In this example, individual metal samples were powder coated with Scotchkote™ 6258 thermosetting epoxy as a barrier coating, and heat cured to a thickness of 300 micrometers and 327 micrometers. The part was preheated to a temperature of 150° C. to 246° C. before applying the powder. The powder was then cured at 177° C. for 30 minutes. These samples were tested in autoclaves with process gas to determine the suitability of the coatings in sour gas environment. A series of tests were performed in which the level of hydrogen sulfide in natural gas was varied from 6,000 parts per million (ppm) to 20,000 ppm and the level of moisture was varied from 50 ppm water to saturation. The samples were also exposed to varying temperatures from 30° C. to 130° C.
[0061] No evidence of corrosion was observed in the samples that were exposed to hydrogen sulfide, and water at temperatures below 79° C.
Example 2
[0062] In this example, small scale rotors (order of magnitude of 2 to 3 inch outer diameter) were powder coated with Scotchkote™ 134. The rotors were preheated to a temperature of 150° C. to 246° C. before the powder was applied. The powder was then cured at 177° C. for 30 minutes to a thickness of 300 micrometers to 327 micrometers. These samples were also tested in autoclaves with process gas to determine the suitability of the coatings in sour gas environment.
[0063] The samples showed no evidence of corrosion when exposed to high levels of hydrogen sulfide (6000 to 20,000 ppm), water (50 parts per million (ppm) to saturation) and 80° C.
Example 3
[0064] In this example, two full-size production rotors were coated with Sermalon™ at a thickness of 178 micrometers to 406 micrometers (7 mil to 16 mil). They were tested in the field under production conditions and passed. These production rotors were installed at site and the coating withstood the corrosive operating gas environment for in excess of 2,000 hours and prevented sour gas attack of the underlying metal components. The samples showed no evidence of corrosion.
Example 4
[0065] In this example, NACE environmental tests were performed on samples of Cronidur 30 representative of backup bearing races. The material passed standard 720 hr proof ring tests per NACE TM0177 Solution A at stress levels representative of backup bearing races without signs of corrosion.
Example 5
[0066] In this example, NACE environmental tests were performed on samples of Haynes 6-B representative of backup bearing landing sleeves. The material passed standard 720 hour proof ring tests per NACE TM0177 Solution A at stress levels representative of backup bearing landing sleeves without signs of corrosion.
Example 6
[0067] In this example, NACE environmental tests were performed on weld samples of Inconel 625 and 17-4 PH representative of the stator can welds. The material passed standard 720 hour proof ring tests per NACE TM0177 modified Solution A at stress levels representative of stator cans without signs of corrosion in the weld.
[0068] The combination of the various embodiments described above provide for a magnetic bearing having superior resistance to corrosive elements such as may be encountered in a sour gas environment.
[0069] The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. The endpoints of all ranges directed to the same characteristic or component are independently combinable and inclusive of the recited endpoint.
[0070] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. | Rotor and stator assemblies that utilize magnetic bearings for supporting the rotor shaft during operation can be suitably used in corrosive environments, such as sour gas. The rotor and stator assemblies include NACE compliant magnetic bearing arrangements for sour gas applications. One embodiment includes a stator assembly that comprises a stator sleeve formed of a magnetic material, a sleeve extender coaxial to the stator sleeve formed of a non-magnetic material fixedly attached to each end of the stator sleeve, wherein a point of attachment is heat treated, and a wall formed of the non-magnetic material fixedly attached to the sleeve extender configured to hermetically house a stator and form the encapsulated stator assembly. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/696,981, filed Jan. 29, 2010, which is a continuation of U.S. patent application Ser. No. 11/877,584, filed Oct. 23, 2007, which is a continuation of U.S. patent application Ser. No. 10/437,867, filed May 15, 2003, now U.S. Pat. No. 7,285,049, issued Oct. 23, 2007, which claims the benefit of U.S. Provisional Application No. 60/381,476, filed May 17, 2002, which are herein incorporated by reference in their entirety. This application is also related to co-pending U.S. patent application Ser. No. 12/696,945 concurrently filed on Jan. 29, 2010, entitled UNIVERSAL OVERLAY GAMES IN AN ELECTRONIC GAMING ENVIRONMENT, which is hereby incorporated by reference.
COPYRIGHT NOTICE
[0002] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent files or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
[0003] This invention pertains generally to networked gaming devices and networked gaming systems. More particularly, the invention is a system and method for dynamically downloading “overlay” games that can be played on a variety of gaming machine devices from a central server.
BACKGROUND
[0004] Gaming devices of various types are well known in the casino and gaming industry. In general, gaming devices such as slot machines, video poker machines, video keno machines, video lottery games, among others, allow users to play a game of chance or a lottery game in exchange for a wager. Depending on the outcome of the game, the player may be entitled to a prize, monetary or otherwise, which is paid to the player.
[0005] In some cases, a gaming device may provide a plurality of games for play by the player from a single machine. For example, certain video poker machines may provide various versions of video poker. In such cases, the player may select and play a game of choice from a menu of games. Game play is then carried out in accordance with the selected game. This arrangement provides the added advantage of providing play of more than one “base” or primary game from a single gaming device thereby providing the player with a more diverse gaming experience and encouraging more game play. Typically, the programming for these games is provided on a memory residing within the gaming device. Upon selection of a game by the player, the associated programming is loaded and executed by a processor of the gaming device.
[0006] Another arrangement which provides the selection and play of multiple base games from a single gaming device utilizes a centralized server which is networked to one or more of the gaming devices. In this arrangement, the programming for the games is stored on the central server rather than residing locally on the gaming device. Upon selection of a game by the player on a gaming device, the selected game is distributed from the central server to the gaming device for execution thereon. Game play is then carried out in accordance with the selected game on the gaming device. This arrangement provides the added advantage that the library of games available for play may be provided centrally from a server, rather than locally on the gaming device. Accordingly, a larger library of games may be practically provided from a central storage source (the server) due to cost considerations.
[0007] While the prior art systems and methods provide more diverse game play of gaming devices by providing selection and play from a plurality of base games from a single device, several disadvantages are presented. First, marketing considerations prevent providing diversity of base games on the gaming devices because the artwork and presentation of a gaming device which is closely tied to the “theme” of the gaming device cannot be dynamically changed in response to the game selected by the player. Thus, it would be inappropriate to provide artwork to a slot machine game on a gaming device which provides play of video poker, for example. Such marketing would create confusion and thus frustration in the players of gaming devices. Second, controls for underlying base games are generally specific to each game. Thus, controls for a slot machine game would generally not be appropriate for controls for a video poker game or a video keno game, for example. Third, many base games incorporate bonus or secondary features requiring either specific mechanical controls and/or displays (e.g., a secondary bonus wheel, or a secondary board game). Furthermore, these secondary features tend to vary from game to game. Thus, while it may be possible to incorporate a base feature across multiple devices, it often becomes impractical or impossible to incorporate the associated bonus features of a based game across multiple devices.
[0008] Accordingly, there is a need for a system and method which provides for the dynamic distribution of overlay games to gaming devices from a central server, where the overlay game may be independent from the base game. The described embodiments satisfy these needs, as well as others, and generally overcome the deficiencies found in the background art.
SUMMARY
[0009] Persons of ordinary skill in the art will realize that the following description of the embodiments is illustrative only and not in any way limiting. Other embodiments of the invention will readily suggest themselves to such skilled persons having the benefit of this disclosure.
[0010] In general terms, one embodiment is a system and method for dynamically distributing and downloading “overlay games” to gaming devices which are networked to a central server. Unlike prior art games for gaming machines, the overlay game is generally independent from the base game or its associated secondary or bonus features. The overlay game is also gaming device independent, and thus does not require complex mechanical displays or controls. Instead, the overlay game may be played using the display and controls of the underlying base game (including, for one preferred embodiment, no player controls).
[0011] A gaming system in accordance with one embodiment will have a set of gaming machines (gaming devices) that have an additional software module therein that enables the gaming machine to (i) request an overlay game, (ii) receive the executable code or executable image of an overlay game from a server, (iii) temporarily store the image or code until the primary game ends (the current game cycle ends) so as to not interfere with any on-going primary game, (iv) start the overlay game, (v) let the overlay game finish, and then (vi) erase the overlay game and/or reload the primary game and/or restart the primary game (by providing a starting execution address to the CPU or some similar action, as required by the specific installation and configuration of the gaming machine and the overlay game). As will be clear to a person having skill in the art and with the benefit of the present disclosure, the exact procedure used by an engineer to get the overlay game ready to execute after it is downloaded, and then to restart or reinitialize the primary game after the overlay game is finished, will depend on the architecture of each particular gaming machine. The exact procedures will be incorporated into the overlay game module, which will be specific to each gaming machine.
[0012] Note that it is currently expected that the image or code that was in the overlay game will be erased, overwritten, or otherwise be made unusable upon restart of the primary game in most gaming machines, as few will have the storage space needed to keep an overlay image on-board. However, in the future as memory and storage costs continue to drop, it may be possible to keep one of more overlay games locally as well as downloading them when an overlay game trigger occurs.
[0013] The overlay games are intentionally different than the primary games or secondary games in gaming machines. First, they are intended to be universal; that is, they are intended to be viewed by a player on any gaming machine having a video display. Thus, the symbols or visual sequences must have universally understandable meanings. There can be no “learning curve,” as is the case with primary games. Second, the interactions with players are intentionally limited. To be able to use it universally (i.e., on as many gaming machines as possible in any particular casino), it must be the case that the overlay game has (i) no player interactions (shows a visual sequence and awards any winnings without the player touching any player input) or (ii) limited player input. Limited player input means a simple button touch to start an overlay game, or something similar; no complex options, no settings, and no preferences as are found in primary games.
[0014] The purpose of the overlay game is to add additional novelty to the gaming floor by having universal entertaining visual (and audio) sequences shown to the player upon either a winning event or an overlay game trigger event (in the later case, the win may be predetermined or not). This is always in addition to a primary game; the overlay game cannot replace a primary or secondary game as a main game; it doesn't have the required complexity to act as the regular player game. For example, not only do overlay games not have the normal player input choices, the overlay game will not have a complete pay table of its own. It is expected that one preferred embodiment of overlay games will have no paytables at all. The overlay game will be used as an entertaining way to present a known outcome (with all calculations and the like, done in the primary game or on a backend system using the overlay game as an additional source of player winnings over and above the primary game), or, the overlay game will use a single random event to determine a single winning amount. In the first case, the overlay game will have no capability to generate any winning event; it acts as a display mechanism for a known result. In the second case, the overlay game may have straightforward, simple mappings from a random event to a limited number of specific winning amounts; no primary-game-style full paytable is required. Thus, overlay games will have code devoted primarily to show an entertaining visual display to a player; there will be little, if any, code for calculating winnings nor will there be code for all the other control mechanisms required in the primary game.
BRIEF DESCRIPTION OF THE DRAWING
[0015] FIG. 1 is a block diagram of a system in accordance with one embodiment.
[0016] FIG. 2 is a block diagram of a gaming machine in accordance with one embodiment.
[0017] FIG. 3 is a flow diagram illustrating overlay game usage during game play.
DETAILED DESCRIPTION
[0018] FIG. 1 illustrates a functional block diagram of an example system 10 arrangement suitable for use with the one embodiment. System 10 comprises a main central server 12 which distributes the overlay games in accordance with one embodiment to a plurality of gaming devices 16 through a network connection (wired or wireless, electronic or photonic). As shown in FIG. 1 , groups of gaming devices 16 may be first networked to a local central server 14 , each of which are then networked to the main central server 12 . As would readily be apparent to one skilled in the art having the benefit of this disclosure, the local central servers 14 may carry out the operations of the main central server 12 at a local level, such as local distribution of overlay games. Thus, network 18 may identify a wide area network connection, whereas networks 20 identify local area networks at individual gaming sites. In the alternative, the entire system 10 may be provided in a single gaming site, where the local networks 20 identify certain sections (e.g., banks of machines) within the site.
[0019] The gaming devices 16 comprise hardware and software for carrying out one or more base games 22 , such as slot games, video poker games, video keno games, bingo games, video lottery games, or any other game where the game's outcome is based at least partially on chance. Additionally, each gaming device 16 further comprises an overlay game module 24 for carrying out the overlay game 26 distributed by the central server for play on the gaming device 16 . The overlay module 24 may be incorporated as part of the base game 22 or may be a separately executed module by the gaming device 16 .
[0020] Each gaming device 16 further comprises artwork and other presentation features associated with the particular base game 22 implemented thereon. Gaming device 16 further comprises bonus or secondary features associated with the particular base game 22 . Overlay games 26 are designed to be suitable for use with any gaming device 16 which executes the overlay module 24 thereon.
[0021] FIG. 2 shows more details of a gaming device (“gaming device,” “game device,” “game machine,” and “gaming machine” are used interchangeably in this disclosure) configured for use with one embodiment. Game device 200 may be any type of electronic gaming machine having at least one video display 202 , a SMIB (Slot Machine Interface Board) 216 , a serial-protocol-based communications means 218 connected to a floor game controller 220 (this would be primarily used with legacy gaming machines), or the floor game controller 220 also having other serial ports 214 . Game machine 200 also has one or more player-usable input devices shown generally as 204 (could be an RFID reader, smart card dock, memory card dock, traditional player card reader, bill and/or coin acceptors, a small touch-screen panel for programmable player buttons and custom messages, or a voucher printer/reader 206 ). Also shown are typical player buttons 208 .
[0022] As will be understood by a person having knowledge in this art, there will also be internal electronic/photonic controls associated with I/O devices 204 and 206 , and player game I/O devices 208 . These will be operably connected to a main game board having a CPU, memory, and programming to run the primary game (and a secondary or bonus game, if there is one) in the game cabinet or game box. The primary and secondary games will be consistent with the game box artwork including all the glass, top box (if there is one), and displays. Internals, other than overlay module 210 , are not shown.
[0023] Shown are two currently available network connections to overlay module 210 . The first, through SMIB 216 , was described above. This would be the connection used with legacy games. Connection 212 is an ethernet connection usable by the game overlay module 210 . Ethernet connection 212 is shown as connected to floor game controller 220 , which acts as a hub for connection to back-end ethernet 222 . Please note that floor game controller 220 is only needed when legacy gaming machines are used; new installations can do away with floor controller 220 , and the overlay game distribution manager 224 shown in floor controller 220 would reside entirely on a back-end server used to distribute overlay games (back-end or main server not shown), connected through an ethernet (SMIB 216 would not be used in such a case).
[0024] Whatever network connection is used, overlay module 210 is a software package that interfaces the overlay game into the gaming machine. This includes the halting of the primary game (always at a play boundary, i.e., between game plays or at the end of a game cycle), receiving the overlay game executable code, placing the image/code in memory, starting the overlay game (pointing to the right place in memory), and upon completion and restoration of the primary game.
[0025] In one preferred embodiment, the game device will include a player interface having a high-resolution touchscreen, approximately 6″ square, in a bezel fitted into the portion of the cabinet below the bolster area (below where the play buttons are found), slanted up at the player at an angle to allow for easy reading and touching (ranging from approximately 25-45 degrees from vertical). The touchscreen would be usable by the primary game and the overlay game, allowing for distinct player input labels for each game.
[0026] Returning to FIG. 1 , overlay game 26 is a new or added layer of promotional play on the gaming device 16 . The overlay game 26 is played by the player using the display, controls and other I/O devices of the based game 22 , and is distributed for play on the gaming device 16 through the network connections 18 , 20 by the central servers 12 , 14 . This arrangement allows new or modified overlay games 26 to be operated and loaded centrally and distributed centrally without affecting the integrity or operation of the base game.
[0027] Game play of the overlay game 26 may be triggered or initiated in various ways in accordance with the invention. For example, game play may be initiated pursuant to activity at a gaming device 16 (e.g., triggered by a game event on the base game or its associated secondary game, triggered after a preset number of plays, triggered after a preset number of plays within a time period, and the like). In other embodiments, play for the overlay game 26 may be centrally determined from predefined criteria (e.g., time of day, size of prize fund). In yet other embodiments, the overlay game 26 may be triggered by the status or identity of the player (e.g., via a player tracking identification means). As would be readily apparent to one skilled in the art having the benefit of this disclosure, various other triggering events may be used, such as any combination of the above, to trigger the play of the overlay game.
[0028] The prize of the overlay game 26 may be funded in various ways as well. One way to fund the overlay game prize is to allocate a certain percentage of wagers placed at the gaming devices 16 . In other embodiments, the prize may be funded by a separate wager for a specific overlay game 26 in response to a prompt from the central servers 12 , 14 to participate in the play of overlay game 26 . The overlay game prize could also be funded from other casino sources such as a marketing promotion. Under this arrangement, the prizes may comprise cash, merchandise, or other services, changeable centrally per overlay game 26 . Limited availability prizes or merchandise may be made available to select groups of players (e.g., players having high levels of player points as tracked by a player tracking system).
[0029] An important advantage to one embodiment is the ability to easily modify the overlay game 26 including its triggering events as well as its funding method as determined by the casino operator. Prior art implementations were strictly limited by the gaming arrangement of the base game 22 . Another important advantage is the ability to utilize existing game terminal display, controls, printers, bill validators, coin acceptors, and coin payout hoppers for operation of the overlay games. The overlay game 26 is simply communicated from the central server to the gaming device 16 for execution by the overlay module 24 . The overlay module 24 provides an interface to existing I/O devices for play of the overlay game 26 thereon. The system arrangement 10 allows the central servers 12 , 14 to automatically transfer funds to and from the gaming devices 16 in response to overlay game awards, as well as overlay game wagers placed by the players.
[0030] The outcome of the overlay game 26 may be determined by the local gaming device 16 or may be determined locally by the central servers 14 , 12 . In either case, the presentation of the game is provided directly on the gaming device 16 using existing I/O devices by the overlay module 24 . According to one embodiment, the display of the overlay game 26 may utilize the entire real estate of the gaming device display. In other embodiments, the display of the overlay game 26 may be presented in a smaller window (e.g., picture-in-picture mode) on the gaming device display.
[0031] One embodiment of an overlay game 26 may enable entry into a centralized multi-player “bonus” feature independent from the base game, which may or may not require additional payment. For example, one of fifty currently-participating players may win a $1000 prize depending on the result of the overlay game. The winner may be determined by the central server 12 by randomly selecting one of the eligible players, for example.
[0032] According to another embodiment, eligible players are notified that they have been entered into a centralized lottery drawing to win a prize to be drawn at a predetermined time. The player remains eligible so long as the player remains actively playing the gaming device 16 .
[0033] According to yet other embodiments of the invention, players may be grouped into teams to allow for competition among groups of players in a team format. The state of the overlay game may be preserved by the central servers 12 , 14 and later restored either at the same or different gaming device 16 . For example, the player's state may be preserved based on the players ID information (e.g., player tracking ID, customer ID). Alternatively, the player's state may be preserved through the use of printed vouchers or other tangible media (e.g., magnetic or smart cards) bearing unique identification information.
[0034] FIG. 3 shows an example of game play according to one embodiment. Box 300 corresponds to a player going into a casino (or a bingo hall, keno hall, and the like) and starting game play at any electronic game machine. Game play will continue as “normal,” where normal is the game play associated with the primary and secondary game (if any) installed on the game machine. Box 300 is left for box 302 , which corresponds to the occurrence of a trigger event.
[0035] As discussed above, a triggering event may be an event that occurs in the primary game (a particular bonus or win event causes the overlay game to be called), or the trigger may be an external one (from a random selection of time or place, to a reward for a certain number of plays, to any other criteria the casino chooses to use). One embodiment fully contemplates internal, external, or combinations of events usable to trigger the overlay game. In each case, the actions correspond to the overlay game software in the game device being invoked and action continuing into box 304 .
[0036] The actions corresponding to box 304 are those needed to start the overlay game. It is expected that most embodiments will have an introductory screen to alert the player that they have been chosen (alternatively, that they won) a special game play with a special game. In one embodiment players will be shown a graphic illustrating the game and their interactions with the game (if any—not a requirement for this invention). In other embodiments, especially those where the overlay game has no player interactions and is designed to be shown very quickly, there will be no introductory visual sequence. The game will be shown; any awards won credited to the player, and are over in a few minutes. In such cases, there is no need for an introductory sequence.
[0037] The overlay game itself will be requested and received by the overlay game module in the gaming machine. It is also possible to configure the system such that the overlay game download begins at the instigation of the server and the overlay game module in the gaming machine receives the overlay game code. In either case, the overlay game module will wait until any current primary game cycle is over and will then load and start the overlay game.
[0038] When describing the overlay games and their visual sequences to a player, it is to be understood that the overlay game may make use of other output devices as well, such as speakers for added dramatic effect. Overlay games must have visual output (video out) in order to work. Audio and other output is preferable but not required.
[0039] Box 304 is left for box 306 . The first action is to start the overlay game. Since the overlay games must work with all game machines on a casino floor, they will be designed to require either no player input or limited player input. In the case of no player input, it will be a display-only game showing a gaming sequence on the screen to the player with no player interaction; the results will be a winning or non-winning event. In the case of some player input, the overlay game is designed to require player input that can be made visually distinguishable to a player using a simple blinking buttons approach. The “blinking buttons approach” includes, but is not limited to, having one of more of the primary game buttons blink or otherwise be visually distinguishable to a player from the other buttons (could turn off the backlights in all buttons except one, for example, instead of blinking), because the overlay game cannot assume anything about the button's physical labels. It is expected that the preferred embodiment of the overlay games will be to make use of the “play” or “start” button, as almost every game machine in a casino has a version of this button. The screen will make it obvious to the player that to start an action (some kind of action sequence on the game display, which will result in a game outcome); the player must touch the blinking (or otherwise distinguishable) button. If there is a touchscreen display, the player will be shown customized areas to touch on the touch screen.
[0040] In any event, the player will initiate game play if applicable. Box 306 is left for box 308 . Box 308 corresponds to the overlay game being “run” or “played,” which means a visual sequence is shown on the gaming machine's video display. Game play, for the overlay games, is intentionally simple and fast. The visual sequence shown to a player will end in a result that has already been determined before the visual sequence is shown to the player, or, a visual sequence in conjunction with a randomly-generated result to determine a winning (or non-winning) game play result. The overlay game visual sequence will be different from the primary or secondary game, and in most cases will not be themed like the primary game (because the overlay game can be shown on any gaming machine in the casino). “Themed” gaming machines include all the artwork on the cabinet, glass, and symbols shown to a player playing the primary game will have a theme, such as those using popular TV programs, those emphasizing a number or combination and named something like “Lucky 7s”, and other themes such as pirates, ancient Egypt, a denomination such as Penny Pigout™, and the like. In each case, the artwork matches the theme of the game and its name.
[0041] An example of an overlay game visual sequence would be a screen shot of two dice; upon touching the “start” button, the dice are visually shown as rolling around until they stop, resulting in a payout or no payout. Another example would be a dart board with the tip of a dart in the foreground. The dart tip would be shown slowly traversing back and forth across a small area, visually appearing to traverse a target. The player would touch the “start” button when they think they are most likely to hit a high score on the dart board. The visual image then shows the dart projected forward in flight and hitting the target for a win or a no-win. Note that it is not necessary for the player to be using actual skill; where the dart lands on the target may be entirely determined by a random number draw.
[0042] Alternatively, the player's action could be programmed to partially affect the dart's path, such that an obviously off-target “start” results in a no-win for that throw and where a possible target hit is still determined by a random event. Whatever implementation is used (all are possible, including the use of a pre-determined outcome), the player uses the indicated input, the game's visual sequence is displayed, and any winning is credited to the player. Box 308 is left for box 310 .
[0043] The actions corresponding to box 310 are those associated with finishing the overlay game visual sequence, pulling into memory the primary game (if needed), and re-initializing the primary game and gaming machine to restart and run the primary game.
[0044] The invention further relates to machine-readable media on which are stored embodiments of the present invention. It is contemplated that any media suitable for retrieving instructions is within the scope of the embodiments. By way of example, such media may take the form of magnetic, optical, or semiconductor media. The invention also relates to data structures that contain embodiments of the present invention and to the transmission of data structures containing embodiments of the present invention.
[0045] Although the description above contains much specificity, these should not be construed as limiting the scope of the invention but as merely providing an illustration of the presently preferred embodiment of the invention.
[0046] One of ordinary skill in the art will appreciate that not all of the above-described system and/or methods have all these components and may have other components in addition to, or in lieu of, those components mentioned here. Furthermore, while these components are viewed and described separately, various components may be integrated into a single unit in some embodiments.
[0047] The various embodiments described above are provided by way of illustration only and should not be construed to limit the claimed invention. Those skilled in the art will readily recognize various modifications and changes that may be made to the claimed invention without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of the claimed invention, which is set forth in the following claims. | A method is disclosed herein for displaying winning and non-winning game results in a traditional gaming environment. The system uses an overlay game to present an entertaining display to a player upon the occurrence of a win or trigger event. An overlay game has limited capabilities and additionally is engineered to be usable on a variety of gaming machines. To be usable on a variety of gaming machines, the overlay game is intentionally kept simple; in one case, it comprises a visual display that is shown to a player upon the occurrence of a trigger event. In another embodiment, it requires a simple button press to start the overlay game. The overlay games are downloaded on an as-needed basis, run on the gaming machine, and then discarded. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. P 44 34 684.0 filed Sept. 28, 1994, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a method for controlling the movement of an armature forming part of an electromagnetic circuit which has at least one armature holding magnet and at least one armature resetting means.
Electromagnetic circuits of the above outlined type are used, for example, for controlling the intake and/or outlet valves in internal combustion engines to achieve an adaptable control for the intake and exhaust gases so that the combustion process may be optimally influenced in accordance with momentary requirements. The course of the control has a significant effect on the various parameters, for example, the condition of the working medium in the intake zone, in the work chamber and in the exhaust zone, the operating frequency and the occurrences in the work chamber itself. Since internal combustion engines operate in a varying manner under widely changing operational conditions, a variable positive control of the valves is of advantage. Such an electromagnetic circuit for internal combustion engine valves is described, for example, in German Patent No. 3,024,109.
A significant problem in the control of the above outlined electromagnet circuits, particularly when used for controlling the setting members in an internal combustion engine, such as the intake and exhaust valves, resides in the accuracy of timing required particularly for the intake valves in the control of engine output. An accurate time control is rendered difficult by manufacturing tolerances, by wear appearing during operation and by the various operational conditions, for example the changing operating frequencies for the reason that these external parameters may effect time-relevant parameters of the system.
A significant problem in the above-outlined electromagnet circuit arrangements is the appearance of the sticking (adhering) of the armature to the holding magnet. Such a sticking is caused essentially by eddy currents in the magnetic circuit. The sticking time (duration of adherence) depends from a number of different parameters such as the size of the air gap, the force of the resetting means (mechanical springs, as a rule) and the gas counter pressure in case of gas control valves. In addition to the unavoidable manufacturing tolerances, in electromagnetically operated engine valves the gas counter pressures which vary during operation cause irregular fluctuations in the duration of adherence so that, as a result, after deenergizing the holding current, the starting moment of the armature motion varies in a non-predeterminable manner.
Since it is possible, to a large degree of reliability, to determine the moment of armature arrival (impact) in a system having two holding magnets each defining terminal position of the armature, it has been attempted to determine the actual moment of separation by an empirical computation process, based on the moment of impact, as disclosed in published European Patent Application 0 264 706. Such a method, however, is not sufficiently reliable under certain accuracy requirements.
Further, for improving such electromagnetic circuits for operating engine valves, it has been proposed to improve the timing accuracy by increasing the bias of the return means acting in the opening direction, and also, to provide measures for varying the magnetic resistance in the magnetic circuit, as disclosed in published European Patent Application 0 405 189.
SUMMARY OF THE INVENTION
Since neither the mechanical solution disclosed in published European Patent Application 0 405 189 nor the computation methods described in published European Application 0 264 706 meet the accuracy requirements, it is an object of the invention to improve the control of the armature movement for electromagnetic circuits of the above outlined type by means of recognizing the beginning of the armature movement.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the method of controlling movements of an armature in an electromagnetic circuit which includes at least one holding solenoid applying magnetic forces to the armature and at least one resetting arrangement for applying a resetting force to the armature, includes the following cyclical steps: switching on a holding current to flow through the solenoid for holding the armature at the solenoid; after a predetermined period, switching off the holding current for causing the armature to begin a motion away from the solenoid; after switch-off of the holding current detecting, across the solenoid, a voltage change caused by the displacement of the armature for recognizing a starting moment of armature motion from the solenoid; and deriving a control signal from signals representing the voltage change ascertained in the course of the detecting step.
The above outlined method according to the invention represents a significant improvement as compared to a method which is based on the recognition of the arrival of the armature at the oppositely located holding magnet and calculates backwardly from that moment, because already the very beginning of the armature motion may be recognized in any given engine cycle. The method according to the invention is based on the recognition that after the decay of the energy in the solenoid, the current flow drops to zero therein. It has been unexpectedly found, however, that after stopping the current, a certain voltage can still be measured across the solenoid. This may be explained by the residual eddy currents in the magnet material, which cause an exponentially decreasing magnetic flux which, in turn, generates a voltage proportionate to the flux change. Also, dependent on the magnet material, a residual field strength is established. If now the armature is set in motion, a significant change occurs in the magnetic circuit by virtue of the fact that the air gap abruptly increases compared to the residual air gap. Such an air gap change results in a change of the magnetic flux which, in turn causes an induced voltage. By sensing such a voltage change, particularly the changes in the voltage course, the beginning of the armature motion may be recognized. It is of advantage to abruptly switch off the holding current to initiate the armature motion. This means that no recovery current is permitted which is ensured by disabling the recovery diode parallel to the solenoid and also, the voltage stability of the final stage transistors for the circuit have to be chosen to be very high to ensure that the current flow decays very rapidly in the solenoid. By virtue of the above outlined measures it is possible to maintain as short as possible the duration of armature adherence between the moment of the deenergization of the holding current and the beginning of the armature motion (to be recognized by the method according to the invention).
According to an advantageous feature of the invention at least one extreme value is detected from the voltage changes caused by the armature motion. The changes appearing in the voltage course may be evaluated in different ways since the voltage, because of the decreasing magnetic flux and thus also because of the exponentially decreasing change of the magnetic flux change first drops to a minimum value. Thereafter, because of the armature motion, a stronger magnetic flux change occurs, so that the voltage again increases. Such a passage through a voltage minimum may be detected without difficulty and results in a very good indication as concerns the actual start of the armature movement. Particularly in the presence of an intentionally provided residual magnetic clearance, by virtue of which the control of the duration of magnet adherence is per se reduced, such a method may be utilized for a very accurate determination of the starting moment of the armature movement. In applications which have greater fluctuations of the duration of adherence, the phenomenon is utilized, according to which the voltage generated by the magnetic flux change caused by the armature motion, again rises to a maximum value after passing through a minimum, before it drops entirely to a zero value. In such applications for determining the beginning of the armature motion the maximum voltage value may be determined after the renewed increase of the voltage, because the total level of the residual magnetic flux depends from the order of magnitude of the duration of adherence which negatively influences the time relationship between the recognition of the voltage minimum and the beginning of the armature motion.
According to a further advantageous feature of the invention, in case of two holding magnets defining the respective opposite terminal positions of the armature, the moment of switching on the current for the respective non-holding solenoid is determined as a function of the recognition of the armature movement at the opposite holding magnet. With the aid of the substantially accurate recognition of the beginning of the armature movement made possible by the method according to the invention, for example the moment of switching on the catching current for the other holding magnet may be adapted accurately to the beginning of the armature motion. In this manner a significant energy saving may be achieved. It is to be noted that in case the catching current is switched on too late, the armature could not be reliably captured. Thus, normally, because of operational safety, the catching current must be switched on prematurely. Such a premature establishment of the catching current, however, has the disadvantage that the moving armature is given an excessive kinetic energy which may lead to a chatter or even to a rebounding of the armature from the pole face. In order to prevent a malfunctioning of the system because of a chatter or a rebounding of the armature, the catching current has to remain switched on for a relatively long period after the arrival of the armature. If, on the other hand, the exact moment of the beginning of the armature motion is known, the time period until the switch-on of the catching current as well as the time period until the switchover of the catching current to the holding current may be controlled in a substantially accurate manner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating the current intensity/time function of the solenoid currents as well as the displacement/time function of an armature motion of a gas control valve actuated by an electromagnetic circuit.
FIG. 2 is a diagram illustrating the voltage and the armature movement as a function of time immediately after deenergization.
FIG. 3 is an enlarged diagram illustrating the armature motion at the moment of motion start and the course of the associated voltage.
FIG. 4 is an evaluating circuit for detecting the voltage minimum and the voltage maximum.
FIG. 5 is a diagram illustrating the course of the individual signals at the circuit elements of the circuit illustrated in FIG. 4.
FIG. 6 is a variant of the circuit shown in FIG. 4.
FIG. 7 is a diagram illustrating an electromagnetic circuit including two holding magnets according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 schematically shows an electromagnetically operated gas control valve of conventional structure used in an internal combustion engine. The valve is illustrated in two operational states A and B, showing the valve in its closed and open position, respectively. The valve is essentially formed of a valve body 1 rigidly coupled with an armature 2 which is connected on either side to springs 3 and 4 which serve as resetting means. The armature 2 is further associated with two holding magnets (solenoids) 5 and 6. The holding magnet 5, in the energized state of its solenoid holds the valve 1 in its closed position via the armature 2 as illustrated in state A. When the holding magnet 5 is deenergized and the holding magnet 6 is energized, the armature 2 is moved towards the holding magnet 6 by the force of the biased spring 4 and the increasing magnetic field of the holding magnet 6, so that the valve body 1 is guided into its open position as illustrated in state B.
In an internal combustion engine at least one intake valve and an exhaust valve are provided for each piston so that the gas control valve serving as the gas inlet valve or the gas exhaust valve is operated in the above outlined manner in a cycle determined by the piston motion. In FIG. 1, underneath the closed and opened states A and B of the valve the course of the respective coil current is shown along the associated time axis. In the closed position (state A) the holding magnet 5 is exposed to the holding current 5i, so that the valve body 1 is held against its valve seat. To move the valve body into its open position, the holding current 5i is interrupted. As determined by the force of the biased spring 4, the armature, together with the valve body 1, starts its motion after a certain duration of adherence (sticking period) T1. After lapse of a certain time period T2 following the beginning of the armature motion, a catching current 6i is applied to the holding magnet 6 which serves the purpose of pulling the armature 2 which moves towards the holding magnet 6, into its lower end position until the open state B is reached. As soon as the armature 2 lies against the pole face of the holding magnet 6, the chatter events are terminated, and thus the catching current 6i may be reduced to a smaller level, corresponding to the level of the holding current. This event occurs at the end of period T3 running from the moment of deenergization. During this occurrence the holding current, as illustrated by the current curve, is cycled between a lower and an upper level in order to reduce current consumption. If the valve is to be closed again, the holding current flowing through the solenoid of the holding magnet 6 is interrupted, so that the above described motion sequence occurs in a reverse order, that is, the valve, after a renewed duration of adherence, again starts moving and is, in a corresponding manner, caught by the upper holding magnet 5 and is again, after lowering the catching current, held in the closed position by the holding current 5i. The motion of the armature 2, together with the valve body 1 is illustrated underneath the two current curves 5i and 6i.
FIG. 2 shows, in an enlarged illustration, the course of the voltage 5v after stopping the holding current in the solenoid 5 (upper curve) and the displacement/time curve 2s of the armature motion.
As it may be recognized from the illustration of the current 5v, immediately after stopping the holding current, the voltage decreases at the solenoid as shown by the curve portion 7. If the armature had maintained its position, a voltage course would be obtained as shown in the phantom line continuation of the curve portion 7.
Since, as noted above, by virtue of the armature motion a significant change in the magnetic circuit occurs, particularly by virtue of the fact that the air gap suddenly increases as compared to the residual air gap, a change in the magnetic flux takes place which results in an induced voltage so that the voltage again increases as indicated by the curve portion 8. The inversion point 9 thus yields a very good indication concerning the actual beginning of the armature motion. Since the increase of the voltage is dependent from the armature displacement, such voltage increases up to a maximum value, as indicated at 10 and thereafter decreases to zero.
In FIG. 3 the voltage curve 5v is shown greatly magnified in the zone of the armature start to the minimum point 9. Measurements have shown that the point 9 of the voltage curve 5v represents a very good indication of the actual start of the armature motion.
In case of larger fluctuations of the duration of adherence which may occur particularly in cases where no air gaps are provided or in case of changes of external conditions, for example, changes in the gas counterpressure, the maximum voltage is, upon its renewed increase, determined in point 10 because the total level of the residual magnetic flux is a function of the order of magnitude of the duration of adherence. Accordingly, by determining the voltage 5v across the solenoid, the start of armature may be recognized with sufficient accuracy.
FIG. 4 illustrates an example of an evaluating circuit. The associated signal curves are illustrated in FIG. 5 and are characterized by the index designating the respective element of the circuit shown in FIG. 4. The voltage 5v applied to the input 11 is first differentiated in a differentiator 12 so that maximum and minimum values applied to the input 11 cause zero values 14 and 15 to appear at the output 13 of the differentiator 12. In a comparator 16 connected to the output 13, the zero values 14, 15 of the voltage 5.13 are converted into respective edges 17 and 18 of a digital signal 5.16. Dependent upon the mode of application, the zero passages should be evaluated either from minus to plus (minimum detection) or from plus to minus (maximum detection). In order to adapt the signal edges 15, 16 to requirements, an inverter 19 may be connected to the output of the comparator 16. The time information contained in the flanks 15, 16 is converted into a voltage signal in the successive stage.
At the circuit input 20 the signal edge 20' which switches off of the holding current through the solenoid, triggers a monostable flip-flop 21 which generates a short pulse 22 which sets a flip-flop 23 and further, with its trailing signal edge triggers another monostable flip-flop 24. The latter generates a gate signal 25 which releases the signal of the comparator 16 or the inverter 19 through an AND-gate 26. By means of the time periods predetermined by the monostable flip-flops 21 and 24, the evaluating window (that is, the time slot in which a minimum and/or maximum is effectively detected) for the voltage evaluation may be set.
The output signal of the AND-gate 26 is applied to the resetting input of the flip-flop 23. Upon a detected maximum and/or minimum the flip-flop 23 is thus reset. An integrator 27 connected to the output of the flip-flop 23 integrates the output voltage of the flip-flop 23. In this manner the voltage at the output 28 of the integrator 27 increases with a constant slope as long as the flip flop 23 is set, that is, until a minimum or a maximum is detected. In this manner the voltage obtained at the output 28 is proportional to the time which elapses from the moment of switch-off of the holding current, that is from the setting of the flip-flop 23 until the detection of the minimum, thus, until the beginning of the motion of armature motion which is determined by the resetting of the flip-flop 23. This may be recognized from the time-wise aligned individual signal curves shown in FIG. 5. In the voltage curve 5.11 in FIG. 5 the minimum and maximum points 9 and 10 are illustrated accordingly.
The resetting of the integrator 27 is effected by the output signal of the monostable flip-flop 21 simultaneously with the setting of the flip-flop 23.
The above-described circuit implementation is to be regarded as an example only; other realizations, based, for example, on digital technology, are also feasible.
Also, the evaluation of the voltage is not limited to the methods described in connection with FIGS. 4 and 5 concerning the maximum-minimum recognition, but may be realized on the basis of other criteria considered to be favorable for the application in question. Thus, for example, an average value from a local maximum and minimum voltage may be determined and the point of intersection of the course between the two extreme values may be determined by such average value.
A further possibility for evaluation is the detection of the deviation from the expected exponential course. FIG. 6 illustrates an example of such a procedure. The major part of the circuit shown in FIG. 6 is identical to that of FIG. 4; only the portion for generating the signal edges as a function of the solenoid voltage is altered. Upon appearance of the pulse at the monostable flip-flop 21, a switch 29 is closed and thus brings the capacitor of a short-time integrator 30 to the same level as the input voltage. After opening the switch 29 the capacitor of the short-time integrator 30 discharges across a resistor according to an e-function. The time constant of such e-function and thus the R-C combination must be selected such that the voltage at the capacitor of the integrator 30 during armature engagement is always slightly greater than the input voltage. If now the armature 2 begins its motion, the voltage detected at the input 11 will be greater than the voltage at the capacitor and the comparator 31 switches its output to a high level. The other procedures correspond to those described in connection with FIG. 4.
FIG. 7 is a diagram of a circuit which illustrates the control of the two solenoids 5 and 6 of the example illustrated in FIG. 1 and relates to a gas control valve in an internal combustion engine. To the input 33 a signal 34 is applied whose leading and trailing edges initiate, respectively, the opening and the closing of the valve. The signal 34 triggers three positive edge controlled monostable flip-flops 35, 36 and 37. The positive edge at the input 33 effects the energization of the monostable flip-flop 35 which remains on the high level for the time period T 1 and thereafter generates a trailing edge. The trailing edge triggers a monostable flip-flop 38 which is connected to the output of the monostable flip-flop 35 and which generates a pulse of very short duration that resets a flip-flop 39. The outputs of the flip-flops 39, 40, 41 and 42 are used for applying a catching current level or a holding current level for the respective opening or closing solenoids of the valve to be actuated that is, the two solenoids 5 and 6 of the valve shown in FIG. 1. The height of the current level is determined by the resistors 43 through 48, each forming a voltage divider. The resetting of the flip-flop 39 switches off the holding current across the closing solenoid since the desired value for the successive current regulator 49 is set to zero.
Further, by the leading signal edge at the input 33 the monostable flip-flop 36 with a time constant T 2 is set. After lapse of the time period T 2 the after-connected monostable flip-flop 50 is triggered which generates a short pulse which, in turn, sets the flip-flop 40. In this manner the desired predetermined input signal for the opening current is set to the level of the catching current. The flip-flop 40 is, by means of the monostable flip-flops 37 and 51 again reset for a time T 3 after the leading signal edge of the signal at the input 33. At the same time the flip-flop 41 is set. By means of this procedure a switch-over from the catching current to the holding current occurs.
The monostable flip-flops 55 through 57 operate in principle in the same manner on the closing side. The input signal is first, however, guided through an inverter 58 which ensures that the rear edge of the signal at the input 33 is utilized as a time-determining edge. At a moment T' 1 after the trailing edge of the input signal (closing flank), the flip-flop 41 is reset by the monostable flip-flops 52 and 55 and thus the current through the opening solenoid 6 is discontinued. By interrupting the current through the opening solenoid 6, the motion of the armature and thus the displacement of the valve are initiated.
In a detector 59 which may contain, for example, a circuit according to FIG. 4, a voltage is generated which is proportionate to the duration of adherence of the valve, that is, it is proportionate to the delay period between the switch-off of the holding current and the beginning of the armature displacement. This value has to be utilized for correcting the delay periods of the monostable flip-flops. In case of a long duration of adherence, the time T' 1 has to be reduced so that in the next cycle the shut-off of the holding current may occur sooner. For this purpose the output voltage of the detector 59 is corrected; it is deducted in a summing circuit from an earlier inputted desired value and applied to the monostable flip-flop 52. It is noted that the longer the duration of adherence, the greater the output voltage of the detector 59. The time constant T' 1 of the monostable flip-flop 52 is proportionate to the applied voltage so that in the next cycle the switch-off of the holding current by the flip-flop 41 occurs exactly that much earlier as the duration of the adhering period of the valve. In this manner there is achieved a control to obtain a constant delay between the appearance of the signal edge at the input 33 and the actual start of armature motion. The desired delay value may be inputted by means of the voltage input U T1des .
The output voltage of the detector 59 is furthermore used to correct the time constants T' 2 and T' 3 which determine the switch-on of the catching current and the holding current on the opposite side. The later the start of the armature motion at the opening solenoid 6, the greater the output voltage of the detector 59. This voltage is added to a preinputted desired value U T2'des or U T3'des and in each instance it is applied to the monostable flip-flops 53 and 54 as time-determining voltages. As a result, at a later motion start, the time constants T' 2 and T' 3 are also extended and, accordingly, the switch-on of the catching current and the switch-over to the holding current occur correspondingly later, in an exact adaptation to the motion of the armature. The voltages U T1des to U T3des may thus be either predetermined as fixed values or, as required, may be dependent from the operational point, for example they may be predetermined by an engine control device.
Other embodiments of the entire process may also be realized in which, for example, after the turn-off phase of the current, when the voltage in the solenoid has dropped below a predetermined value, a current is applied to the solenoid. Such a current has to be necessarily smaller than the holding current which is required for holding the armature. If a negative current is selected then, as a particular advantage, a more rapid decay of the magnetic field may be achieved and thus the duration of adherence may be reduced. This effect, however, is limited by the generation of additional eddy currents.
The applied current generates an additional magnetic flux, as a result of which motions of the armature may be registered for a longer period after the armature is dropped. By an appropriate design of the magnetic circuit and the moved components motions can thus be recognized which lie in the phase of the highest armature velocity and thus permit a very accurate time allocation.
It is to be understood that the system according to the invention is not limited to the above-described example for an electromagnetic actuation of a gas control valve in an internal combustion engine but may find application in electromagnetic switching devices where only a single holding magnet is present. Thus, the invention may find application in gas control valves in which, for example, a spring assumes the closing function and a holding magnet assumes the opening function. In such an arrangement too, the duration of adherence of the armature is of significance because for introducing the closing function for the switch-off of the holding current the detection of the duration of adherence is of significance in order to effect a timely closing of the valve.
The method according to the invention also permits a function control because a significantly delayed or omitted armature motion is also recognized and thus a corresponding setting signal may be generated.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | A method of controlling movements of an armature in an electromagnetic circuit which includes at least one holding solenoid applying magnetic forces to the armature and at least one resetting arrangement for applying a resetting force to the armature. The method includes the following cyclical steps: switching on a holding current to flow through the solenoid for holding the armature at the solenoid; after a predetermined period, switching off the holding current for causing the armature to begin a motion away from the solenoid; after switch-off of the holding current detecting, across the solenoid, a voltage change caused by the displacement of the armature for recognizing a starting moment of armature motion from the solenoid; and deriving a control signal from signals representing the voltage change ascertained in the course of the detecting step. | 5 |
FIELD OF THE INVENTION
This invention relates to a tampon and particularly to a wrapped tampon.
BACKGROUND OF THE INVENTION
There are several considerations which are utilized in attempting to design a satisfactory tampon. Among these considerations are the prevention of leakage, ease of insertion and removal and ease of manufacturing.
Attempts to meet certain defined objectives amongst these considerations usually produce a lessening of efficacy in obtaining other objectives. For example, the prior art is replete with examples of insertion aids. These aids are usually in the nature of chemicals which provide some form of lubrication to minimize the friction upon insertion. Insertion aids, while performing this function, also form a barrier between the menstrual fluid and the absorbent material with a resultant interference in the efficiency of uptake.
Recently, absorbency characteristics of tampons have been improved by the inclusion of a class of compounds know as "superabsorbents". These materials rapidly absorb fluid and in so doing actually build up a negative pressure at the surface of the absorbent component of the tampons. As a result, when removal occurs extra force is needed to, in essence, tear the tampon away from the vaginal tissue which has been drawn tightly to the tampon surface.
Attempts have been made in the past to minimize this negative pressure by providing either physical or chemical barrier layers between the vaginal tissue and the superabsorbent material. For example, superabsorbent is used as a blend traditionally with more conventional absorbent material. In another approach, an outer wrap capable of retaining fluid has been used (see U.S. Pat. No. 4,056,103).
The tampon of this invention is one which is easily made and due to its unique and unusual construction is easy to insert and withdraw while offering a substantially complete barrier to leakage caused by bypass flow or heavy flow in a short period of time.
SUMMARY OF THE INVENTION
According to this invention a tampon having a fluid permeable outer wrap, an absorbent core and a withdrawal string is constructed so that the tampon is folded in half after wrapping. The withdrawal string is disposed about the outer surface of the tampon along the slightly overlapped edges of the wrap. As a result, the tampon during insertion has a wedge-shaped leading edge. After insertion is complete the tampon springs back because of the nature of the absorbent material putting pressure against the sides of the vaginal wall. During withdrawal, because the string encircles the outer surface of the tampon the downward facing edges are drawn together thereby minimizing the width of the tampon and providing for easier withdrawal due to this reduced width.
DETAILED DESCRIPTION OF THE INVENTION
The subject invention can be readily understood by reference to the drawings in which
FIG. 1 is a view partially in cross section of a bent tampon according to the subject invention.
FIG. 2 is a view of a tampon completely folded and
FIGS. 3A, B and C are cross sectional depictions of absorbent taken along line 3--3 of FIG. 1.
FIG. 4 is a representative cross sectional view of the wrapped tampon according to this invention.
Turning now to FIG. 1, a bent tampon partially in cross section is depicted therein. An outer wrap 10 surrounds an absorbent material 12 on the outer face of the tampon with an inner face of the outer wrap 11 present on the inward side after folding. As can be seen from the cross section on the outer side, a single thickness is used and in this particular embodiment the withdrawal string 13 is positioned between the wrap and the absorbent component.
The configuration depicted in FIG. 1 is that which is associated with the tampon in place with the sides of the tampon bowed slightly and pressing against the vaginal walls.
FIG. 2 depicts the tampon immediately prior to withdrawal where the sides of the tampon are abutting. This particular configuration has an adhesive area for attachment of the string at the portion of the wrapper 10 which extends beyond the absorbent layer 12. This adhesive area is represented by dotted lines 14.
FIG. 2 also indicates that the string may be knotted as depicted by 15 but this is not essential.
With regard to the fastening of the string, this may be done as indicated in FIG. 2 by conventional adhesive, by heat activatable adhesive either locally or along the path of the string or, if the string is made of a heat fusible material, it may be ultrasonically sealed or fused to the wrapper. If this is the case the configuration depicted at FIG. 4 is preferred. As can be seen in FIG. 4 the absorbent material 12 is surrounded by outer wrap 10 and the withdrawal string 13 is positioned between an upper and lower overlapping edge 10a and 10b of the wrapper. Fusing either by heat sealing or by ultrasonically sealing either locally or continuously or adhering by local application of heat to activate either periodic or continual application of heat activatable adhesive can be used to produce the wrapper seal and string attachment when the configuration depicted at FIG. 4 rather than that depicted in FIG. 1 is chosen. Because of this versatility, the positioning of the string 13 between the overlapped edges of the outer wrap 10a and 10b are currently preferred.
FIG. 3 depicts distinct cross sectional shapes of absorbent material for utilization in the tampon of this invention. The abutment surfaces A which provide the inner surface of the tampon after folding should be mating and preferably are flat so that the tampon can be folded to occupy the least amount of space upon withdrawal. The outer surface may be flat so that a rectangle is formed as is the case with FIG. 3A or may be arcuate as shown in FIGS. 3B and 3C. The configuration depicted in FIG. 3C is hemispherical so that when the tampon is folded a circular cross section is produced. In FIG. 3B an elliptical cross section is produced after the tampon is folded.
Currently, a rectangle with rounded edges such as that depicted at FIG. 3A is preferred due to ease of manufacture and assembly.
It is contemplated that a tampon according to this invention could contain superabsorbent as part of the absorbent component. The inclusion of the superabsorbent is well known but the characteristic ease of removal described in the specification would be particularly beneficial to overcome the difficulties inherent in removal where superabsorbent material is present as part of the absorbent core. | A tampon which is designed to be folded, has foldable absorbent material, a fluid pervious outerwrap which is overlapped at its edge and a withdrawal string that encircles the tampon at the overlapped edge of the wrap. After folding, the string and overlapped edge are on the outside surface of the tampon. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 62/203,552 filed Aug. 11, 2015, the disclosure of which is hereby incorporated herein by reference.
FIELD OF INVENTION
[0002] This invention relates to the field of recoil-reducing muzzle devices for firearms. More specifically, the invention comprises a vectored flow nozzle and expansion chamber with a means of substantially diverting the main, forward trajectory of gas flow of a gunshot to strike a surface more directly, thereby producing a counterforce to reduce recoil.
BACKGROUND OF THE INVENTION
[0003] Muzzle brakes, categorically, are seen as being incompatible with combat, as they are often criticized as causing more problems than they solve. To define terms, muzzle brakes are muzzle devices that are affixed to the end of a firearm's muzzle for the primary purpose of reducing recoil. The term “compensator” is often used synonymously. Regardless, muzzle brakes and compensators feature very conventional designs that branch off very little from two main archetypes. One of the quintessential designs is an open, multi-baffle design featuring one or more surfaces that allow expanding gases to strike, thereby imparting an indirect, somewhat angled counter-recoil force. Most gases exit this type of design laterally outward to the sides of the compensator and strike the cooler air of the outside atmosphere all at once, causing a bright flash and concussion felt by the shooter and those nearby. These designs often vary in the number of baffle chambers or in the tolerance allowed for each bullet to pass through during its flight, but they work under the same design principles. Designs featuring upward-facing ports demonstrate another design architype. These devices utilize jets of expanding gases firing upward to produce a force to counteract the upward movement of the muzzle. The result is lessened muzzle rise but also a blinding flash appearing directly in the shooter's immediate field of view. Both types of designs allow gases to expand into ports or open baffle chambers and do nothing to bend or substantially alter the primary, forward trajectory of the gases from a gunshot. In short, they leverage the property of expansion alone.
BRIEF SUMMARY OF THE INVENTION
[0004] Briefly described, aspects of the present invention may provide an improved recoil-reducing apparatus in front of the muzzle of a firearm. It is an aspect of this invention to provide a highly efficient anti-recoil apparatus that addresses both horizontal and vertical recoil simultaneously. It is another aspect of this invention to minimize back-blast and flash experienced by the shooter. These aspects of the invention are accomplished utilizing a vectored flow nozzle, an expansion chamber, substantial anti-recoil surfaces, compression, strategically-placed ports, dimpled surfaces, ports, and exit recess prongs.
[0005] It is an aspect of this invention to more efficiently use the force contained in the primary, forward trajectory of a gun's gases in a way that alters that trajectory and generates a counter-recoil force as a result. An embodiment of the present invention utilizes a vectored flow nozzle positioned in front of the muzzle (and there are many means of attachment including muzzle engagement via threads or even over another muzzle device as a “quick-detach” mount) and a prominent, primary anti-recoil surface inside an expansion chamber to provide an enhanced means of using hot, expanding gases from a gunshot to impart more forces onto a baffle-like counter-recoil surface by changing the trajectory of the gases. The shape of the vectored flow nozzle may be aptly described as a short section of bent conduit or angled throat which actively guides the gases escaping from a firearm's muzzle away from their straight, longitudinally forward trajectory. The vectored flow nozzle is positioned very closely against the muzzle of the gun, yet is part of the compensator; this close proximity allows the vectored flow nozzle to interact with the gases before they get much chance to expand. Dimensionally, the space between the walls of the vectored flow nozzle is large enough to allow the projectile to pass through untouched. Upon firing, the gunshot's hot, expanding gases leave the firearm's muzzle, enter the compensator, are deflected by the vectored flow nozzle from their initial trajectory (i.e. expanding and traveling straight forward, coaxial to the gun's barrel) to their new trajectory (i.e. expanding and traveling forward but now at a lowered angle, downward from the centerline of the gun's barrel). This new trajectory aims the gases more directly at one or more prominent counter-recoil surfaces within the expansion chamber immediately following the vectored flow nozzle. Conversely, the projectile, due to its stabilization (for example, from the spin imparted from the firearm's rifling), continues along its straight pathway along the barrel's centerline axis unchanged by the vectored flow nozzle and exits the compensator safely. The present compensator's expansion chamber is positioned in front of the vectored flow nozzle; this expansion chamber extends beneath the centerline of the barrel and is defined by generally planar side-walls, a ceiling, a primary counter-recoil surface, a compression ramp connecting the vectored flow nozzle and the bottom of the primary anti-recoil surface, and a front wall in an exemplary embodiment. Once the gases pass through the vectored flow nozzle, they flow forward and downward along the compression ramp (the floor directly connecting the vectored flow nozzle and the bottom of the primary anti-recoil surface), which compresses the gases—the compression ramp acts as an anti-recoil surface in itself. Gases strike the counter-recoil surface, and impart a greater force into the primary anti-recoil surface than were they merely allowed to stay on their initial, original trajectory and expand into the counter-recoil surface. Furthermore, the front wall of the invention which contains the departure recess where the bullet exits may also be substantially curved or angled to increase forces that lower muzzle rise in an exemplary embodiment.
[0006] To enhance the change in primary gas trajectory, dimples or ridges may be included on the exemplary embodiment on the compression ramp laterally forward of the vectored flow nozzle. The dimples, similar to those on a golf ball, interact with gas flow and alter the boundary layer between laminar flow and turbulent flow. The gases rush by the compression ramp on their way to collide with the primary anti-recoil surface on the far end of the expansion chamber positioned beneath the centerline axis of the barrel. With dimples (it should be noted that these may take the form of ridges or similar artifacts—the term dimples may denote either dimples or other similar features and should be considered synonymous) on the compression ramp, the gases rush by more closely to the compression ramp's surface. The result is a greater change in the primary trajectory of the gases allowing a more direct collision with the primary anti-recoil surface. In an exemplary embodiment, the primary anti-recoil surface may be a curved surface to maximize surface area. In an alternative embodiment, the primary anti-recoil surface may be a substantially straight, angled surface to maximize the degree to which the gases strike the anti-recoil surface head-on.
[0007] To further enhance the change in primary gas trajectory, one or more interior thrust beams may be provided within the expansion chamber. An interior thrust beam spans the internal width of the expansion chamber and provides numerous benefits. These benefits include, for example, providing the gases an additional surface to thrust against, providing structural support for the compensator itself, and providing the gases a structure that may directly influence their trajectory as they rush into the expansion chamber. The interior thrust beam may take the shape of an inverted airfoil, for instance, in an alternative embodiment of the invention, wherein that shape is employed to leverage fluid dynamics and create a net downward force, thereby mitigating muzzle rise. Furthermore, internal thrust beams may complement or be used in place of the vectored flow nozzle, depending upon the embodiment. In an exemplary embodiment of the invention, multiple interior thrust beams are used to direct gases toward the primary anti-recoil surface to maximize the net counter-recoil forced generated.
[0008] It is another aspect of the invention to reduce flash. Very closely related to flash reduction, it is another aspect of the invention to reduce back-blast as felt by the shooter. The vectored flow nozzle forces the gas to take a longer route through the expansion chamber due to its new trajectory (diagonally forward and downward is longer than its traditional straight forward trajectory), giving these gases more opportunity to mix with the ambient air within the expansion chamber—more exposure to air within the expansion chamber has the effect of slowing the gases down more prior to exiting the compensator (reducing gas plumes from gas striking outside air). Furthermore, the vectored flow nozzle prevents most gas from exiting the compensator via the departure recess—thereby further mitigating any flash in the shooter's field of view. The expansion chamber further comprises a plurality of elongated, approximately horizontal ports on the lateral side walls of the expansion chamber proximal to the anti-recoil surface. Theses ports allow for oxygen exposure to the under-oxygenated gases flowing through the expansion chamber, thereby allowing an opportunity for combustion to begin internally, rather than allowing gases to be exposed to fresh oxygen only after departing from the compensator.
[0009] Furthermore, these ports allow some expanding gases to bleed off and exit the compensator in such a way that does not cause a plume once gas strikes the air of the outer atmosphere, thereby further minimizing flash. Gases exiting the compensator through these ports are allowed to exit in a manner that minimizes their presence in the shooter's field of view. In the compensator's preferred embodiment, these ports are positioned proximal to the primary anti-recoil surface and angled surfaces connected to the ports on their leading edges called bleed ramps. These bleed ramps provide guidance for gases as they exit the compensator via the ports. The bleed ramps send gases laterally outward and longitudinally forward from the compensator, in a diagonal direction. This imparts a direction to the exiting gases that moves them away from the shooter, while also forcing gases to exit in a controlled fashion, thereby minimizing concussion. Because gases strike different parts of the expansion chamber at different times, the bleed ramps force gases to take a pre-determined course—a course which, due to the nature of fluid dynamics, becomes one that gases approaching the ports also take as a result (in essence gases follow the trajectory of the preceding gas ahead of it). In terms of gas flow, some gas will exit via the ports, while other gas is simultaneously striking the primary anti-recoil surface. Once the gas has struck this surface, the gas flows along the path of the gases that have already just exited the compensator, thereby influencing the path of the gases that would otherwise reflect back at the shooter. Instead, these gases exiting via the ports exit laterally outward and longitudinally forward from the ports (as opposed to laterally directly to the side, or worse, back at the shooter).
[0010] In another embodiment of the invention, ports may be placed on the ceiling on the invention to maximize the production of downward forces that combat muzzle rise. Interestingly enough, due to the volume of the expansion chamber, ports placed on the ceiling of the compensator not only allow fresh oxygen to enter the expansion chamber causing an increased likelihood of having any flash or combustion contained within the compensator internally, but also allow the hot gases of the gun shot to bleed off into the atmosphere in such a way that minimizes the opportunity for under-oxygenated gases to strike the outer atmosphere all at once and flash. The shape of the compensator allows for ceiling ports to further increase forces that lower muzzle rise while also minimizing flash. Ports may be placed close to or distant from the front wall containing the departure recess depending on the desired effect that is to be achieved. Ports further away from the front wall serve more, for example, to introduce oxygen to the expansion chamber, to reduce flash, and to provide moderate muzzle climb reduction whereas ports proximal to the front wall provide, for example, more muzzle climb reduction. Furthermore, ports arranged away from the front wall may extend to the side walls to further introduce oxygen to the expansion chamber.
[0011] Additionally, in yet another embodiment of the invention, ports in the form of substantially forward-facing vents may be positioned on the primary anti-recoil surface as well as on the front wall, whether curved or angled, in an effort to diffuse gases forward, in front of the compensator, thereby lowering the internal pressure of the expansion chamber when hot gases are rushing through it and diffusing the blast forward. Such ports may be angled slightly upward to impart a downward force. To further decrease internal pressure within the expansion chamber, ports, comprising various port shapes, may be placed proximal to the approximately planar side walls of the compensator.
[0012] In another embodiment of the invention, flash reduction and back-blast reduction can be further mitigated by an internal structure within the expansion chamber, called the internal flow mound. The internal flow mound is positioned above the centerline axis of the barrel on the ceiling of the expansion chamber, proximal to the front wall of the compensator. Essentially, the internal flow mound is a structure that decreases the total internal height of the expansion chamber. When gases strike the primary anti-recoil surface, some gases that do not exit the compensator via ports or the exit recess begin to travel upward, forming a circular pattern, or eddy, within the expansion chamber. If another shot is fired within close enough succession while the gases forming an eddy pattern remain within the expansion chamber, the subsequent shot's gases may expel from the compensator far more gases than would come from a single shot—the result is an increased flash and back-blast. The internal flow mount decreases the total diameter of the maximum eddy possible within the expansion chamber, thereby decreasing any likelihood of increased flash or back-blast due to internal flow dynamics.
[0013] In addition to the above mentioned means for reducing flash and back-blast, an exemplary embodiment of the compensator utilizes and arrangement of prong-like structures surrounding the expansion chamber's bullet departure recess. These prongs interact with the gases exiting the expansion chamber where the bullet exits. Upon striking the outside air these gases begin to form a toroidal shape, or plume. The prongs force the gases beginning to form a plume to flow past and around the prongs, thereby spreading out the gases increasing their exposed surface area and preventing the gases from having the opportunity to ignite all at once causing flash. In its preferred embodiment, the compensator's prong arrangement leaves the very top and bottom areas closed to stop any remaining flash from entering the shooter's field of view or prevent any gases from being channeled downward (during prone shooting gases directed downward will kick up dust and debris). Prongs can further provide a number of additional less obvious benefits that lend themselves readily to combat, such as being sized appropriately to facilitate the attachment of a bayonet or simply provide a means of stabbing or poking (i.e. breaking a window, or prodding enemy personnel).
[0014] According to an embodiment, a recoil-reducing apparatus configured to be affixed to a muzzle of a gun having a gun barrel having a longitudinal axis comprises a muzzle engagement recess configured to be positioned coaxial to and longitudinally forward of the gun barrel, a vectored flow nozzle positioned coaxial to and longitudinally forward of the muzzle engagement recess, and an expansion chamber positioned longitudinally forward of the vectored flow nozzle. The vectored flow nozzle is configured to deflect expanding gases off the longitudinal axis and to divert the expanded gases along a new trajectory vertically downward relative to the longitudinal axis.
[0015] According to an embodiment, a recoil-reducing apparatus configured to be affixed to a muzzle of a gun having a gun barrel comprises a muzzle engagement recess configured to be positioned coaxial to and longitudinally forward of said gun barrel and an expansion chamber positioned longitudinally forward of the muzzle engagement recess. The expansion chamber comprises a front wall, a ceiling extending from the muzzle engagement recess to the front wall and comprising an internal flow mound proximal to said front wall, an anti-recoil surface extending from the front wall and facing the muzzle, a compression ramp extending longitudinally from the muzzle engagement recess to the anti-recoil surface, first and second lateral walls extending from the muzzle engagement recess to the front wall and from the ceiling to the compression ramp, and a departure recess defined in the front wall and positioned longitudinally forward of and coaxial to said gun barrel.
[0016] According to an embodiment, a recoil-reducing apparatus configured to be affixed to a muzzle of a gun having a gun barrel comprises a muzzle engagement recess configured to be positioned coaxial to and longitudinally forward of said gun barrel, an expansion chamber positioned longitudinally forward of said muzzle engagement recess, and a thrust beam spanning a width of the expansion chamber.
[0017] According to an embodiment, a recoil-reducing apparatus configured to be affixed to a muzzle of a gun having a gun barrel comprises a muzzle engagement recess configured to be positioned coaxial to and longitudinally forward of said gun barrel and an expansion chamber positioned longitudinally forward of said muzzle engagement recess. The expansion chamber comprises a front wall, a ceiling extending from the muzzle engagement recess to the front wall, an angled anti-recoil surface extending from the front wall and facing the muzzle, a compression ramp extending longitudinally from the muzzle engagement recess to the angled anti-recoil surface, first and second lateral walls extending from the muzzle engagement recess to the front wall and from the ceiling to the compression ramp, a departure recess defined in the front wall and positioned longitudinally forward of and coaxial to said gun barrel, and at least one port for exhaust gases to exit the expansion chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 shows a perspective view of the compensator affixed to the end of a gun barrel.
[0019] FIG. 2 shows a perspective view of the embodiment of the compensator displayed in FIG. 1 with additional features.
[0020] FIG. 3 shows an exploded view of the compensator's embodiment displayed in FIG. 2 .
[0021] FIG. 4 shows a sectional view of an embodiment of the compensator in FIG. 3 .
[0022] FIG. 5 shows the sectional view of the embodiment of the compensator from FIG. 4 illustrating gas flow.
[0023] FIG. 6 shows a sectional view of an alternate embodiment of the compensator from FIG. 4 with a modified means of attachment to the gun barrel.
[0024] FIG. 7 shows a sectional view of an alternate embodiment of the compensator in FIG. 4 with an angled anti-recoil surface.
[0025] FIG. 8 shows a sectional view of an alternate embodiment of the compensator in FIG. 7 with an angled front wall.
[0026] FIG. 9 shows a sectional view of an alternate embodiment of the compensator in FIG. 5 with a curved front wall, interior thrust beams, and a forward facing vent.
[0027] FIG. 10 shows a perspective view of an alternate embodiment of the compensator displayed in FIG. 1 with alternative port arrangements.
[0028] FIG. 11 shows an exploded view of an alternate embodiment of the compensator displayed in FIG. 3 featuring an interior thrust beam.
DETAILED DESCRIPTION
[0029] Unconventional compensator designs, such as those featuring an asymmetric expansion chamber with a prominent anti-recoil surface, may allow gases to expand and, in doing so, strike a baffle surface and impart some force, which combats the gun's recoil indirectly. In this design, gases do not strike the baffle surface head-on, or rather, normal to the baffle's surface. Instead, gases strike the baffle surface at a glancing angle—this is highly inefficient, as more energy is transferred when gases strike normal to a counter-recoil surface. Leveraging the principles and insight gathered from studying fluid dynamics as it relates to firearms, specifically compressible supersonic and even hypersonic flow, it becomes readily apparent that massive levels of force, friction, velocity, heat, etc. are present. Where the gas flows, force and energy follow as well. Even what may seem like a somewhat small change in flow can yield vastly different results given the forces at work. That said, these traditional muzzle brake and compensator designs do not attempt to alter the primary vector of the escaping gases (i.e. straight forward) as they leave the muzzle. A need remains to be able to actively alter and influence the primary gas trajectory and redirect the gases onto a more direct collision course with a counter-recoil surface, thereby achieving a highly efficient degree of recoil reduction, and allowing for the compensator to take on both rearward recoil and muzzle climb (upward recoil) simultaneously.
[0030] Traditional muzzle brakes or compensators can obscure the shooter's field of view (i.e. the area directly vertically above the muzzle of a gun), blind them, redirect uncomfortable pressure waves back at them or to those in the immediate vicinity, or—even worse—give away the shooter's position to the enemy due to flash. These common downsides are major detractors when considering their use in combat. Muzzle flash is caused when under-oxygenated gases exit a gun barrel and are exposed to the cool air of the outer-atmosphere in such a way that the gases achieve a high ratio of volume to surface area. When a critical mass is reached and the cooler outside air interacts with the hot expanding gases of a gunshot, the gas becomes exposed to enough oxygen to allow for full combustion. Due to a high ratio of internal volume to surface area (for example, in the case of a shape such as a toroid or gas plume), the ignition happens all at once, resulting in a bright, conspicuous blast—similar to a thermobaric explosion. A need remains to be able to effectively accomplish both recoil reduction as well as flash reduction and back-blast reduction in such a way that all are accomplished effectively.
[0031] In FIG. 1 , a gun barrel 11 having an axis 13 down the barrel's centerline is shown at a perspective view. To more clearly describe the compensator, an axes system is defined whereby the arrow at 15 indicates the vertical axis, the arrow at 17 indicates the lateral axis, and the arrow at 19 indicates the longitudinal axis. This embodiment of the compensator is affixed to the gun barrel 11 along its axis 13 via its muzzle engagement recess 33 . The compensator is a coaxial extension of the gun barrel along the barrel's centerline axis. In this embodiment, the compensator's muzzle engagement recess 33 attaches to the gun barrel via threads (not shown) on the end of the gun. The engagement recess 33 is thus positioned coaxial to and longitudinally forward of the gun barrel 11 . To better assist in installing the compensator, wrench flats 29 on the lateral sides of the muzzle engagement recess 33 are shown per an exemplary embodiment. Anatomically, this view also shows one of the side walls 39 on the lateral side of the compensator, along with horizontally elongated ports 27 , the expansion chamber ceiling 31 , curved primary anti-recoil surface 43 , front wall 41 , and the departure recess 35 . The elongated ports 27 are substantially parallel to the ceiling 31 and their openings in terms of vertical height are ideally smaller than the diameter of the departure recess. The elongated ports 27 may be level (i.e. at 0 ° relative to the longitudinal axis 19 ) at their optimal angle so as not to, upon firing, impart any force on the gun barrel 11 that may add to muzzle climb due to gases escaping at a longitudinal angle, while also keeping gases out of the shooter's immediate field of view. Alternatively, the elongated ports 27 may be angled upward as even a small upward angle of +5° to +15° can assist in generating additional force to counter muzzle rise. Conversely, the elongated ports 27 may be angled slightly downward. For example, a downward angle of −5° to −15°, while suboptimal for counteracting muzzle rise, can nevertheless be employed to angle gases further away from the shooter's immediate field of view. While the elongated ports 27 are illustrated as being generally uniform, alternative embodiments may take the form of port arrangements with as few as one elongated port on each side of the planar side walls 39 . Additionally, the elongated ports 27 may take the form of different lengths.
[0032] When the gun is fired, a projectile travels along the barrel's axis 13 , passes through the compensator at the muzzle engagement recess 33 and exits the compensator at the departure recess 35 . Expanding gases (not shown) take a very different path. The projectile's stability allows for virtually a straight trajectory along the barrel's centerline axis 13 . The gases, on the other hand, leave the barrel 11 , are deflected off of their forward trajectory along the barrel's centerline axis 13 by the vectored flow nozzle (not shown) and are diverted to their new trajectory that is longitudinally forward and vertically downward. This new trajectory diverts gases onto a more direct course with the curved primary anti-recoil surface 43 , and exiting the compensator via the elongated ports 27 and, to a minor extent, also via the departure recess 35 .
[0033] In terms of manufacturing materials, the compensator may be manufactured through additive means (such as 3D-printing) or via investment casting and welding. Furthermore, it is recommended that the disclosed anatomical parts of the compensator be integral with each other for strength, resulting in one solid item, and homogeneous in terms of the material used. Suitable materials may include steel, nickel-chromium alloys, titanium, cobalt chrome, or other sturdy metals.
[0034] In FIG. 2 , an exemplary embodiment to the compensator shown in FIG. 1 is illustrated. This embodiment additionally includes prongs 53 surrounding the departure recess 35 . As some gases (not shown) exit via the departure recess 35 , they expand into the prongs 53 and break apart, preventing a gas plume and minimizing flash. Furthermore, this embodiment of the compensator includes orientation bars 63 defined on the ceiling 31 of the expansion chamber. These orientation bars 63 serve to assist in installing the compensator on a barrel 11 in a straight, level manner. For instance, the orientation bars 63 , when at the 12 o'clock position, confirm the compensator is orientated in the correct vertical position, thereby allowing the compensator to work as designed. The orientation bars 63 , thus, act as a visual cue, allowing a user looking at the compensator to quickly determine the compensator's position (i.e. whether it is off-center or not).
[0035] FIG. 3 shows an exploded view of the embodiment of the compensator seen in FIG. 2 in the form of two longitudinally-cut halves. This view provides insight in to the inner workings of the compensator. The threads 37 defined in the muzzle engagement recess 33 are now visible. The vectored flow nozzle 21 lies longitudinally forward of the threads 37 and the muzzle engagement recess 33 . The vectored flow nozzle 21 is integral to the compensator and connects the muzzle engagement recess 33 to the rest of the compensator, acting as a gateway to the expansion chamber 25 . In terms of its dimensions, the vectored flow nozzle's walls surround the barrel's axis 13 and come in very close proximity to the projectile (not shown) when it passes through the compensator along the barrel's axis 13 . The vectored flow nozzle 21 is placed very closely to the end of the gun barrel (not shown) due to the threads 37 in the muzzle engagement recess 33 attaching to the end of the gun barrel (not shown), thereby placing the vectored flow nozzle 21 very close to, but not attached to, the gun barrel. The gun barrel (not shown) engages via the threads 37 and upon firing, expels hot, expanding gases (not shown) longitudinally forward and vertically level along the barrel's axis 13 until it reaches the vectored flow nozzle 21 , at which point, the gases change course to flow vertically downward and longitudinally downward as they enter the expansion chamber 25 . After gases change their primary trajectory to one with a downward angle, the downward angle of the gases increases as they rush past the compression ramp 47 . In this embodiment, a plurality of dimples 49 is defined on the surface of the compression ramp 47 . The compression ramp 47 acts as an anti-recoil surface, pushing the gun barrel down when gases strike it. The compression ramp dimples 49 increase the surface area of the compression ramp, induce drag on the gases rushing past them (thereby acting as their own counter-recoil surfaces), and draw gases closer to the surface of the compression ramp 47 . The net effect is more gases on a direct collision course with the curved primary anti-recoil surface 43 and therefore more counter-recoil force generated by the compensator. Furthermore, the vectored flow nozzle 21 , assisted by the dimples 49 on the compression ramp 47 , allows for a decrease in flash produced by the compensator because gases no longer simply follow the barrel's axis 13 and exit via the departure recess 35 .
[0036] FIG. 4 shows a sectional view of the embodiment of the compensator from FIG. 3 affixed to a threaded gun muzzle 23 , allowing a more clear view of the vectored flow nozzle 21 . As depicted, the vectored flow nozzle very clearly is angled to guide gas flow 65 forward and downward, yet allow a clear, straight path for a projectile 61 to pass through the compensator without deviating from its trajectory along the barrel's axis 13 . As stated previously, the vectored flow nozzle 21 is integral to the rest of the compensator and dictates the downward angle of gas flow 65 into the expansion chamber 25 . As the projectile 61 passes through the compensator, it passes through the vectored flow nozzle 21 within very close proximity to each other; this tight tolerance allows the vectored flow nozzle to engage with the gas flow 65 before it has a change to really expand. Optimally, the inner diameter of the vectored flow nozzle will be very comparable if not equal to the diameter of the exit recess 35 , which is only slightly larger than the diameter of the projectile 61 . Furthermore, optimally, the downward angle of the walls of the vectored flow nozzle 21 ranges from −15° to −30° from the barrel's axis 13 . The larger the projectile 61 caliber is, the steeper the recommended downward angle of the vectored flow nozzle becomes so as to prevent gases from exiting a therefore physically larger departure recess 35 . Furthermore, steeper downward angles in the walls of the vectored flow nozzle 21 impart more counter-recoil forces due to more gas flow 65 striking the curved primary anti-recoil surface 43 . Gases 65 flow along their new trajectory, are deflected downward more as they rush past the dimples 49 on the compression ramp 47 , at which point gases proceed to strike the curved primary anti-recoil surface 43 and exit via the elongated ports 27 . The port bleed ramps 55 , defined in the elongated ports 27 , are angled surfaces that further vector gases diagonally (i.e. laterally outward and longitudinally forward) away from the shooter so as to minimize any concussion or flash experienced.
[0037] FIG. 5 shows the sectional view of the embodiment of the compensator from FIG. 4 once gas strikes the curved primary anti-recoil surface 43 . The elongated ports (not shown) and port bleed ramps (not shown) are only omitted from this figure to illustrate the interaction of the eddy 67 within the compensator. Some gas flow 65 forms an eddy 67 and circles within the compensator. To minimize this, an internal flow mound 51 , defined in the expansion chamber's ceiling 31 and being in close proximity to the front wall 41 , reduces the maximum diameter the eddy 67 can become while also leaving clearance for the projectile 61 , thereby minimizing the potential for increased flash during rapid firing. The internal flow mound 51 extends vertically downward from the ceiling 31 in close proximity to the projectile 61 as it passes through the expansion chamber 25 . In an exemplary embodiment, the flow mound 51 may be as close as a few one hundredths of an inch—it may be as close as possible without risking possible contact with the projectile, taking into account the manufacturing tolerances for both, the compensator as well as the projectile. In its preferred embodiment, the integral flow mound 61 extends vertically downward to be level to the upper portion of the departure recess 35 .
[0038] FIG. 6 shows a sectional view of an alternate embodiment of the compensator from FIG. 4 with a modified means of attachment to the gun barrel 11 . This embodiment attaches over an existing muzzle device 59 where the muzzle engagement recess 33 connects via a quick-detach mount 57 and functions in otherwise the same manner as the embodiment of the compensator shown in FIG. 4 . For the purpose of clarity, an example of an existing muzzle device 59 is a traditional muzzle brake featuring a quick-detach mount 57 allowing itself to be affixed to the gun barrel 11 .
[0039] FIG. 7 shows a sectional view of an alternate embodiment of the compensator from FIG. 4 featuring aflat primary anti-recoil surface 45 . The flat primary recoil surface provides gas flow 65 the opportunity to strike a substantially planar surface angled to be perpendicular to its trajectory, resulting in the generation of a sharp impulse of anti-recoil force and is angled relative to the longitudinal axis of the gun barrel 11 .
[0040] FIG. 8 shows a sectional view of yet another embodiment of the compensator from FIG. 4 featuring an angled front wall 41 that joins the angled flat primary anti-recoil surface 45 . This configuration angles the front wall 41 with the angled flat primary anti-recoil surface 45 to maximize the total surface area perpendicular to the gas flow 65 due to the aiming of these gases by the vectored flow nozzle 21 .
[0041] FIG. 9 shows a sectional view of an alternate embodiment of the compensator in FIG. 5 a curved front wall 68 that joins the curved primary anti-recoil surface 43 , thereby catching and cradling gas flow 65 in a way that provides a downward force and therefore further decreases muzzle climb. FIG. 9 also features a plurality of interior thrust beams 72 , which serve to redirect the trajectory of the gas flow 65 to maximize the effectiveness of the curved primary anti-recoil surface 43 . The interior thrust beams 72 within the expansion chamber 25 span the lateral width of the chamber, provide structural integrity and act as an additional surface for the gas flow 65 to strike against. In an exemplary embodiment, the interior thrust beams 72 are substantially wing-like in appearance and structure, being relatively flat, having a relatively thin cross-section, and able to influence the path of gas flow 65 . The curved front wall 68 naturally allows for maximum surface area when catching expanding gases from the gas flow 65 that may be traveling along the barrel axis 13 and departing from the intended downward trajectory due to the aiming of these gases by the vectored flow nozzle 21 . Furthermore, this alternate embodiment also features a forward-facing vent 71 defined in the curved primary anti-recoil surface 43 allowing the gas flow 65 to exit the compensator substantially forward. In this illustration, the forward-facing vent 71 is angled slightly upward to allow gas flow 65 exiting the compensator to impart a downward force further mitigating muzzle rise.
[0042] FIG. 10 displays a perspective view of an alternate embodiment of the compensator in FIG. 1 featuring various porting configurations. Elongated ports 27 can be seen on the side walls 39 of the compensator alongside 73 non-elongated wall ports. These different port types can work together forming a synergy between the two types, wherein non-elongated wall ports 73 allow for gas flow (not shown) to be aimed, generating more force to counter recoil and lower the compensator's internal pressure, elongated ports 27 allow for flash reduction and concussion mitigation. In addition to these, vertical ports 69 can be seen proximal to the front wall 41 . Furthermore, ports that are distant from the front wall 41 , hereafter referred to as distal ports 70 , can be seen someone proximal to the muzzle engagement recess 33 . Distal ports 70 allow gas flow to exit in a way allowing for a lower internal pressure within the compensator while also introducing oxygen into the compensator, limiting flash, lowering recoil, and mitigating muzzle rise. Furthermore, several forward-facing vents 71 can be seen defined in the curved primary anti-recoil surface 43 . These forward-facing vents 71 provide another means of reducing pressure within the compensator but also may provide muzzle climb reduction as well.
[0043] FIG. 11 displays an exploded view of an alternate embodiment of the compensator in FIG. 3 featuring a plurality of interior thrust beams 72 . This three dimensional, exploded view provides additional insight in terms of the preferred positioning of the interior thrust beams 72 positioned within the expansion chamber 25 .
[0044] Various embodiments of invention are described below.
[0045] A recoil-reducing apparatus configured to be affixed to a muzzle of a gun having a gun barrel, wherein the apparatus comprises: a muzzle engagement recess configured to be positioned coaxial to and longitudinally forward of said gun barrel; a vectored flow nozzle positioned coaxial to and longitudinally forward of said muzzle engagement recess; an expansion chamber positioned longitudinally forward of said vectored flow nozzle comprising: a front wall; a ceiling extending from the muzzle engagement recess to the front wall; an angled anti-recoil surface extending from the front wall and facing the muzzle; a compression ramp extending longitudinally from the vectored flow nozzle to the flat anti-recoil surface; first and second lateral walls extending from the vectored flow nozzle to the front wall and from the ceiling to the compression ramp; a departure recess defined in the front wall and positioned longitudinally forward of and coaxial to said gun barrel and said vectored flow nozzle; and a plurality of approximately horizontal elongated ports defined in the first and second lateral walls proximal to the flat anti-recoil surface, wherein the expansion chamber defines an asymmetric internal volume expanding downward relative to the longitudinal axis of the gun barrel; and/or
[0046] Said compression ramp includes a plurality of surface dimples; and/or
[0047] A plurality of prongs are positioned longitudinally forward of and in close proximity to said departure recess; and/or
[0048] Said muzzle engagement recess engages said muzzle via threads on said gun barrel; and/or
[0049] Said muzzle engagement recess engages an existing muzzle device on said gun barrel via a quick-detach mount; and/or
[0050] Said ceiling in said expansion chamber further comprises an internal flow mound proximal to said front wall; and/or
[0051] Said approximately horizontal elongated ports further comprise bleed ramps; and/or
[0052] Said front wall is angled.
[0053] A recoil-reducing apparatus configured to be affixed to a muzzle of a gun having a gun barrel, wherein the apparatus comprises: a muzzle engagement recess configured to be positioned coaxial to and longitudinally forward of said gun barrel; a vectored flow nozzle positioned coaxial to and longitudinally forward of said muzzle engagement recess; an expansion chamber positioned longitudinally forward of said vectored flow nozzle comprising: a front wall; a ceiling extending from the muzzle engagement recess to the front wall; a curved anti-recoil surface extending from the front wall and facing the muzzle; a compression ramp extending longitudinally from the vectored flow nozzle to the curved anti-recoil surface; first and second lateral walls extending from the vectored flow nozzle to the front wall and from the ceiling to the compression ramp; a departure recess defined in the front wall and positioned longitudinally forward of and coaxial to said gun barrel and said vectored flow nozzle; and a plurality of approximately horizontal elongated ports defined in the first and second lateral walls proximal to the curved anti-recoil surface, wherein the expansion chamber defines an asymmetric internal volume expanding downward relative to the longitudinal axis of the gun barrel; and/or
[0054] Said compression ramp includes a plurality of surface dimples; and/or
[0055] A plurality of prongs are positioned longitudinally forward of and in close proximity to said departure recess; and/or
[0056] Said muzzle engagement recess engages said muzzle via threads on said gun barrel; and/or
[0057] Said muzzle engagement recess engages an existing muzzle device on said gun barrel via a quick-detach mount; and/or
[0058] Said ceiling in said expansion chamber further comprises an internal flow mound proximal to said front wall; and/or
[0059] Said approximately horizontal elongated ports further comprise bleed ramps; and/or
[0060] Said front wall is angled.
[0061] Although the description above contains many specificities, these should not be construed as limiting the scope of embodiments but as merely providing illustrations of some of several embodiments. Different embodiments may include different combinations of one or more disclosed features.
[0062] While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. For instance, while the illustrations and the associated descriptions may include different aspects of the invention, one or more features may be omitted in a given embodiment without departing from the scope of the invention. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.
DRAWINGS—REFERENCE NUMERALS
[0063] 11 gun barrel
[0064] 13 barrel axis
[0065] 15 vertical axis
[0066] 17 lateral axis
[0067] 19 longitudinal axis
[0068] 21 vectored flow nozzle
[0069] 23 gun muzzle
[0070] 25 expansion chamber
[0071] 27 elongated ports
[0072] 29 wrench flats
[0073] 31 ceiling
[0074] 33 muzzle engagement recess
[0075] 35 departure recess
[0076] 37 threads
[0077] 39 side wall
[0078] 41 front wall
[0079] 43 curved primary anti-recoil surface
[0080] 45 angled primary anti-recoil surface
[0081] 47 compression ramp
[0082] 49 compression ramp dimples
[0083] 51 internal flow mound
[0084] 53 prongs
[0085] 55 port bleed ramps
[0086] 57 quick-detach mount
[0087] 59 Existing muzzle device
[0088] 61 projectile
[0089] 63 orientation bars
[0090] 65 gas flow
[0091] 67 eddy
[0092] 68 curved front wall
[0093] 69 vertical ports
[0094] 70 distal ports
[0095] 71 forward-facing vent
[0096] 72 interior thrust beam
[0097] 73 non-elongated wall ports | A firearm compensator, to be affixed to the muzzle of a gun for reducing at least one of flash and recoil, utilizes a vectored flow nozzle, an expansion chamber containing a prominent thrust surface and flow-directing structures below the barrels center line, and flash-hiding ports. A compression ramp containing dimple-like structures connects the bottom of the gun muzzle to the bottom of the prominent thrust surface. Upon firing the gun, gasses depart from their linear trajectory as they flow past the vectored flow nozzle, flow diagonally downward past a dimpled compression ramp in the expansion chamber, and strike the thrust surface. A plurality of substantially horizontal elongated ports in the expansion chamber aids in flash suppression. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to Korean Patent Application No. 10-2009-0025521, filed on Mar. 25, 2009, and all the benefits accruing therefrom under 35 U.S.C. §119, the contents of which in its entirety are herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field
A photostimulation apparatus is disclosed.
2. Description of the Related Art
Recently, light-sensitive proteins activating or inhibiting nerve cells in response to light with specific wavelength have been developed in the field of brain study. Using the light-sensitive proteins, it is possible to control the nerve cells in the neural circuitry more freely and elaborately. With the conventional electrical microstimulation using a micro-stimulant, target nerve cells can be activated only. For the study of the neural circuitry, it is required to stimulate specific cells and to measure response from nerve cells in other area resulting from the inter-connection inside the neural circuitry, at the same time. With an artificial electrical stimulation, it is difficult to measure the subtle electrical physiological response from other cells because of noise.
In contrast, with photostimulation, the target nerve cells can be selected freely through selection of promoters. Once light-sensitive proteins are expressed in the target nerve cells, both activation and inhibition can be controlled freely by controlling the wavelength of photostimulation. Accordingly, with photostimulation, the neural circuitry can be studied more elaborately and systematically. Moreover, it may be helpful in studying how a specific neuropsychiatric disease is connected with specific brain nerve cells and how it causes problems in the neural circuitry, as well as in treating the disease. Especially, in clinical practice, whereas the conventional deep brain stimulation technique allows only activation of nerve cells through electrical stimulation, the photostimulation technique allows both activation and inhibition. Hence, it may provide an epoch-making turning point in the treatment of neuropsychiatric diseases.
The cerebral cortex of the human brain is a region that plays a key role in memory, attention, perceptual awareness, thought, language, and consciousness. It constitutes the outermost layer of the cerebrum. The functions of the areas of the cerebral cortex are well known. Located right beneath the skull, the cerebral cortex may be easily damaged by accidents or diseases. On the other hand, accessibility to treatment is relatively high because it is located at the outer side of the brain. Therefore, the cerebral cortex makes a good target for neural photostimulation.
SUMMARY OF THE INVENTION
A photostimulation apparatus may be provided which may activate and/or inhibit nerve cells in the living body by irradiating light on a large area. The apparatus may further inject a photosensitive material into the living body without insertion into the living body.
According to an aspect of the invention, a photostimulation apparatus may include: a membrane for insertion into a living body; and at least one cell disposed on the membrane. Each cell may include a first light source for irradiating light to a photosensitive material in the living body.
According to another aspect of the invention, a photostimulation apparatus may include: a membrane for insertion into the living body; and at least one first light source disposed on the membrane for irradiating light to a photosensitive material in the living body.
Using the photostimulation apparatuses, the processes of injecting photosensitive material into the living body, irradiating light to the injected photosensitive material, and measuring an electrical signal from the living body for verification of photostimulation may be carried out with a single apparatus. Hence, the number of surgical operations on the living body may be reduced.
Further, since the apparatus is placed on the surface of cortex or dura, damage to the brain tissue may be minimized and a large area may be activated and/or inhibited simultaneously using light. Accordingly, it may be effectively utilized in the study of the brain, treatment of neuropsychiatric diseases, or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and advantages of the disclosed exemplary embodiments will be more apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1A is a perspective view of a photostimulation apparatus according to an exemplary embodiment;
FIG. 1B is an enlarged perspective view of the region A in FIG. 1A ;
FIG. 2A is a perspective view of a photostimulation apparatus according to another exemplary embodiment;
FIG. 2B is an enlarged perspective view of the region B in FIG. 2A ;
FIG. 3A is a schematic view of a photostimulation apparatus according to an exemplary embodiment inserted into the human body; and
FIG. 3B is a schematic view of a photostimulation apparatus according to another exemplary embodiment inserted into the human body.
DETAILED DESCRIPTION
Exemplary embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth therein. Rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of this disclosure to those skilled in the art. In the description, details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the presented embodiments.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of this disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Furthermore, the use of the terms a, an, etc. does not denote a limitation of quantity, but rather denotes the presence of at least one of the referenced item. The use of the terms “first”, “second”, and the like does not imply any particular order, but they are included to identify individual elements. Moreover, the use of the terms first, second, etc. does not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. It will be further understood that the terms “comprises” and/or “comprising”, or “includes” and/or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
In the drawings, like reference numerals in the drawings denote like elements. The shape, size and regions, and the like, of the drawing may be exaggerated for clarity.
FIG. 1A is a perspective view of a photostimulation apparatus according to an exemplary embodiment, and FIG. 1B is an enlarged perspective view of the region A in FIG. 1A .
Referring to FIGS. 1A and 1B , a photostimulation apparatus may include a membrane 2 and at least one cell 1 disposed on the membrane 2 . The photostimulation apparatus may be used as inserted at a location relatively close to the brain of a living body such as human or animals.
The membrane 2 may be prepared to have a dimension and a thickness appropriate for insertion into the living body by means of nanofabrication. For example, the membrane 2 may have a thickness t of about 1 mm or smaller. The membrane 2 may also have a thickness t of about 100 μm (micrometers) or smaller. Further, the membrane 2 may have a dimension of about 300 mm or smaller. As used herein, the dimension means the longest spatial length of an entity. For a polygon, the dimension may mean the length of the largest side. For an ellipse, the dimension may mean the major axis. For example, the membrane 2 may have the shape of a rectangular plate, with sides L 1 , L 2 about 300 mm or smaller. The length of the sides L 1 , L 2 may be the same or different. In another exemplary embodiment, the membrane 2 may have the shape of a disc or may have other different shapes.
The membrane 2 may be made of an organic material or an inorganic material. Further, the membrane 2 may be made of a flexible material so that it may be bent depending on the brain's motions. For example, the membrane 2 may be made of polyimide, polydimethylsiloxane (PDMS), or other suitable materials.
The at least one cell 1 may be disposed on the membrane 2 . In an exemplary embodiment, each cell 1 may have the shape of a rectangular plate, with sides L 3 , L 4 about 5 mm or smaller. The length of the sides L 3 , L 4 may be the same or different. The at least one cell 1 may be arranged regularly or irregularly.
In an exemplary embodiment, the at least one cell 1 may include a plurality of cells 1 arranged in arrays. For example, the plurality of cells may be arranged in an array having the shape of a rectangular lattice. The plurality of cells 1 may be spaced apart from each other by distances d 1 , d 2 in the transverse and longitudinal directions, respectively. For example, the distances d 1 , d 2 between the plurality of cells 1 may be about 1 mm or smaller. The distances d 1 , d 2 in the transverse and longitudinal directions may be the same or different. Since each cell 1 is spaced apart from each other, the membrane 2 may be folded or bent at the portion where the cells 1 are spaced apart from each other. As a result, the whole photostimulation apparatus may be bent according to the contour or motion of the brain.
The shape of the array of the plurality of cells 1 shown in FIGS. 1A and 1B are only exemplary. In other exemplary embodiments, the array may have a circular shape or may have other different shapes. Alternatively, the at least one cell 1 may be arranged on the membrane 2 irregularly.
Further, the shape of the cell 1 illustrated in FIGS. 1A and 1B are only exemplary. In other exemplary embodiments, the cell 1 may have the shape of a polyhedron different from those in FIGS. 1A and 1B or a curved figure. Each cell 1 may be formed by laminating a material on the membrane 2 . Alternatively, the cell may refer to a region formed on the membrane 2 by forming a light source or the like on the membrane 2 , which will be described later.
Each of the at least one cells may irradiate light with a specific wavelength to a photosensitive material in the living body in which the photostimulation apparatus is inserted to activate and/or inhibit the nerve cells in which the photosensitive material are expressed. Further, each cell 1 may detect the behavior of the brain nerve cells in response to the irradiation of light to the photosensitive material. In addition, the photosensitive material may be injected into the living body using each cell 1 .
The photosensitive material forms ion channels or ion pumps in the nerve cell which activate or inhibit the nerve cell by passing cations or anions into the nerve cell in response to the irradiated light. The photosensitive material may be, for example, ion channels/pumps and receptors chemically modified in response to light, naturally occurring photosensitive proteins, or the like.
The ion channel and receptor modified in response to light may have a structure in which a photoswitch is attached or injected adjacent to the receptor. For example, the ion channel may be a Shaker potassium channel. And, the receptor may be an ionic glutamate receptor (e.g. iGluR6) gated by light. The photoswitch may have an azobenzene group isomerized by light and, for example, may have a structure in which a potassium channel antagonist and an iGluR6 agonist are covalently bonded. By irradiating light with a specific wavelength, e.g. about 460 nm (nanometers), to the ion channel and receptor, a nerve cell may be activated, thereby generating an electrical signal. On the contrary, by irradiating light with a specific wavelength, e.g. about 580 nm (nanometers), the generation of the electrical signal from the nerve cell may be inhibited.
The photosensitive protein is based on rhodopsin which isomerizes when light with a specific wavelength is irradiated. For example, it may include the multiple-component Drosophila sp. visual system rhodopsin cascade (ChArGe), channelrhodopsin-2 (ChR2), or the like. By irradiating light with a specific wavelength to the photosensitive protein, e.g. light with a wavelength of about 460 nm (nanometers) for ChR2, the photosensitive protein may be activated to allow flow of cations into the nerve cell, thereby resulting in activation of the nerve cell.
For this purpose, each cell 1 may include a first light source 11 . The first light source 11 may irradiate light with a specific wavelength for activating or inhibiting the nerve cell by means of the photosensitive material. For example, for activation of the nerve cell, the first light source 11 may irradiate light with a wavelength shorter than about 500 nm (nanometers). On the contrary, for inhibition of the nerve cell, the first light source 11 may irradiate light with a wavelength of about 500 nm (nanometers) or longer.
In an exemplary embodiment, each cell 1 may further include a second light source 12 in addition to the first light source 11 . The first light source 11 and the second light source 12 may irradiate light with different wavelengths. For example, the first light source 11 may irradiate light with a wavelength shorter than about 500 nm (nanometers), and the second light source 12 may irradiate light with a wavelength of about 500 nm (nanometers) or longer. Accordingly, the nerve cell may be activated using the first light source 11 and, at the same time, the nerve cell may be inhibited using the second light source 12 .
The first light source 11 and the second light source 12 may be an organic light-emitting element or an inorganic light-emitting element. For example, the first light source 11 and the second light source 12 may be an organic light-emitting element such as an organic light-emitting diode (OLED) or an inorganic light-emitting element such as a light-emitting diode (LED), laser diode (LD) and vertical-cavity surface-emitting laser (VCSEL).
In an exemplary embodiment, each cell 1 may further include an injector 13 for injecting the photosensitive material into a living body. By injecting the photosensitive material into the living body using the injector 13 and irradiating light to the injected photosensitive material using the first and second light sources 11 , 12 , the nerve cell may be activated and/or inhibited by means of the photosensitive material. The injector 13 may be linked to a channel, valve, etc. through which the photosensitive material is transferred. Further, for control of the injection volume of the photosensitive material, the injector 13 may be connected to a micro dispenser, micro multiplexer, or the like.
In an exemplary embodiment, each cell 1 may further include an electrode 14 which detects an electrophysiological signal from the nerve cell activated or inhibited as light is irradiated by the first and second light sources 11 , 12 to the photosensitive material. The electrode 14 may be made of a conducting material such as metal. By detecting an electrical signal using the electrode 14 , the activation and/or inhibition of the nerve cell in the living body may be monitored. Further, in an exemplary embodiment wherein a plurality of cells 1 are arranged on the membrane 2 in arrays, the electrical signal can be detected from a larger area.
The arrangement of the first and second light sources 11 , 12 , the injector 13 and the electrode 14 in the cell 1 , and the arrangement of the cells 1 on the membrane 2 illustrated in FIGS. 1A and 1B are only exemplary. In other exemplary embodiments, the arrangements may be different from those illustrated in FIGS. 1A and 1B .
FIG. 2A is a perspective view of a photostimulation apparatus according to another exemplary embodiment, and FIG. 2B is an enlarged perspective view of the region B in FIG. 2A .
Referring to FIGS. 2A and 2B , a photostimulation apparatus may include a membrane 2 and at least one first light source 21 disposed on the membrane 2 . The photostimulation apparatus may be used as inserted at a location relatively close to the brain of a living body such as human or animals. The configuration and function of the membrane 2 are the same as those of the above exemplary embodiment described referring to FIGS. 1A and 1B . Therefore, a detailed description thereof will be omitted.
The at least one first light source 21 may be disposed on the membrane 2 . Each first light source 21 may have the shape of a hollow disc. In an exemplary embodiment, the first light source 21 may have a diameter D 1 of about 5 mm or smaller. The at least one first light source 21 may be arranged regularly or irregularly.
In an exemplary embodiment, a plurality of the first light sources 21 may be arranged in arrays. For example, the plurality of the first light sources 21 may be arranged in an array having the shape of a rectangular lattice. At this time, each first light source 21 may be spaced apart from each other by distances d 3 , d 4 in the transverse and longitudinal directions, respectively. For example, the distances d 3 , d 4 between the plurality of first light sources 21 may be about 1 mm or smaller. The distances d 3 , d 4 in the transverse and longitudinal directions may be the same or different. The whole photostimulation apparatus may be bent according to the contour or motion of the brain as the membrane 2 is folded or bent at the portion where the first light sources 21 are spaced apart from each other.
The shape of the array of the plurality of first light sources 21 shown in FIGS. 2A and 2B are only exemplary. In other exemplary embodiments, the array may have a circular shape or may have other different shapes. Alternatively, the at least one first light source 21 may be arranged on the membrane 2 irregularly.
The first light source 21 may irradiate light with a specific wavelength for activating or inhibiting the nerve cell by means of a photosensitive material. For example, for activation of the nerve cell, the first light source 21 may irradiate light with a wavelength shorter than about 500 nm (nanometers). On the contrary, for inhibition of the nerve cell, the first light source 21 may irradiate light with a wavelength of about 500 nm (nanometers) or longer.
In an exemplary embodiment, at least one injector 23 may be further disposed on the membrane 2 . Further, a plurality of the injectors 23 may be arranged in arrays. For example, the plurality of injectors 23 may be arranged in an array having a shape identical to that of the array of the plurality of first light sources 21 . The plurality of injectors 23 may be arranged such that one or more of the first light sources 21 are positioned between each injector 23 . In other words, in an array of the plurality of first light sources 21 , the injector 23 may be positioned replacing the first light source 21 with a specific interval. In another exemplary embodiment, the plurality of injectors 23 and the plurality of first light source 21 may be arranged in arrays having different shapes.
By injecting the photosensitive material into the living body using the injector 23 and irradiating light to the injected photosensitive material using the first light source 21 , the nerve cell may be activated and/or inhibited by means of the photosensitive material. For injection of the photosensitive material, the injector 23 may be linked to a channel, valve, etc. through which the photosensitive material is transferred. Further, for control of the injection volume of the photosensitive material, the injector 23 may be connected to a micro dispenser, micro multiplexer, or the like.
In an exemplary embodiment, a second light source 22 may be positioned in each of the at least one first light source 21 . Since each first light source 21 has the shape of a hollow disc, the second light source 22 may be positioned in the hollow area of the disc. For example, if the first light source 21 has a diameter D 1 of about 180 μm (micrometers), the second light source 22 positioned in the first light source 21 may have a diameter D 2 of about 128 μm (micrometers) or smaller.
The first light source 21 and the second light source 22 may irradiate light with different wavelengths. For example, the first light source 21 may irradiate light with a wavelength shorter than about 500 nm (nanometers), and the second light source 22 may irradiate light with a wavelength of about 500 nm (nanometers) or longer. Accordingly, the nerve cell may be activated using the first light source 21 and, at the same time, the nerve cell may be inhibited using the second light source 22 .
The first light source 21 and the second light source 22 may be an organic light-emitting element or an inorganic light-emitting element. For example, the first light source 21 and the second light source 22 may be an organic light-emitting element such as an OLED or an inorganic light-emitting element such as an LED, LD and VCSEL.
In an exemplary embodiment, the at least one second light source 22 may have the shape of a hollow disc, and an electrode 24 may be positioned in each second light source 22 . For example, if the second light source 22 has a diameter D 2 of about 128 μm (micrometers), the electrode 24 positioned in the second light source 22 may have a diameter D 3 of about 20 μm (micrometers) or smaller. The electrode 24 may detect an electrical signal generated from the nerve cell as light is irradiated to the photosensitive material by the first and second light sources 21 , 22 . The electrode 24 may be made of a conducting material such as metal. By detecting the electrical signal using the electrode 24 , the activation and/or inhibition of the nerve cell may be monitored.
FIG. 3A is a schematic view of a photostimulation apparatus according to an exemplary embodiment inserted into the human body.
Referring to FIG. 3A , a hole penetrating the human skull 200 may be formed on a portion of the skull 200 , and a photostimulation apparatus 100 may be positioned in the hole. Since the photostimulation apparatus 100 exposed through the hole below is located close to the brain, injection of a photosensitive material, irradiation of light to the photosensitive material, or detection of an electrical signal emitted from the nerve cell by means of the photosensitive material, or the like are possible.
FIG. 3B is a schematic view of a photostimulation apparatus according to another exemplary embodiment inserted into the human body.
Referring to FIG. 3B , a photostimulation apparatus 100 may be inserted beneath the human skull 200 . That is, the photostimulation apparatus 100 may be located between the skull 200 and the brain. In this case, a portion of the skull 200 may be made thinner by peeling and the photostimulation apparatus 100 may be located at the thin portion of the skull 200 . As a result, the whole photostimulation apparatus 100 may be located close to the brain, and a relatively larger area may be activated and/or inhibited using light.
While the exemplary embodiments have been shown and described, it will be understood by those skilled in the art that various changes in form and details may be made thereto without departing from the spirit and scope of this disclosure as defined by the appended claims. In addition, many modifications can be made to adapt a particular situation or material to the teachings of this disclosure without departing from the essential scope thereof. Therefore, it is intended that this disclosure not be limited to the particular exemplary embodiments disclosed as the best mode contemplated for carrying out this disclosure, but that this disclosure will include all embodiments falling within the scope of the appended claims. | A photostimulation apparatus may include: a membrane for insertion into a living body; and at least one cell disposed on the membrane. Each cell may include a first light source for irradiating light to a photosensitive material in the living body. Further, a photostimulation apparatus may include: a membrane for insertion into a living body; and at least one first light source disposed on the membrane for irradiating light to a photosensitive material in the living body. Since the photostimulation apparatus is placed on the surface of cortex or dura, it may minimize damage of the brain tissue and may activate and/or inhibit a large area simultaneously using light. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a pin tumbler lock.
2. Description of the Prior Art
Tumbler locks have been configured essentially permitting absolutely no change in unlocking conditions. On the other hand, a variety of more or less flexible locks have been provided recently, which may be re-set to operate under different unlocking conditions to repel the original key used during a construction work. However, such a lock of the prior art has such drawbacks as alteration of the unlocking condition is confined to only once and moreover provides no free conditioning so that the existing lock must be replaced if the current key is lost or to prevent others from attempting a trespass. More flexible locks have been recently provided permitting multiple re-setting after manufacture. The U.S. Pat. No. 3,999,413 discloses for example a lock assembly of the wafer tumbler type.
On the other hand, although a lock assembly of the pin tumbler type is also provided to permit multiple re-setting, it has generally remained intricate in construction and no simple assembly is available as the wafer type. The U.S. patent application Ser. No. 393,493 filed on Aug. 28, 1964 for example relates to a lock assembly of the pin tumbler type, but the lock of this reference comprises an adjustment mechanism which changes the length of tumblers and is operable from outside by means of a special element for exclusive use, bearing a disadvantage of an intricate and large construction so that it may be inapplicable to a low cost, simple lock.
SUMMARY OF THE INVENTION
An object of this invention is to provide means of easy replacement of a key with a different key for a lock of the pin tumbler type.
Another object of the present invention is to provide a lock of the pin tumbler type which features plurality of re-setting, with a simple inside mechanism so that an improved lock can be made available with respect to productivity, manufacturing cost and durability.
Another object of the invention is to provide a lock of the pin tumbler type having a considerable number of unlocking conditions.
Another object of the invention is to provide a lock of the pin tumbler type which permits a reversible change of the unlocking condition without decreasing the number of unlocking conditions by replacement of keys.
Another object of the invention is to provide a lock assembly of the pin tumbler type which allows replacement of a key by means of operating the current key or otherwise the re-setting key eliminating an intricate operation mechanism for the exclusive key replacement purpose.
The characteristics of the present invention is to provide a cylinder pocket in the inner surface of the cylindrical housing as well as a plug pocket in the plug to house upper and lower pins which are slidable radially in the pockets. An auxiliary pocket holding an auxiliary upper pin free to slide therein is provided in the housing to correspond to the plug pocket at a certain rotated distance from the housing pocket. Further, a change pin is so used that it shifts its position from the plug pocket to the auxiliary pocket and vice versa where the plug pocket and auxiliary pocket correspond to each other.
As described in the previous paragraph, the change pin is either interpositioned between the upper pin in the housing pocket and the lower pin in the plug pocket or removed therefrom. More particularly, the projected height of a key which pushes up the lower pin changes depending on agreement of the slide line which is the border between the cylinder and plug, with the border between the upper and lower pins or with the border between the upper pin and change pin. This means a replacement of the key with a different key. To replace the key, the current key or otherwise the paired key for replacing operation (hereinafter referred to as a re-setting key) is turned to rotate the plug till the plug pocket is brought to the position in agreement with the auxiliary pocket, removed from that position, and a new key or relative re-setting key is inserted to be turned back to the original position. In case a re-setting key is employed, the plug may be prevented from being rotated by a key to the pocket mating position. The change pin is movable into the auxiliary pocket from the plug pocket leaving the lower pin, but unmovable from the plug pocket into the housing pocket, which is for the purpose on one hand that the border between the change pin and lower pin is not brought into agreement with the border between the cylindrical housing and the plug at the mating position of the plug pocket and housing pocket, and on the other hand the border between the change pin and lower pin can be brought into agreement with the border between the housing and the plug at the mating position of the plug pocket and auxiliary pocket. Such construction is possible by way of providing means of concavo-convex engagement of the change pin with the lower pin and of releasing the engagement only at the mating position of the plug pocket and auxiliary pocket. Means to release the engagement of the change pin and the lower pin may comprise application of a magnetic force, or restoring force of a spring, or component force of the turning effort of the plug extended to the change pin to slip up into the auxiliary pocket.
As described above, the plug is rotatable when the upper face of the change pin is brought into agreement with the slide line at the mating place of the auxiliary pocket and the plug pocket, and in addition when the lower face of the change pin is in agreement with the slide line. Accordingly, said mating position permits the use of not only the current key or the re-setting key but a different key or the relative re-setting key whose height of the key projection is proportionately higher or lower by the length of the change pin. Therefore, keys can be replaced at this position. Further, if another new key or the relative re-setting key is inserted and turned back to the mating position of the plug pocket and the housing pocket, the original key or the relative re-setting key is no longer effective to rotate the plug. This is because either of the borders composed by the upper pin, lower pin and the change pin no longer agrees with the slide line between the housing and plug by insertion of the original key due to the change pin having been either removed or added.
According to the present invention, a change pin is used in the manner in which its position is interchanged between the auxiliary pocket and plug pocket so that a re-setting mechanism for changing the unlocking condition can be considerably simplified. The position of a change pin being reversibly changeable, alteration of the unlocking condition is also reversibly possible. Since the lock of this invention freely permits re-setting of the unlocking condition for vertually any number of times by operating a key or the relative re-setting key to change the position of the change pin, there is absolutely no need of taking the lock apart for re-setting purposes. If the current key is lost, the owner, by changing the unlocking condition without replacing the lock, can make the lost key no longer effective to operate the lock, preventing use for a trespass or the like. If the lock of this invention is mounted to a hotel guest room door, problems that may arise from a missing key or unauthorized use of a duplicated key can be eliminated by changing the unlocking condition each time a guest checks out. Further, the lock of this invention permits the selection of a number of reversible re-setting conditions, which is not found in the prior art, so that it may be advantageously operated by a master-key at a building site where the original key needs to be replaced with a new key after the construction. Re-setting operation is considerably simple, since the unlocking condition can be changed by turning the original key or the paired re-setting key to rotate the plug onto the position of the auxiliary pocket, removing the original key or the original paired re-setting key, and inserting a new key or a new paired re-setting key to turn the plug back onto its original position. Since there is a pair of conditions at each position of the auxiliary pockets, n number of auxiliary pockets will make an aggregate of 2 n conditions. By dividing a change pin into two, 3 n conditions will be available and 4 n by dividing it into 3. On the other hand, a manufacturer of locks will find a particularly improved productivity in the lock of this invention, because each pair of pins for pin tumblers can be fabricated and assembled in the same way to a tumbler lock which provides a number of unlocking conditions by merely changing the position of the change pins.
Further characteristics of the invention will be explained more in detail in the subsequent description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of one embodiment of the invention;
FIG. 2 is a cross-sectional view of the lock assembly of FIG. 1 with the first key inserted, taken essentially along the lines I--I of FIG. 1;
FIG. 3 is a cross-sectional view like FIG. 2, but with the first key turned through 90° clockwise about its longitudinal axis;
FIG. 4 is a cross-sectional view like FIG. 3, but with the first key replaced with the second key;
FIG. 5 is a cross-sectional view like FIG. 4, but with the second key turned through 90° counter-clockwise about its longitudinal axis;
FIG. 6 is an enlarged cross-sectional view of certain components shown in FIG. 4;
FIG. 7 to 11 show another embodiment, FIG. 7 corresponding to the cross section of the lock assembly of FIG. 1 taken along the lines I--I with the first key inserted;
FIG. 8 is a cross-sectional view like FIG. 7, but with the first key turned through 90° clockwise about its longitudinal axis;
FIG. 9 is a cross-sectional view like FIG. 8, but with the first key replaced with the second key;
FIG. 10 is a cross-sectional view like FIG. 9, but with the second key turned through 90° counter-clockwise about its longitudinal axis;
FIG. 11 is an enlarged cross-sectional view of a side section of certain components shown in FIG. 9;
FIG. 12 shows another embodiment, corresponding to the cross sectional view shown in FIG. 2;
FIG. 13 shows still another embodiment, corresponding to the cross sectional view shown in FIG. 2;
FIG. 14 also shows another embodiment, corresponding to the cross sectional view shown in FIG. 2;
FIG. 15 shows still nother embodiment, corresponding to the cross sectional view shown in FIG. 2;
FIGS. 16 to 18 show another embodiment, FIG. 16 corresponding to the cross sectional view shown in FIG. 2;
FIG. 17 is a partial cross-sectional view showing the manner in which replacement of the key is completed;
FIG. 18 is a partial cross-sectional view showing the manner in which the original key is inserted; and
FIG. 19 is a perspective view showing a utility example of the lock according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 to 6 show the preferred embodiment of a lock assembly of the two-sided pin tumbler type according to the present invention. Reference number 1 designates a cylindrical housing and 2, a cylinder plug. Said cylinder plug 2 is rotatably mounted in the cylindrical housing 1 along the slide line A and is functional to operate a working lever not shown in the drawings. Reference number 3 designates a key-slot. Reference number 4 designates a series of pockets provided in the inner surface of the cylindrical housing 1, extending radially therein and being displaced from one another along the longitudinal axis of the housing. Reference number 5 designates a series of plug pockets provided in the cylinder plug 2 to correspond with the mating housing pockets 4. The plug pockets 5 face the mating cylinder pockets 4 at a certain rotated position. Each cylinder pocket 5 and plug pocket 4 houses an upper pin 6 and lower pin 7 respectively and a change pin 8 is allocated to the fixed pocket interpositioned between said upper pin 6 and lower pin 7. Said upper pin 6 is supported within the housing pocket 4, and is spring biased from the bottom by means of a spring 9. The lower pin 7 is slidably inserted into the plug pocket 5 and is provided with an engaging cavity 7b on the upper end 7a.
Said change pin 8 as shown enlarged in FIG. 6 comprises a cylindrical body 81 and a working pin 82 slidable into said body 81. Said working pin 82 is formed with a magnetic material such as iron to be attracted by a magnet. The working pin 82 comprises a shaft 82a and a head 82b, the head 82b being tapered to form a frustum of a cone. Said cylindrical body 81 is provided with a hole 81a through which passes the shaft 82a of said working pin 82 and a receiving cavity 81b into which the head 82b of said working pin 82 is seated. When the working pin 82 is seated in the cylindrical body 81, the upper end of the head 82b of the working pin 82 and the upper end of the cylindrical body 81 are leveled even with the shaft 82a of the working pin 82 partially protruding outside the lower end of the cylindrical body 81. The projected part of the shaft 82a performs engagement with the receiving cavity 7b of said lower pin 7.
Therefore, the lower pin 7 is always in engagement with the change pin 8 so long as the change pin 8 is applied. Each of those pins 6, 7 and 8 overlaps each other within the pockets 4 and 5, composing a border B between the upper pin 6 and lower pin 7, a border C between the upper pin 6 and change pin 8 and a border D between the change pin 8 and lower pin 7. The border D between said change pin 8 and lower pin 7 always remains at the side of the lower pin 7 in a cavernous state.
Assuming that the first key 10 representing the current key or the paired re-setting key is inserted into the key-slot 3, when the upper guide edge 10a and the lower guide edge 10b of said first key 10 push to move each lower pin 7, bringing said border B or C into agreement with said slide line A, the plug 2 becomes rotatable within the cylindrical housing 1. Otherwise, rotation of the plug is restricted.
In addition to the housing pockets 4, said cylindrical housing 1 is provided with auxiliary pockets 11 arranged at an angular distance a 90° from the position of said cylindrical housing pockets 4. The auxiliary pockets may be allocated to correspond to all of said cylindrical housing pockets 4 but this will not always be necessary. Furthermore, said angular distance may not necessarily be 90°. An auxiliary upper pin 12 is supported by a spring 13 within the auxiliary pocket 11. As shown enlarged in FIG. 6, the auxiliary upper pin 12 comprises a magnet 121 and a casing 122 which houses the magnet 121, the inside wall on the casing 122 being tapered to shape a countersink 122b to match the tapered head 82b of said working pin 82. The magnet 121 is seated in the casing 122 and fixed in its recess to attract said working pin 82 and partially pull the head 82b of the working pin 82 into said casing 122.
As has been described, the cylindrical housing 1 being provided with an auxiliary pocket 11 paired with the housing pocket 4, said plug pocket 5 has a passage linked not only with the corresponding housing pocket 4 but also with the paring auxiliary pocket 11. Said change pin 8 is either positioned on the side of the plug pocket 5 or held inside the auxiliary pocket 11.
Performance of the embodiment will now be described with reference to FIGS. 2 to 5 showing operating conditions at the cross section taken along the lines I--I of FIG. 1. As shown in FIG. 2, if the first key 10 is inserted into the key-slot 3, the upper guide edge 10a of the first key 10 pushes up the lower pin 7, bringing the border B between the lower pin 7 and upper pin 6 into agreement with the slide line A. On the other hand, the lower guide edge 10b of the first key 10 pushes down the lower pin 7, bringing the border C between the upper pin 6 and the change pin 8 which engages with said lower pin 7 into agreement with the slide line A. The cylinder plug 2 is rotatable when said condition is satisfied at other positions as shown in FIG. 1.
Assuming that the first key 10 which satisfies said condition is turned through 90° to the right, the plug pockets 5 and 5 correspond to the auxiliary pockets 11 and 11 respectively at the diagrammatical left and right respectively. FIG. 3 shows such a condition, under which the change pin 8 which has been turned together with the cylinder plug 2 faces the auxiliary pocket 11 shown at the diagrammatical leftside and the working pin 82 is attracted to the magnet 121. Therefore, a part of the head 82b of the working pin 82 is admitted into the casing 122 of the auxiliary upper pin 12 and at the same time the shaft 82a of the working pin 82 is released from the engaging cavity 7b of the lower pin 7.
Now, if the first key 10 is pulled out at this position and the second key 14 which is a new key or a new re-setting key is inserted, the condition of the relative components changes as shown in FIG. 4. More particularly, the radius length between the axis of rotation of the second key 14 and its upper guide edge 14a is shorter than that represented by the upper guide edge 10a of the first key 10 by the size of the cylindrical body 81 of said change pin 8, and the distance to the lower guide edge 14b of the second key 14 is longer than that represented by the lower guide edge 10b of the first key 10 by the size of the cylindrical body 81 of said change pin 8. Therefore, as shown in the drawing, the left change pin 8 is released from retention by the lower pin 7 and pushed into the left-side auxiliary pocket 11, aligning the border D between the changer pin 8 and lower pin 7 with the slide line A. In the right-side auxiliary pocket 11 in FIG. 4 the change pin 8 is pushed out of the auxiliary pocket 11 leaving only a part of the head 82b of the working pin 82 attracted by the magnet 121 in the casing 122. If the second key 14 is turned back through 90° the condition changes into the one shown in FIG. 5. It will be obviously noted upon comparison of FIG. 5 with FIG. 2 that the change pin 8 has changed its position between the corresponding plug pocket 5 and the auxiliary pocket 11. Specifically, the unlocking condition has been changed. The lock of this invention is configured so that the cylinder plug 2 is not rotatable with a matching key onto the assigned position where the plug pocket 5 agrees with the auxiliary pocket 11 in case a re-setting key is used. If the second key 14 is pulled out under the condition shown in FIG. 5 for replacement with the first key 10, the slide line A being non-aligned with the borders D and B, the cylinder plug 2 is prevented from rotating.
Furthermore, the first key 10 can be turned on from the position shown in FIG. 3 or the second key 14 from the position in FIG. 4 to that in FIG. 5, which may be best described with reference to FIG. 6 which is an enlarged view of the right-side auxiliary pocket 11 shown in FIG. 4. The working pin 82 being pushed into the side of the auxiliary upper pin 12 passing over the slide line A, said working pin 82 may not seem to be movable. However, both the head 82b of the working pin 82 which extrudes from the slide line A and the countersink 122b on the opening end of the casing 122 of the auxiliary upper pin 12 being tapered, a turning effort extended to the cylinder plug 2 from outside and a resultatnt component of a force generating in the direction of the tapered face of the countersink 122b, will press the head 82b of the working pin 82 to the tapered countersink 122b and guide it in the direction of the slide line A to slip down the working pin 82 overcoming the attraction of the magnet 121. The reason for providing the engaging cavity 7b on the upper end 7a of said lower pin 7 is to bring the upper end 7a of the lower pin 7 into agreement with the slide line A when the lower pin 7 is pushed up to shift the change pin 8 from the plug pocket 5 into the auxiliary pocket 11, and to release engagement of the lower pin 7 and change pin 8. The function of the lower pin 7 and change pin 8 generally proves unsuccessful if the concavo-convex relation is reversed.
FIGS. 7 to 11 show another embodiment wherein the upper pin 6 and lower pin 7 are identical to the previously described embodiment but a change pin 8, the accompanying auxiliary pocket 11 and the auxiliary upper pin 12 are different. The change pin 8 comprises a small cylindrical projection 83 which is received by the cavity 7b of the lower pin 7, a large cylindrical body 84 of which sliding is guided by the inside wall of the plug pocket 5 and a tapered part 85 extending between said large body portion 84 and said small projection 83. The auxiliary pocket 11 is shaped to a stepped hole. More particularly, the auxiliary pocket 11 has an opening 111 whose diameter is identical to that of said plug pocket 5 and an enlarged hole 113 beyond the enlarging step 112 which is provided slightly inside the slide line A. Further, an auxiliary upper pin 12 is a stepped pin having a projection 123 and the magnet 121 is not used. The projection 123 of said auxiliary upper pin 12 has a diameter interfitting in said opening 111 and a length identical to that of the depth of the opening 111 of said auxiliary pocket 11.
Now, operation of the lock according to this embodiment will be described. FIG. 7 shows that the first key 10 is inserted into the key-slot 3, wherein the upper guide edge 10a of the first key 10 pushes up the lower pin 7 bringing the border C between the change pin 8, which engages with the lower pin 7, and the upper pin 6 into agreement with the slide line A on one hand, and on the other, the lower guide edge 10b of the first key 10 pushes down the lower pin 7, bringing the border B between said lower pin 7 and upper pin 6 into agreement with the slide line A. If the first key 10 is turned on to the right through 90° under this condition, the lock is conditioned as shown in FIG. 8. As in the case of the previous embodiment, if the lock is positioned so that under which the auxiliary pocket 11 corresponds to the plug pocket 5 by a turn of the cylinder plug 2, the auxiliary pin 12, the change pin 8 and lower pin 7 are always overlapped with each other. It is possible to turn the first key 10 further ahead from the state shown in FIG. 8, which will be described later with reference to FIG. 11.
If the first key 10 is removed and the second key 14 is inserted under the condition in FIG. 8, the lock will be positioned as shown in FIG. 9. The upper guide edge 14a of the second key 14 pushes up the lower pin 7 to shift the change pin 8 into the auxiliary pocket 11 shown at the right-side of the drawing, bringing the upper end 7a of the lower pin 7 into alignment with the slide line A. On the other hand, the pushing stroke of the lower pin 7 by the lower guide edge 14b of the second key 14 decreases, and the change pin 8 is pushed out of the auxiliary pocket 11 shown at the left-side of the drawing, bringing the border C between the change pin 8 and auxiliary pin 12 into alignment with the slide line A. If the second key 14 is turned counter-clockwise through 90° from the position in FIG. 9, the lock will be positioned as shown in FIG. 10. It will be obviously noted by comparing FIG. 10 with FIG. 7 that the position of the change pin 8 has been interchanged between the corresponding plug pocket 5 and auxiliary pocket 11. This means that the unlocking condition has been changed. Under this condition, therefore, the lock is no longer turnable by the first key 10. FIG. 11 is an enlarged diagram of the right-side auxiliary pocket 11 shown in FIG. 9, which is the same as the left-side auxiliary pocket 11 in FIG. 8, wherein the cylinder plug 2 is rotatable because of the tapered part 85 arranged on the change pin 8 and the enlarging step 112 provided in the auxiliary pocket 11. More particularly, if the cylinder plug 2 is turned along the slide line A under the condition shown in FIG. 11, the tapered part 85 of the change pin 8 comes into contact with the corner 114 of said enlarging step 112 due to the resultant component of a force generated in the tapered direction, which slips up the change pin 8 releasing the small diametrical projection 83 of change pin 8 from engagement with the cavity 7b of lower pin 7. Only the upper end 7a of lower pin 7 therefore comes in alignment with the slide line A permitting the rotation. In this instance, if the concavo-convex relation is reversed, rotation is restricted even though the lower pin 7 is disengaged from the change pin 8.
Factors common to the above described two embodiments are: the positions of change pin 8 is reversibly changeable by means of the auxiliary pocket 11 in the cylindrical housing 1; the change pin 8 is changeable in the auxiliary pocket 11 by rotating the cylinder plug 2, i.e. the vertically positioned key being turned through 90° to produce the change at a horizontal position according to the embodiment; the key is replaced at this horizontal position; and not only said first key 10 and the second key 14, but other keys are applicable at the horizontal position. In addition to the foregoing, however, if a new key, the second key 14 for example, is inserted and turned back to the upright position, only the second key 14 is effective at this vertical position. Furthermore, the number of unlocking positions will be 2 n if the number of the auxiliary pockets 11 is n and is changeable reversibly, and therefore is auxiliary pockets 11 are provided to correspond to all the cylindrical housing pockets 4, 2 l reversible unlocking conditions will be available with l number of housing pockets 4. This means that if 12 housing pockets are provided on the upper and lower part as shown in FIG. 1 for example, a lock will provide 12 12 or 4,096 unlocking conditions. Furthermore, such a lock may be provided with a variety of combinations of different length of the change pins 8, lower pins and upper pins for example to compose many groups, each having 4,096 conditions. Further, according to the embodiments, engagement of the lower pin 7 with the change pin 8 is conducted in the cavity provided on the lower pin 7 and the projection on the change pin 8.
Another embodiment is shown in FIG. 12. This embodiment has a strong resemblance to the embodiment previously described with reference to FIGS. 1 to 6 with the exception that the upper pin 6 is provided with a pointed edge 6a, the auxiliary pin 12 needs no magnetic material, a working pin 82 of the change pin 8 is spring biased so that the head 82b and shaft 82a respectively of the working pin 82 are always leveled with the cylindrical body 81 of change pin 8, i.e. the top and bottom of the change pin 8 are always held even by means of a spring 86, and unlike the previous embodiments the head 82b of working pin 82 need not be tapered to a shape of a frustum of a cone.
The pointed projection 6a of said upper pin 6 pushes down the working pin 82 by that length to bring the lower pin 7 into engagement with the change pin 8, and as regards the relation between the lower pin 7 and upper pin 6 as well as the relation between the change pin 8 and upper pin 6, the upper pin 6 slips up its pointed projection 6a into the housing pocket 4 resisting the spring 9 as the cylinder plug is turned so that rotation of the cylinder plug 2 is not prevented. To replace a key, the first key 10 is first turned to the right through 90° under the condition shown in FIG. 12. The lower pin 7 and change pin 8 are positioned as shown by imaginary lines in FIG. 12. The first key 10 is then removed under this condition and the second key not shown in the drawing is inserted and turned back through 90° to complete re-setting. Under this condition, even if the original first key 10 is inserted, rotation is restricted owing to non-alignment of the slide line A with borders B, C and D.
Still another embodiment is shown in FIG. 13. This embodiment also strongly resembles the previously disclosed embodiment referred to in FIGS. 1 to 6. The upper pin 6 is provided with a pointed edge 6a in the same manner as in the aforementioned embodiment shown in FIG. 12. Instead of an auxiliary upper pin 12, a working pin 82 of the change pin 8 is a magnet to attract the working pin 82 to the auxiliary upper pin 12 in the auxiliary pocket 11. To replace a key, the first key 10 is turned to the right through 90° from the condition shown in FIG. 13, when the lower pin 7 and change pin 8 in the cylinder plug 2 shown at the lower part of the drawing slip up the pointed edge 6a of upper pin 6 into the housing pocket 4 at the initial stage of rotation resisting a spring 9. The lower pin 7 and change pin 8 when turned through 90° are positioned as shown by imaginary lines in the drawing. The change pin 8 has been disengaged with the lower pin 7 by this time. Now the first key 10 is removed, the second key not shown in the drawing is inserted and turned back through 90°, replacement of a key is completed.
Still another embodiment is shown in FIG. 14. According to this embodiment, the lower pin 7 is provided with a cavity 7c, within which an engaging element 71 is supported by means of a spring 72 to push it forward to extend from said casing cavity 7c at all times. The force of spring 72 is weaker than the spring 9 in the housing pocket 4. The engaging element 71 comprises a bar magnet and is positioned with its leading N pole radially outwardly and trailing S pole radially inwardly. Change pin 8 is also provided with a casing cavity 8a to receive the engaging element 71. The auxiliary upper pin 12 comprises a magnet and is arranged with its N pole radially inwardly and S pole radially outwardly. The poles are arranged so that the auxiliary upper pin 12 and the engaging element 71 repel each other. To replace a key, the first key 10 is turned to the right through 90° from the condition in FIG. 14 in which the key is inserted, and the lower pin 7 and change pin 8 are positioned as shown in imaginary lines in FIG. 14. At this position, the engaging element 71 is repelled to disengage with the change pin 8 by the magnetic force of the auxiliary upper pin 12. If the first key 10 is removed under this condition and the second key not shown in the drawing is inserted and turned back through 90°, replacement of a key is completed. An embodiment according to FIG. 15 shows a plurality of change pins 8 positioned between the upper pin 6 and lower pin 7, in this instance a maximum of 3 change pins 8 being interpositioned between the upper pin 6 and lower pin 7. Although the embodiment shows that the change pin 8 appears to be divided into 3 pieces, an engaging hole 8b is provided through the center of the change pin 8 to permit projection of the engaging element 71 therethrough. To replace a key, assuming the lock condition is as per FIG. 15, with the first key 10 inserted, the first key 10 is turned to the right through 90° to mate the auxiliary pocket 11 and plug pocket 5 with each other, and the lower pin 7 and change pin 8 are positioned as shown in imaginary lines in FIG. 15. Under this condition, there are always 3 change pins 8 interpositioned between the auxiliary upper pin 12 and lower pin 7 with the engaging element 71, repelled by a magnetic force of the auxiliary upper pin 12, being released from engagement with all the change pins 8. If the first key 10 is removed under this condition and the second key not shown in this drawing is inserted and turned back through 90°, replacement of a key is completed. At this time, any number of change pins 8, 3 pieces, 2 pieces, 1 piece only or none at all, may be left in the auxiliary pocket 11. Therefore, referring to the unlocking condition, since there are 4 unlocking conditions at each place, n number of auxiliary pockets 11 will aggregate to 4 n unlocking conditions and reversible to change. If all the 12 housing pockets 4 are provided with auxiliary pockets 11 with reference to FIG. 1 for example, 4 12 =16,777,216 unlocking conditions will be available.
FIGS. 16 to 18 show still another embodiment. According to this embodiment, the lower pin 7 is provided with an engaging cavity 7b and the change pin 8 with a pointed edge 8c which can slip up to be received by the engaging cavity 7b. The embodiment is characteristic in that the depth of the housing pocket is equal to the total length of the upper pin 6 and change pin 8 less the height of said pointed edge 8c. To replace a key, the first key 10 under the condition shown in FIG. 16 is turned to the right through 90° to condition the lower pin 7 and change pin 8 as shown by imaginary lines in the drawing, so that the change pin 8 engages with the lower pin 7 with only its pointed edge 8c projecting into the plug pocket 5 from the auxiliary pocket 11. The first key 10 can of course be turned further on, because the pointed ege 8c of the change pin 8 slips up into the auxiliary pocket 11. Then, if the first key 10 is removed at its rotated position through 90°, and the second key 14 is inserted and turned back through 90°, replacement of a key is completed as shown in FIG. 17. In this instance, even though the second key 14 is removed and the original first key 10 is inserted, the key is no longer rotatable because the upper pin 6 is blocked by the bottom of the housing pocket 4 preventing the change pin 8 from slipping up into the housing pocket 4.
Replacement of the change pin 8 is automatically performed by operating a key according to each of the preceding embodiments, in addition to which other such means may be applicable for shifting of the change pin 8 to an aligned position of the plug pocket 5 and auxiliary pocket 11, i.e. shifting from the plug pocket 5 into the auxiliary pocket 11, or to the contrary may be operated by inserting from outside a magnet bar into a slot provided near the auxiliary pocket 5 in the cylindrical housing 1 or other mechanical means operable from outside.
Above described embodiments have been confined to a lock assembly of pin tumbler type, but an example of its usefulness may now be referred to a door lock of a hotel guest room. FIG. 19 shows such an example. Reference number 21 designates a door, 22 a latch and 23 a dead bolt. A lock 24 is provided for exclusive use by a guest and another lock 25 for hotel administration purpose so that the guest and hotel will not use the same key-hole. The tumbler lock of this invention is mounted for exclusive use by the guest. By providing the pin tumbler lock of the present invention, unlocking conditions may be easily changeable without replacing its cylinder, and countermeasures for lost, stolen or duplicated keys can be assured of extremely easy and quick operation, ensuring safety measures against any attempt of illegal trespassing and the like. Furthermore, the hotel administration keys need no alteration for replacement of a guest's key, eliminating the drawbacks of a master key such as a maid's key or emergency key becoming no longer effective with a certain room, or of replacing the keys of all hotel rooms in order to replace one. | A tumbler lock comprising housing pockets in an outer housing and plug pockets in a cylindrical plug rotatably mounted in the housing holding slidably outer and inner pins respectively, auxiliary pockets in the housing corresponding to the plug pockets at a certain rotated position circumferentially spaced from the housing pockets holding therein auxiliary pins, and change pins which may be interpositioned between the inner, outer and auxiliary pins and interchanged between the respective pockets so that the change pins may be freely shifted to reset the back to be operated by different keys. | 8 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/147,469, entitled “Power Regulator For Use With Wireless Communication Device,” filed Jun. 26, 2008, which claims the benefit of U.S. Provisional Application Ser. No. 60/937,396, filed Jun. 26, 2007, U.S. Provisional Application Ser. No. 60/937,397, filed Jun. 26, 2007, and U.S. Provisional Application Serial No. 61 / 012 , 262 , filed December 7 , 2007 , the substance of which is incorporated herein by reference for the entire disclosures of these prior applications.
TECHNICAL FIELD
[0002] The systems and methods relate generally to the field of process control systems. More specifically, the disclosed systems and methods relate to field devices powered at least partly by process control loops.
BACKGROUND
[0003] Conventional process control systems generally include basic components for sensing, measuring, evaluating, and adjusting or otherwise controlling a variety of process variables. Additionally, common systems include components that provide means for communicating information about process control variables between sensing, measuring, or adjusting components and evaluation components. One such system for communicating information is a two-wire system that creates a loop that physically connects a sensing, measuring, evaluating, or adjusting device to a controller.
[0004] Sensing, measuring, evaluating, and/or adjusting devices in industrial production environments are generally referred to as field devices. Field devices commonly sense or monitor one or more process control variables such as temperature, pressure, or rate of fluid flow, among others. Many of these field devices can communicate information about the sensed or monitored variable to a process controller by regulating electrical current on the two-wire system. The controller in this type of environment can sense the electrical current, such as by using a current sense resistor, and translate the sensed magnitude of the current, as well as any sensed change of the current, into information about the sensed or monitored control variable. Many common field devices can receive information from the controller and effect changes or adjustments to the sensed or monitored control.
[0005] Two methods of communicating information using a multi-wire loop system include analog signaling methods, such as communicating information via an analog current signal, and digital signaling methods that can communicate information as a frequency shift keyed carrier signal which can be superimposed on, and coexist with, an analog signaling method on the multi-wire loop. One digital signaling method is the Highway Addressable Remote Transducer (“HART”) communications protocol from the HART® Communication Foundation. As referred to herein, HART refers to any past or present version of the HART protocol, including Wireless HART, variants of such versions, as well as any future version that may be created so long as those future versions are compatible or can be modified to be compatible with the systems and methods disclosed herein.
SUMMARY
[0006] According to one embodiment, a power management circuit can comprise a power regulator and a wireless communication device. The power regulator is configured to maintain a voltage level at an input and includes an input and an output. The input is configured to receive a current signal communicated between a power supply and a field device. The output is configured to deliver charging power. The wireless communication device is in electrical communication with the power regulator and is configured to receive the charging power to power the wireless communication device. The charging power is generated from the voltage level at the input and the current signal. The charging power also changes in response to a change in the current signal.
[0007] A process control system comprises a field device, a power supply, and a power management circuit. The power supply is in electrical communication with the field device. The power supply is configured to transmit a current signal to the field device. The field device is configured to regulate the current signal. The power management circuit is in electrical communication with each of the field device and the power supply. The power management circuit comprises a power regulator and a wireless communication device. The power regulator is configured to maintain a voltage level at an input. The power regulator includes an input and an output. The input is configured to receive the current signal. The output is configured to deliver charging power. The wireless communication device is in electrical communication with the power regulator and is configured to receive the charging power to power the wireless communication device. The charging power is generated from the voltage level at the input and the current signal. The charging power changes in response to a change in the current signal.
[0008] A method for managing power for a wireless communication device comprises receiving a current signal at an input, the current signal being transmitted between a power supply and a field device. The method further comprises regulating a voltage level at the input and generating charging power from the voltage level at the input and the current signal, wherein the charging power changes in response to a change in the current signal. The method yet further comprises delivering the charging power to an electrical storage device and delivering the charging power from the electrical storage device to a wireless communication device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the same will be better understood from the following description taken in conjunction with the accompanying drawings in which:
[0010] FIG. 1 is a system block diagram of a process control loop;
[0011] FIG. 2 is a system block diagram of a process control loop; and
[0012] FIG. 3 is a system block diagram of a power management circuit.
DETAILED DESCRIPTION
[0013] Most components and methods disclosed are described with reference to the drawings. In drawings, like reference numbers are used to refer to like elements throughout the drawings. In the following description, to aid in explanation, a number of specific details are provided to promote understanding of the disclosed subject matter. It may be evident, however, that certain of these specific details can be omitted or combined with others in a specific implementation. In other instances, certain structures and devices are shown in block diagram form in order to facilitate description. Further, it should be noted that although specific examples presented can include or reference specific components, a specific implementation of the components and methods disclosed and described is not necessarily limited to those specific examples and can be employed in other contexts as well. Those of ordinary skill in the art will readily recognize that the disclosed and described components and methods can be used to create other components and execute other methods in a wide variety of ways.
[0014] FIG. 1 is a system block diagram of a process control system 100 . As illustrated, a field device 102 can include connection terminals 104 , 106 to which control loop wires 108 , 110 can be connected. A controller 112 can include a power supply 114 that is operable to supply electrical current (e.g., loop current) and voltage to the control loop wires 108 , 110 . In particular, a positive terminal of the power supply 114 can be in electrical communication with the control loop wire 108 and a negative terminal of the power supply 114 can be in electrical communication with the control loop wire 110 . In one embodiment, the power supply 114 can produce loop current magnitudes levels from approximately 3.5 mA to approximately 20 mA during normal operation, with maximum current values as high as approximately 130 mA during maximum fault conditions. However, any of a variety of other current or voltage ranges may be provided by the power supply, such as may correspond with voltage and current parameters for a particular field device, for example.
[0015] In one embodiment, as illustrated in FIG. 1 , the field device 102 can include a current regulator 116 that is operable to change amounts of loop current provided through the control loop wires 108 , 110 . Using the current regulator 116 , the field device 102 can regulate the amounts of electrical current to communicate a control process variable to the controller 112 . For example, if the field device 102 is configured to sense temperature, the current regulator 116 can regulate the amounts of current provided through the control loop wires 108 , 110 to indicate the monitored temperature. It will be appreciated that any of a variety of suitable alternative embodiments can indicate a control process variable in the field device such as, for example, a current shunt, a voltage shunt, or the like.
[0016] In order to communicate the amount of current to the controller 112 , in one embodiment, the controller 112 can include a current sense resistor 118 which can operate to sense the loop current provided through the control loop wires 108 , 110 . However, it will be appreciated that the controller 112 can sense loop current or other variables in any of a variety of suitable alternative configurations. Additionally or alternatively, the process control system 100 can include digital signaling components (not shown) to facilitate the communication of information as a carrier signal on the control loop wires 108 , 110 . In one embodiment, the field device 102 can include Highway Addressable Remote Transducer (“HART”) communication components, such as wireless HART communication components. However, the process control system can include components for any of a variety of suitable alternative communication protocols such as, for example, ISA SP100 and Fieldbus among others.
[0017] It will be appreciated that the process control system 100 can communicate with an associated network to provide information to a host controller. Conventionally, the controller 112 communicates with the associated network via wired communication. However, in some embodiments, the controller 112 may not support wired communication with the network (e.g., when digital signaling equipment is not present on the controller 112 or during failure of digital certain signaling equipment). Therefore, in one embodiment, as illustrated in FIG. 2 , a wireless adapter device 220 can be included. As will be described in more detail below, the wireless adapter device 220 can include components and circuitry that are configured to provide wireless radio frequency (“RF”) communications with an RF-based network in a facility that can communicate with a controller 212 or other suitable controllers. The wireless adapter device 220 can function as a gateway between components that can provide digital signaling for a field device 202 and a wireless communication network (not shown) in a facility. The controller 212 can be the controller 112 of FIG. 1 or as another suitable controller. The field device 202 can be the field device 102 depicted and described in FIG. 1 or can be another suitable field device.
[0018] Conventionally, the wireless adapter device 220 can be powered by dedicated power sources such as, for example, a separate wired power circuit, a battery, or a solar power cell, among others. However, installation and maintenance of a wireless adapter device powered by these dedicated power sources can be costly and time consuming. Therefore, as illustrated in FIG. 2 , the wireless adapter device 220 can provided in electrical communication with the control loop wires 208 a, 208 b, 210 a , 210 b such that the wireless adapter device 220 can be powered from loop current through the control loop wires 208 a , 208 b , 210 a, 210 b. In such an embodiment, the wireless adapter device 220 can include a power management circuit 222 provided between nodes L1P and L1N which can be connected in series with the control loop wires 208 a and 208 b. As described in more detail below, insertion power can be provided to the power management circuit 222 to power the wireless adapter device 220 without substantially interfering with the loop current. Accordingly, the wireless adapter device 220 can be powered by the process control system 200 without hindering the field device 202 from communicating a control process variable to the controller 212 (e.g., via current on loop wires 208 a, 208 b, 210 a, 210 b ).
[0019] FIG. 3 is a system block diagram of one embodiment of the power management circuit 222 . It will be appreciated that, the power management circuit 222 can be used in any of a variety of process control systems such as illustrated in FIGS. 1 and 2 , among other systems. The power management circuit 222 can be electrically connected between nodes L1P and L1N to facilitate the flow of loop current through the power management circuit 222 when the nodes L1P and L1N are connected in series with the loop wires 208 a and 208 b. The flow of loop current through the power management circuit 222 and can induce an insertion voltage across nodes L1P and L1N. Conventionally, this insertion voltage is insufficient to power the wireless adapter device 220 . Therefore, the power management circuit 222 can include a voltage converter 228 connected to the insertion voltage at an input 230 . An output 232 of the voltage converter 228 can be connected with certain electronic components of the wireless adapter device 220 such as an amplifier 234 , a current loop amplifier 250 , a HART interface logic device 225 , and a microcontroller 247 . The voltage converter 228 can convert the insertion voltage to an appropriate source voltage for powering each of the electronic components of the wireless adapter device 220 .
[0020] The power management circuit 222 can include a wireless communication device 224 . The wireless communication device 224 can be configured to provide wireless RF communications to transmit information (e.g., process variable information) between the wireless adapter device 220 and an RF based network in a facility. In certain embodiments, the wireless communication device 224 can include a transceiver that is supportive of any of a variety of wireless platforms such as IEEE 802.11, Bluetooth, microwave, infrared, or the like. In addition, the power management circuit can further include HART interface logic 225 associated with the wireless communication device 224 to facilitate communication according to a HART protocol.
[0021] It will be appreciated that the power available from the loop current (e.g., insertion power) to power the wireless communication device 224 is generally the multiplicative product of the loop current and the insertion voltage. Typically, the wireless communication device 224 consumes more instantaneous power than is available as insertion power. The power management circuit 222 can include an electrical storage element device 226 that is configured to store insertion power and deliver the stored insertion power to the wireless communication device 224 as needed. Although the electrical storage device 226 is illustrated in FIG. 3 to comprise a supercapacitor, it will be appreciated that, any of a variety of alternative suitable electrical storage devices can be provided such as a general purpose energy storage capacitor or a battery, for example.
[0022] The electrical storage device 226 can be charged by a second voltage converter 244 . As illustrated in FIG. 3 , the electrical storage device 226 can be in electrical communication with output OUT of the second voltage converter 244 . The second voltage converter 244 can transfer substantially all of the insertion power available, less the power consumed by the first voltage regulator 232 , to charge the electrical storage device 226 . Electrical energy can be provided from the electrical storage device 226 to meet the instantaneous and long term power requirements of the wireless communication device 224 .
[0023] It will be appreciated that the storage capacity of the electrical storage device 226 can be many times greater than the insertion power such that charging of the electrical storage device 226 can take a relatively long period of time (potentially ranging from about one minute to a few hours). When the power from the electrical storage device 226 becomes depleted, the voltage (e.g., radio voltage) of the electrical storage device 226 can also become depleted. To optimize the delivery of the power from the electrical storage device 226 at a substantially constant voltage, the power management circuit 222 can include a third voltage converter 252 that is in electrical communication with each of the electrical storage device 226 and the wireless communication device 224 . The third voltage converter 252 can generate a constant regulated radio voltage regardless of whether the electrical storage device 226 is charged to maximum capacity or is nearly depleted.
[0024] Conventionally, the insertion voltage has been regulated to a desired setpoint with a current shunt provided in parallel with the power management circuit 222 . In such an arrangement, loop current is divided between the power management circuit and the current shunt (e.g., a current divider circuit). If the loop current changes (e.g., due to a changing process variable), the current through the current shunt correspondingly changes to maintain the balance between the current shunt and the power management circuit thereby maintaining a constant insertion voltage drop. It will be appreciated however that any current that flows through the current shunt is not available to power the wireless adapter device and is wasted.
[0025] The second voltage converter 244 can be configured to regulate the insertion voltage without the need for a conventional-type current shunt. In some conventional configurations, voltage converters maintain a consistent voltage level at their output by varying the power transferred from their input. Generally, this conventional voltage regulator configuration is suitable where there is ample power provided at the input (e.g., to satisfy the power demands of a circuit electrically connected to the output of the voltage regulator). However, when the current and power provided at the input (e.g., input power) is limited, as is the case with the loop current into the power management circuit 222 , and the demand on the output is higher than the input power, as is the case with the electrical storage device 226 , a conventional voltage converter configuration may transfer too much power to the output thereby reducing the voltage at the input.
[0026] The second voltage converter 244 , therefore, can be configured as a power converter to sense and control the insertion voltage at the input 230 and to balance the insertion power with the power transferred into the electrical storage device 226 . In one embodiment, the insertion voltage can be compared with a reference voltage to regulate the insertion voltage. For example, as illustrated in FIG. 3 , the amplifier 234 can be in communication with a feedback input FB of the second voltage converter. A reference voltage is shown to be connected to a positive input 238 of the amplifier 234 . A variable scaler 242 can be connected to a negative input 236 of the amplifier 234 . The insertion voltage can be provided to the amplifier 234 through the scaler and the amplifier 234 can compare it to the reference voltage. The amplifier 234 can provide a control signal to the feedback input FB to regulate the insertion voltage to the reference voltage. It will be appreciated, however, that a power converter can be provided in any of a variety of suitable alternative arrangements to maintain an insertion voltage drop at a particular level.
[0027] The power management circuit 222 is therefore configured to control the insertion voltage while allowing full loop current (less the miniscule current consumed by the other circuits) to flow to the electrical storage device 226 (e.g., to power the wireless adapter device 220 ). Accordingly, the second voltage converter 244 can overcome some of the shortcomings of using a conventional current shunt to regulate the insertion voltage. For example, the insertion power (less the miniscule power consumed by the other circuits) generated from the insertion voltage and the loop current can be delivered to the electrical storage device 226 . When the loop current changes (e.g., when a control process variable changes), the change in power is transmitted to the electrical storage device 226 via the second voltage converter 244 (e.g., the power management circuit 222 can track and adapt in real-time).
[0028] It will be appreciated that the power management circuit 222 can be configured as an “Energy Pump” circuit which converts the insertion voltage to a higher voltage and can also charge the electrical storage device 226 to a higher voltage. Since the precise amount of energy transfer is monitored and compared against a reference voltage (e.g., by the amplifier 234 ) the insertion voltage can be precise (DC voltage) and stable (AC noise) during the operation of the field device 202 . It will also be appreciated that the power extracted from the insertion voltage can be regulated to maintain the loop insertion voltage at a constant value.
[0029] The variable scaler 242 can vary the voltage provided to the negative input 236 of the amplifier 234 to facilitate selective control of the insertion voltage. By controlling the insertion voltage, the power provided to the electrical storage device 226 can change when the loop current changes (e.g., when the process variable changes). For example, when the loop current increases, the insertion voltage can be increased to increase the insertion power provided to the electrical storage device 226 . By increasing the insertion power, the electrical storage device 226 can be charged quickly thereby increasing the power available from the electrical storage device 226 for operating the wireless communication device 224 .
[0030] The variable scaler 242 can therefore be controlled to maximize the insertion power provided to the electrical storage device 226 . In one example, for a field device (e.g., 202 ) that is configured to operate at a 1 Volt DC (“VDC”) insertion voltage and at a minimum of 3.5 mA, the power management circuit 222 can provide more power to the electrical storage device than would be available from a conventional current shunting system (e.g., 3.5 mW). If the loop current increases to 20 mA, the power management circuit 222 can generate 20 mW of insertion power, without the variable scaler 242 changing the 1 VDC insertion voltage. However, if the variable scaler varies the insertion voltage to about 2.5 VDC, then the power management circuit 222 can generate about 50 mW of insertion power which, in some instances, is enough to power the wireless communication device 224 directly (e.g., without first charging the electrical storage device 226 ). It will be appreciated that a power management circuit can be configured to handle any of a variety of insertion voltages (e.g., 0.5 VDC, over 2.5 VDC).
[0031] In one embodiment, as illustrated in FIG. 3 , the power management circuit 222 can include a microcontroller 247 coupled with the variable scaler 242 . In one embodiment, the microcontroller 247 can control the variable scaler 242 based upon a predefined setpoint. In another embodiment, the microcontroller 247 can control the variable scaler 242 dynamically (e.g., according to an algorithm). It will be appreciated that the microcontroller 247 can include a microprocessor, an arithmetic logic unit, or any of a variety of other suitable electronic components. However, any of a variety of additional or alternative components can facilitate control of the variable scaler 242 . It will be appreciated that the setpoint can be configured at time of installation, or can be dynamically configured such as with the microcontroller 247 or across a wireless communication network by a host system as required or desired.
[0032] It will be appreciated that the insertion voltage drop induced by the flow of current through the power management circuit can provide an additional voltage drop to the process control system 200 . When the wireless adapter device 220 is connected between nodes L1P and L1N, the magnitude of the insertion drop voltage should be such, that when the insertion drop voltage is combined with the other voltage losses in the process control system 200 , the power supply voltage is not exceeded. For example, the combined voltage losses across the loop wires 208 a, 208 b, 210 a, 210 b, the wireless adapter device 220 , the field device 202 , and the current sense resistor 218 should be maintained at or below the power supply voltage.
[0033] It will be appreciated that the power supply voltage and corresponding voltage losses can vary for different process control system configurations. Conventionally, the insertion voltage drop on a power management circuit is permanently set at a low level (e.g., about 1 VDC) in order to ensure compatibility with various process control system configurations. However, if these conventional power management circuits are provided on a process control system with low cumulative voltage losses, insertion power can be lost. For example, if the power supply 214 can supply about a 5 VDC voltage, and the combined voltage losses of a process control system (ignoring the insertion voltage drop) total about 2 VDC, the process control system can accept an insertion voltage drop of up to about 3 VDC. However, if the insertion voltage drop of the conventional power management circuit has been set at about 1 VDC, the insertion power will be comparatively less than a conventional management circuit having an insertion voltage drop of about 3 VDC. Therefore, the power management circuit 222 can be configured to control the insertion voltage drop (e.g., stabilize, regulate) to maximize the insertion power for any of a variety of process control system configurations.
[0034] It will be appreciated that as the electrical storage device 226 reaches maximum capacity, the voltage across the electrical storage device 226 can rise above proper operating limits. Rather than shunting current and power away from the power management circuit 222 (e.g., with a current shunt), a voltage shunting circuit can be provided in communication with the electrical storage device 226 . The voltage shunting circuit can be configured to prevent an over-voltage condition within the electrical storage device 226 . In one embodiment, as illustrated in FIG. 3 , a voltage shunt 246 can be provided in parallel with the electrical storage device 226 , such that as the electrical storage device 226 reaches capacity, the voltage shunt 246 can bypass current and power to prevent the voltage across the electrical storage device 226 from further increasing. In such an embodiment, the power delivered from the output 232 of the voltage converter 228 (less the miniscule power consumed by the other circuits) can be shunted by the voltage shunt 246 to balance the power and regulate the voltage across the electrical storage device 226 . As power is delivered from the electrical storage device 226 to the wireless communication device 224 , the voltage shunt 335 can cease shunting until the electrical storage device 226 is at capacity again.
[0035] It will be appreciated to power various components of the power management circuit 222 , a stable voltage can be provided from the insertion voltage drop. In one embodiment, as illustrated in FIG. 3 , a voltage converter 252 can be provided to create a constant regulated control voltage to power certain electronic components of FIG. 3 .
[0036] The power management circuit 222 can provide fast deployment that allows the application of loop currents in excess of the loop current normal operating ranges (e.g., about 3.5-20 mA, up to about 130 mA). This fast deployment can allow a user installing wireless adapter device 220 to rapidly charge the electrical storage device to provide minimal delay after installation to power the wireless communication device 224 . To facilitate this fast deployment, the power management circuit 222 includes a fast deployment circuit configured to sense a magnitude of the loop current, and when the magnitude of the loop current reaches a threshold value, maintain the voltage level at the input at an elevated level to facilitate a substantial increase in the charging power delivered to the electrical storage device. In one embodiment, the power management circuit 222 can include a sense resistor 248 and a loop current amplifier 250 . The microcontroller 247 can monitor the loop current across the sense resistor 248 and compare it with a threshold value. When the magnitude of the loop current exceeds the threshold value, the microcontroller 247 can define a setpoint for maximum insertion voltage with using the variable scaler 242 , and the power management circuit can then receive maximum insertion power. In one embodiment, the microcontroller can compare the loop current against a threshold value of 25 mA. When the loop current exceeds 25 mA for a period of time the variable scaler 242 can be set to provide a maximum insertion voltage drop.
[0037] The power management circuit 222 can include over-current protection. This over current protection can limit the amount of insertion power when an excessive amount of loop current is being provided to the power management circuit. To facilitate over-current protection the power management circuit 222 can include an over current protection circuit configured to sense the magnitude of the loop current and, when the magnitude of the loop current reaches an over-current threshold value, disable the power regulator. In one embodiment, over current protection circuit can include the sense resistor 248 and the loop current amplifier 250 . The positive input and negative input of the loop current amplifier 250 can be electrically connected on opposite sides of the sense resistor 248 to monitor the magnitude of the loop current. If the loop current exceeds a maximum threshold, the output of the loop current amplifier can provide a signal to shut down the power regulator thereby limiting the insertion power provided to the power management circuit 222 . In one embodiment, the loop current amplifier 250 can compare the loop current against about a 130 mA threshold. When the loop current exceeds 130 mA, the loop current amplifier 250 can provide a signal to shut down the power regulator.
[0038] The power management circuit 222 can include a power save capability. The power management circuit 222 can monitor the loop current (e.g., through sense resistor 248 ). If the magnitude of the loop current is reduced to a negligible amount, the power management circuit 222 can power down all significant power consuming circuits to preserve the power stored in the electrical storage device. When the loop current regains a particular magnitude (e.g., greater than a negligible amount), the power management circuit 222 can return power to the circuits that were previously shut down. If a process control system has a power outage, this function can help ensure that the wireless adapter device 220 will be immediately available with the electrical storage device at capacity when power returns. If a user has pre-charged the wireless adapter device 220 (e.g., in a lab), this feature can ensure that the wireless adapter device 220 will be fully powered and immediately available to begin radio communications when it is installed on a process control system.
[0039] The power management circuit 222 can include an instant-on function, whereby an auxiliary power is established to power the internal control circuitry before the electrical storage device charges up.
[0040] The power management circuit 222 can include dynamic radio duty cycle management. In particular, the power management circuit 222 can inform a wireless communication network of the insertion power available to power the wireless communication device 224 . Accordingly, the wireless communication network can dynamically configure a maximum radio duty cycle to match the insertion power available to power the wireless communication device 224 . When the insertion power is elevated, a duty cycle can be increased to achieve faster update rates for changing process variables. However, when the insertion power is depleted, the duty cycle can be reduced to ensure that the power demand by the wireless communication network does not exhaust the storage capacity of the electrical storage device thereby causing an ultimately loss of radio communication until the electrical storage device can be recharged.
[0041] What has been described above includes illustrative examples of certain components and methods. It is, of course, not possible to describe every conceivable combination of components or methodologies, but one of ordinary skill in the art will recognize that many further combinations and permutations are possible.
[0042] In particular and in regard to the various functions performed by the above described components, devices, circuits, systems and the like, the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (for example, a functional equivalent), even though not structurally equivalent to the disclosed structure, which performs the function in the examples provided. In addition, while a particular feature may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired or advantageous for any given or particular application.
[0043] The foregoing description of embodiments and examples has been presented for purposes of illustration and description. It is not intended to be exhaustive or limiting to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed and others will be understood by those skilled in the art. The embodiments were chosen and described for illustration of various embodiments. The scope is, of course, not limited to the examples or embodiments set forth herein, but can be employed in any number of applications and equivalent devices by those of ordinary skill in the art. Rather it is hereby intended the scope be defined by the claims appended hereto. | A method is provided for managing power for a wireless communication device. The method includes receiving a loop current at an insertion voltage at an initial input, the loop current being generated by a power supply. The method further includes comparing a reference voltage to the insertion voltage and generating a feedback signal based at least upon the comparison of the reference voltage to the insertion voltage. The method still further includes regulating the insertion voltage based at least upon the feedback signal, delivering charging power to an electrical storage element, wherein the charging power is a function of the insertion voltage and the loop current, and storing the charging power in the electrical storage element. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of copending U.S. patent application Ser. No. 650,960, filed Sept. 14, 1984, entitled "Improved Sewage Sludge Treatment Apparatus" (the "copending application") that issued as U.S. Pat. No. 4,582,612 which, in turn, was a continuation-in-part of U.S. patent application Ser. No. 560,058, filed Dec. 9, 1983, which issued as U.S. Pat. No. 4,487,699 (the "original patent").
BACKGROUND OF THE INVENTION
This invention relates to an improvement to the apparatus for treating sewage and, in particular, sewage sludge, set forth in the above-identified copending application and original patent. More specifically, the present invention relates to apparatus for dispersing streams of prechanneled sludge to be treated throughout an oxygen-rich atmosphere by pressurized streams of gas directed toward and impinging on the streams of sludge.
Traditionally, sewage, and specifically sludge, has been difficult to treat because it is, almost by definition, extremely variable in composition. In addition to human liquid and solid organic waste, the sludge to be treated in accordance with the present invention may include industrial and commercial sludge which is susceptible to aerobic treatment. In general, the present invention provides a means and process for highly efficient interaction of sludge particles with oxygen, in the form of O 2 gas and/or O 3 gas.
The present invention preferably employs the use of hyperbaric vessels containing pressurized oxygen and the sludge, and provides means for increasing the surface area of sludge to be treated and the interaction time in which sludge is oxygenated compared to prior art apparatus and processes.
A further feature of the present invention resides in the substantially infinite adjustability of the various components of the apparatus and process so that they can be finely tuned at any time and adjusted automatically, semi-automatically and/or manually to treat different types, compositions and thicknesses of various sludges without requiring the use of alternate equipment.
The present invention is intended primarily for treatment of activated sludge, namely, waste from domestic, commercial and industrial sources which create a biologically degradable material. A batch of the pH adjusted waste to be treated is divided into small droplets and the droplets are dispersed within a pressure vessel where they are oxygenated by being exposed to oxygen (O 2 ) and ozone (O 3 ) for a substantial period of time. The Biological Oxygen demand (BOD) and the Chemical Oxygen Demand (COD) of the waste are substantially saturated and satisfied. The addition of ozone produces an almost complete destruction and elimination of coliform, fecal coliform, salmonella and other harmful bacteria from the batch of sludge being treated. Although the coliform and fecal coliform bacteria are not in themselves particularly harmful, when they are present, it is recognized that other harmful bacteria are present. Thus, when the coliform and fecal coliform bacteria are destroyed, it is an indication that the other harmful bacteria, which are more difficult to detect, are also destroyed.
The present invention is intended to be used in a large scale sewage treatment system for use in treating activated sludge which is generally too thick to be treated efficiently on a large scale basis by presently existing commercial equipment known to the inventor. The present invention can be incorporated with presently existing wastewater treatment plants. Most existing wastewater treatment plants are capable of producing sludge with a solid content of about one and one-half percent by weight. The present invention has been designed to treat sludge having a solid content of greater than four percent to about six percent by weight, more preferably from about five percent to about six percent. The process and apparatus are believed to be most cost effective with sludge having solids content of about five and one-half percent to six percent by weight.
The present invention is an improvement of the inventions illustrated, described and claimed in the prior filed copending application and original patent, the disclosures of which are hereby incorporated by reference herein. The sludge treating systems, processes and apparatus disclosed in the copending application and original patent enhanced the treatment of sludge compared to the systems, processes and apparatus previously known for that purpose. The present invention is a novel improvement of the inventions of the copending application and original patent. The improvement comprises an efficient means of dispersing the sludge in the reactor assembly by impinging streams of pressurized oxygen-rich gas upon streams of sludge dispersed from the channeling means of the first dispersing means of the apparatus of the copending application and original patent. Thus, this invention relates to novel second dispersing means for dispersing the sludge particles throughout the oxygen-rich atmosphere within the reactor assembly. The present invention preferably is used with the same systems and the same types of reactor assemblies used in the processes and apparatus disclosed in the copending application and original patent. Therefore, only the components of the overall system which are necessary to understand the present invention will be described herein.
It is believed that the gas impingement second sludge dispersing means of the present invention divides the sludge streams resulting from the channeling means of the first dispersing means into smaller and lighter weight particles having a greater surface area per volume ratio than the second dispersing means disclosed and claimed in the copending application or original patent. This increases the relative oxygenation of the particles and thus increases the efficiency of the oxygenation process. In addition, the lighter weight particles with the greater surface area descend slower throughout the oxygen-rich atmosphere in the upper portion of the reaction chamber, increasing interaction time in which the sludge is oxygenated compared to apparatus and processes of the prior art and of the copending application and original patent. The greater interaction time also enhances the overall efficacy of the process.
SUMMARY OF THE INVENTION
The present invention includes an apparatus for use in a sewage sludge treatment system comprising means for enhancing the surface area of the sludge to be treated and the time of interaction of finely divided sludge particles with oxygen-rich atmosphere including a vessel including sludge inlet means for conveying sludge to the vessel to be accumulated in a lower portion of the vessel, a sludge delivery means having a discharge end for delivering the sludge from the lower portion to an upper portion of the vessel, oxygen inlet means for delivering oxygen to the upper portion of the vessel, sludge outlet means for removing sludge from the lower portion of the vessel, and gas outlet means for removing gas from the upper portion of the vessel, first dispersing means and a plurality of second sludge dispersing means located within the upper portion of the vessel, the first sludge dispersing means being generally axially aligned with and attached to the discharge end of the sludge delivery means, the first sludge dispersing means including a plurality of channeling means for channeling the sludge from the sludge delivery means through outlets in the first sludge dispersing means toward the second sludge dispersing means, each of the second sludge dispersing means being generally aligned with a channeling means of the first sludge dispersing means, wherein the improvement comprises a recycling means for recycling the gas from the upper portion of the vessel through a pumping means to pressurize the gas and into the second dispersing means, the second dispersing means comprising a plurality of gas dispersing nozzle assemblies, each nozzle assembly directing a stream of the pressurized gas toward one of the channeling means of the first dispersing means, whereby the stream of pressurized gas from the nozzle assemblies impinges upon a major portion of the sludge being channeled from the first sludge dispersing means, divides the sludge into fine particles and disperses the sludge particles within the upper portion of the vessel to become oxygenated as they interact with oxygen in the upper portion of the vessel, the oxygenated particles falling to and being collected in the lower portion of the vessel.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there is shown in the drawings a form which is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a vertical cross-sectional view, partly in side elevation, of one embodiment of a reactor assembly and related components in accordance with the invention.
FIG. 2 is a horizontal cross-sectional view through a portion of the reactor assembly of FIG. 1, showing one of the gas dispersing nozzle assemblies of the second dispersing means in horizontal cross-section, and two of the other gas dispersing nozzle assemblies of the second dispersing means in plan view.
FIG. 3 is a vertical cross-sectional view through a portion of the reactor assembly of FIG. 1 taken along line 3--3 of FIG. 2 to show one of the gas dispersing nozzle assemblies of the second sludge dispersing means in side elevation.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to the drawings in detail, wherein like numerals indicate like elements, there is shown in FIG. 1 a reactor assembly 100 with which the present invention may be used. Reactor assembly 100 includes a treatment vessel 102 supported above a foundation of any suitable type and strength by support members 104. Although treatment vessel 102 can be of any desired size, it is preferred that it be capable of handling a large volume of sludge. Typical dimensions of the vessel having a shape illustrated in FIG. 1 would be about twelve feet in diameter and about sixteen feet in height. Treatment vessel 102 may be made in shapes other than that illustrated. The vessel should be able to withstand pressures of at least six atmospheres, since it is preferred that the sludge be subjected to a hyperbaric, that is, pressurized treatment. Accordingly, the material used to make the vessel should be durable, as well as easy to maintain, and non-reactive with an acidified sludge environment. A suitable material would be stainless steel, for example. Various modifications of the reactor assembly will be apparent to those skilled in the art, depending on the particular situation. These modifications may depend, in part, on the composition of the sludge, its viscosity, solids contents, etc.
As illustrated in FIG. 1, sludge 106 is contained in a lower portion of the vessel, after entering the vessel through reactor inlet conduit 108. The "lower portion" of the vessel includes any portion of the vessel containing liquid and need not be limited to any particular volume of sludge within the vessel. However, it is important that there be an "upper portion" of the vessel not containing sludge located above the lower portion and below a first dispersing means 138 and a second dispersing means generally designated by numeral 158. The upper portion of the vessel likewise is not defined by any specific volume, but should be sufficient to contain the first dispersing means illustrated in the form of distributor head 138 and gas dispersing nozzle assemblies 172 of second dispersing means 158. The upper portion should have sufficient volume so that the dispersed sludge can interact completely with the oxygen-rich atmosphere in the upper portion.
A manhole opening 110 is located in a portion of treatment vessel 102, preferably at the top. A flange 112 is formed around the upper rim of the manhole opening. In addition, treatment vessel 102 is provided with a plurality of viewports 116. To aid in viewing the contents of the vessel, a number of lighting sources can also be provided. An example of one such light source 118 is illustrated generally schematically in FIG. 1. The sludge in the lower portion of vessel 102 is mixed by mixer 114.
The sludge is delivered from the lower portion of the vessel to the upper portion by a pump through a series of conduits. Sludge 106 travels through a reactor circulation conduit 120, reactor circulation valve 122, reactor circulation pump 124, and reactor circulation valve 126 into internal reactor circulation conduit 128. The sludge then passes through elbow conduit 130 connected at one end by flanges to inlet conduit 128 and at another flanged end to upright delivery conduit 132. Conduit 132 is attached via a flanged outlet to a first or lower section 140 of a first dispersing means or distributor head 138. To support the conduits 128, 130, 132 and lower section 140 of the first sludge dispersing means 138, a support structure is provided, preferably centrally located within vessel 102.
The support structure includes flange support member 134 attached to flanged elbow 130 at one end and to flange support member 136 at the other end. Support member 136 is welded or otherwise secured in a suitable manner to the bottom of the treatment vessel.
In addition to the first or lower section 140, the distributor head 138 comprises a second or upper section 142. Channeling means are formed between lower section 140 and upper section 142 of distributor head 138. The channeling means takes the form of a plurality of channels 144 which preferably, and as illustrated, converge to form a common or single inlet passageway towards the bottom of lower section 140. The upper portion of channels 144 diverge in a generally radial pattern. Sludge entering the lower portion of channels 144 is dispersed from the channel outlets, preferably through nozzle assemblies 146, such that a major portion of the sludge is directed in streams toward the plurality of gas dispersing nozzle assemblies 172 of second dispersing means 158, each of which is aligned with a channel outlet.
Also preferably associated with upper section 142 are a plurality of nozzle assemblies 146, with each nozzle assembly being aligned with or directly adjacent to the outlet end of each channel formed in distributor head 138. Depending on the type and viscosity of the sludge, the nozzle assembles, which include adjustable nozzle elements, help direct the stream of sludge particles within the upper portion of treatment vessel 102 toward gas dispersing nozzle assemblies 172 of second dispersing means 158.
To tune the reactor to different types and/or viscosities of sludge and to purge the channeling means of any blockage, the distance, and therefore the size of the channels between lower section 140 and upper section 142 of distributor head 138 is adjustable. As illustrated in FIG. 1, one end of shaft 148 is attached to the upper section 142. The other end of shaft 148 is attached to the lift bar or plate 150. The lift bar or plate 150 is raised or lowered by activating hydraulic lift means secured to the cylinder mounting plate 154 which is bolted to the flange 112. A gasket (not shown) is located between the bottom of the plate and the top of the flange to maintain a fluid tight seal. Thus, hydraulic cylinders 152 are mounted to plate 154 and hydraulic cylinder piston rods 156 are attached to the underside of lift bar or plate 150. To raise upper bar or plate 150 and therefore shaft 148 and upper section 142 of distributor head 138, pressurized hydraulic fluid flows from a hydraulic supply and pump system described in the original patent to a pressure manifold 196 through conduit 198 and remote control lift inlet valve 200 into hydraulic cylinder lift means 152. Lift outlet conduit 202 extends from each hydraulic cylinder 152 and hydraulic fluid is returned through lift outlet conduit 202 through remote control lift outlet valve 204 and into hydraulic return manifold 206. By controlling the opening and closing of the remote control valves, the upper section 142 of distributor head 138 reciprocates away from and toward lower section 140. The structure and generation of the illustrated preferred form of first dispersing means 138 is described in more detail in the copending application, particularly with respect to FIGS. 13 through 15.
Gas dispersing nozzle assemblies 172 of second dispersing means 158 are adjustably attached to the inner peripheral walls of the treatment vessel 102 by any suitable means, such as a threaded connection, a ball and socket assembly or the like.
The dotted lines in the upper portion of treatment vessel 102 generally illustrate the flow path of sludge from the first sludge dispersing means 138 toward a second sludge dispersing means 158 by which the sludge is dispersed in the form of streams 208 and fine particles 210 throughout the upper portion of the vessel until the particles fall by gravity to the sludge pool 106 in the lower portion of the vessel.
Because of the force with which the sludge impinges against the pressurized gas directed through the second dispersing means 158, the sludge is dispersed as particles 210 throughout the upper portion of the treatment vessel. In this way, the sludge is fully oxygenated by oxygen and/or ozone. Although sludge spray and particle lines 208 and 210 generally show some typical dispersal patterns, it will be apparent to those skilled in the art that the indicated streams of particles are only exemplary and do not purport to show the exact, or all possible, streams resulting from the operation of reactor assembly 138.
The oxygen-rich atmosphere within the upper portion of each of the treatment vessels 102 preferably is also supplied through a manifold system as best illustrated in FIG. 1. While some activation of the sludge would occur in an atmosphere of air, the sludge becomes more highly activated and more completely treated when small sludge particles fully interact with an oxygen-rich atmosphere. It is also presently preferred to use a pressurized oxygen-rich atmosphere, by which oxygenation occurs still more quickly and completely.
As used herein, the terms "oxygen" and "oxygen-rich atmosphere" mean that the atmosphere contained in the upper portion of the treatment vessel is substantially comprised of oxygen in the form of O 2 gas and/or O 3 gas (ozone). It is presently preferred to have a mixture of O 2 and O 3 in the proportion of about 90-95% by volume O 2 and 5-10% by volume O 3 . The presently preferred pressure range is from about 45 pounds per square inch gauge (p.s.i.g.) to about 65 p.s.i.g. It is believed that 60 p.s.i.g. is the optimum pressure to be used in accordance with the present invention.
O 2 from a source, such as a liquid oxygen tank (not shown), is pumped through O 2 supply conduit 212 and remote controlled O 2 inlet valve 214 into an O 2 manifold 216 associated with each treatment vessel 102. Along the length of O 2 manifold 216 are several O 2 entry ports, two of which are indicated schematically as 218, 220 in FIG. 1, through which O 2 flows into the upper portion of treatment vessel 102. Ozone is generated by any conventional ozone generator, not illustrated. The ozone is then pumped through O 3 supply conduit 222, through remote controlled O 3 inlet valve 224 and into O 3 manifold 226. O 3 entry ports, two of which are shown at 228, 230 in FIG. 1 allow the ozone to enter the upper portion of treatment vessel 102.
To flush the upper portion of any undesirable gas or to release the gas pressure within treatment vessel 102, there is provided an outlet conduit 232 and a remote controlled outlet or bleed-off valve 234. Outlet conduit 232 can be vented to the atmosphere, to pollution control equipment, or to other storage or treatment areas not directly relevant to the present invention. A pressure relief valve 238 is connected by pressure relief conduit 236 to the upper portion of the treatment vessel. The threshold of the pressure relief valve can be adjusted depending upon the particular circumstances involved in the treatment system. A pressure sensor 240 includes pressure sensing means and signal generating means of conventional design to indicate the pressure within the upper portion of treatment vessel 102.
The present invention includes a recycling means 160 for recycling the gas from the upper portion of the treatment vessel 102 through a pumping means 162 to pressurize the gas into the second dispersing means 158. In the preferred embodiment, the recycling means 160 is external to the treatment vessel 102 and comprises an intake pipe 164, a valve 165 in pipe 164, a pumping means 162, a gas discharge pipe 166, a valve 167 in pipe 166, a gas dispersing manifold 168, and a plurality of gas conduit means 170 connecting manifold 168 to each of a plurality of gas dispersing nozzle assemblies 172. The valved gas intake pipe 164 conducts gas from the upper portion of the treatment vessel 102 to pumping means 162. The valved gas discharge pipe 166 then conducts the gas from the pumping means 162 through a gas dispersing manifold 168 external to the vessel 102. A gas conduit means 170 extending through the vessel wall conducts the gas from manifold 168 to nozzle assemblies 172 of second dispersing means 158, as seen in FIGS. 1 and 2. In the preferred embodiment, the valves 165 and 167 are remotely controlled valves and the pumping means 162 includes a hydraulic motor-driven pump.
A plurality of gas dispersing nozzle assemblies 172 of the second dispersing means 158 is best shown in FIGS. 2 and 3. Each nozzle assembly 172 includes a means for adjusting the alignment of the nozzle assembly with respect to one of the channeling means 144 of the first dispersing means 138. Each nozzle assembly 172 directs a stream of pressurized gas, as illustrated in FIG. 1, from recycling means 160 toward one of the channeling means 144 of the first dispersing means 138. The stream of pressurized gas 174 from the nozzle assemblies 172 impinges upon a major portion of the sludge 106 being channeled from the first sludge dispersing means 138. The streams of pressurized gas impinging on the sludge 106 divide the sludge into fine particles and disperse these sludge particles within the upper portion of vessel 102. The sludge particles become oxygenated by interacting with oxygen in the upper portion of the vessel 102. The oxygenated particles fall and are collected in the lower portion of vessel 102.
The gas dispersing nozzle assembly 172, as best shown in FIGS. 2 and 3, comprises a nozzle 176 and a hollow swing joint 178 having a movable portion 180 and a fixed portion 182. The movable portion 180 and the fixed portion 182 are held together in a fluid tight manner. In the preferred embodiment, the fixed and movable portions 180 and 182, respectively, are secured together in a desired alignment by a nut and bolt fastening means 184, as shown in FIGS. 2 and 3, with a gasket 186 between the fixed and movable portions 180 and 182, respectively. Gaskets 185, 187 are also used to assure a fluid tight fit, between the fastening means and swing joint components.
The fixed portion 182 preferably is mounted to the gas conduit 170 by a threaded connection 188 for rotational movement, as best shown in FIG. 2. In addition, the nozzle 176 preferably is mounted to the movable portion 180 by a threaded connection 190. In the preferred embodiment, a threaded coupling portion 192 secures the fixed portion 182 of the swing joint 178 in position with respect to the conduit 170, and a threaded coupling portion 194 secures the nozzle 176 in position with respect to the movable portion of the swing joint 180, as shown in FIGS. 2 and 3.
The components of the present invention preferably are interrelated to a local control station for controlling the operation of input of sludge to be treated, treated sludge output, hydraulic mixing, driving and pumping means, O 2 and O 3 supply means, gas outlet means, and the like. The local control stations preferably are controlled by a master control station, including data processing means. A general description of the operation of the system according to the present invention, as controlled by the local and master control stations and data processing means was previously described and can be referenced to the original patent. Therefore, it need not be described in detail in this application.
It will be recognized by those skilled in the art that changes may be made to the above-described embodiment of the invention without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiment disclosed, but is intended to cover all modifications which are within the scope and spirit of the invention as defined by the appended claims. | Provided in an apparatus for sewage treatment is an improvement including, a recycling means for recycling gas from the upper portion of a vessel through a pumping means to pressurize the gas and into a second dispersing means, a second dispersing means comprising means for enabling a stream of pressurized gas from a plurality of gas dispersing nozzle assemblies to impinge upon a major portion of sludge being channeled from a first sludge dispersing means and to divide and disperse sludge particles within the upper portion of the vessel to become oxygenated as they interact with oxygen in the upper portion of the vessel, and to enable the oxygenated particles to fall to an to be collected in the lower portion of the vessel, each nozzle assembly directing a stream of the pressurized gas toward one outlet of a channeling means of the first dispersing means, the outlets of the first sludge dispersing means being arranged radially about the first sludge dispersing means, the nozzle assemblies being arranged radially about the first sludge dispersing means and along an inner wall of the vessel in generally horizontal alignment with the outlets. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to an apparatus and method for influencing fish swimming behaviour. The invention uses a moving visual stimulus to influence fish swimming behaviour particularly, but not necessarily exclusively, for fish farming applications.
RELATED ART
[0002] Previous research has used water currents to control fish swimming behaviour. Such research has used water currents to encourage fish to swim against the current. This research shows that the productivity and quality of farmed fish can be improved markedly when optimal swimming speeds are held over prolonged periods of time. [References: Nahhas et al. 1982; Leon, 1986; Houlihan and Laurent, 1987; East and Magnan, 1987; Totland et al. 1987; Christiansen et al. 1989; Christiansen and Jobling, 1990; Christiansen et al. 1992; Hinterleitner et al., 1992; Jobling et al., 1993; Jørgensen and Jobling, 1993; Young and Cech, 1993b, 1994a, 1994b; Hammer, 1994; Yogata and Oku 2000; Azuma, 2001].
[0003] It is known that the optimal swimming speed varies according to the species of fish and conditions (e.g. water currents and the degree of curvi-linear swimming). Optimal swimming speed is a balance between a state of inactivity (where the positive benefits of exercise training cannot be gained) and excessive exercise (where excess energy is consumed by that given level of activity).
[0004] It is known that pronounced increases in growth can be achieved when optimal swimming speeds are maintained for prolonged periods of time. This is considered beneficial for commercial fish farming because it allows more production cycles per annum and/or more time to fallow seacage sites between rearing periods. [References: Nahhas et al. 1982; Leon, 1986; Houlihan and Laurent, 1987; East and Magnan, 1987; Totland et al. 1987; Christiansen et al. 1989; Christiansen and Jobling, 1990; Christiansen et al. 1992; Hinterleitner et al., 1992; Jobling et al., 1993; Jørgensen and Jobling, 1993; Young and Cech, 1993b, 1994a, 1994b; Hammer, 1994; Yogata and Oku 2000; Azuma, 2001.]
[0005] It is also known that food conversion efficiency is improved markedly (typically by about 20%) when optimal swimming speeds are maintained for prolonged periods of time. Since feed represents about 60% of total production cost in commercial fish farming, significant savings can be gained by the fish farming industry if optimal swimming speeds are sustained. [References: Leon, 1986; East and Magnan, 1987; Christiansen and Jobling, 1990; Christiansen et al. 1992; Jobling et al., 1993; Jørgensen and Jobling, 1993; Yogata and Oku 2000.]
[0006] Fish growth is often variable within a given stock but more uniform rates of weight increase and length increase can be achieved with sustained optimal swimming. It will be understood that a narrower size distribution for farmed fish is advantageous since then a higher proportion of the fish will be suitable for sale and consumption at premium prices. Conventional size grading techniques require time and effort and are stressful for fish but this procedure can be reduced to a minimum when uniform rates of growth are maintained. [References: East and Magnan, 1987; Jobling et al., 1993; Jørgensen and Jobling, 1993.]
[0007] The composition, texture and taste of fish fillets ultimately determines the final value of the aquacultural product and these are all improved when fish swim for prolonged periods at their optimal swimming speed. Various scientific reports have demonstrated that sustained swimming improves muscular development (via changes in muscle fibre size, diameter and capillarization), the biochemical and energetic composition of flesh (via changes in lipid, glycogen and water etc) as well as the taste and organo-leptic property of flesh. [References: Greer Walker and Pull, 1973; Davison and Goldspink, 1977; Johnston and Moon, 1980; Davie et al., 1986; Totland et al. 1987; Christiansen et al. 1989; Hinterleitner et al., 1992; Sanger, 1992; Young and Cech, 1993b, 1994a, 1994b; Yogata and Oku, 2000.]
[0008] High density rearing and routine aquacultural processes (e.g. hauling, size grading and transport) can induce “stress” in farmed fish and can also have other undesirable consequences. This can lead in turn to reduced flesh quality in the final product.
[0009] Sustained optimal swimming of a population of fish in the same direction has been shown to reduce basal stress levels and the number of aggressive encounters amongst conspecifics. [References: Butler et al., 1986; East and Magnan, 1987; Lackner et al., 1988; Christiansen and Jobling, 1990; Christiansen et al., 1992; Boesgaard et al., 1993; Jørgensen and Jobling, 1993; Jobling et al., 1993; Young and Cech et al., 1993a, 1994b; Adams et al., 1995; Shanghavi and Weber, 1999; Milligan et al. 2000; Iguchi et al., 2002.]
[0010] It is known that the swimming behaviour of farmed fish can be controlled through manipulation of water currents. [References: East and Magnan, 1987; Totland et al. 1987; Christiansen et al. 1989; Christiansen and Jobling, 1990; Christiansen et al. 1992; Jobling et al., 1993; Jørgensen and Jobling, 1993; Young and Cech, 1993b, 1994a, 1994b; Yogata and Oku 2000; Azuma, 2001.] Indeed, in research into this area, the swimming speed of fish has only been manipulated with water currents to date. However, due to the logistics and cost of controlled pumping, this is both impractical in sea cages and uneconomic under most commercial farming conditions. For this reason it has not yet been possible to control fish swimming in increasingly high volume facilities even though a large proportion of commercial fish farming occurs in seacages and major benefits could be gained in terms of improved productivity and quality.
[0011] Furthermore, it is not practicable to use naturally occurring water currents for this application (e.g. river currents or tidal flows) since these are uncontrollable on a large scale and will not necessarily give rise to optimum swimming speeds.
SUMMARY OF THE INVENTION
[0012] In view of the difficulties associated with providing controllable water currents at a suitable scale for commercial fish farming, the present inventors have realised that there is a need for a more convenient system for stimulating fish to swim at or close to their optimum swimming speeds, so as to provide the various advantages that such swimming allows.
[0013] It is known that fish have the ability to maintain their position in water with respect to a visual stimulus. This is known as the optomotor response. This is an important innate behaviour for position stabilisation. There are several examples that demonstrate the functional basis of this naturally-occurring behaviour. In one example, stream-dwelling fishes (e.g. salmon) can freely swim in a stationary position in fast flows of water. These fish can hold their position in a flow because they visually “fix” their swimming position relative to the stationary background. Without this form of visual stabilisation they would be swept downstream. In another example, some fishes also use the optomotor response to maintain their position within a school. They assess their own position visually and adjust their swimming speed to maintain a tight schooling structure (see Shaw and Tucker, 1965).
[0014] It is known, via experiment, that the swimming optomotor response can be induced by establishing a moving visual stimulus beside a fish (i.e. fish will swim alongside a moving visual background). Experimental biologists have exploited the optomotor response to examine various biological properties and particularly the visual system of fish. For example, the minimum sensitivity of fish eyes to light can be determined by moving a mechanical background of black and white stripes around a fish in a stationary glass cylinder. A light source illuminates the black and white stripes and when the light level is increased to a point at which the fish can “see” the black and white stripes the fish will orientate (i.e. swim) with the moving background. The minimum level of light required to initiate the optomotor response is taken as the level of spectral sensitivity (Pener-Salomon, 1974. Teyssedre and Moller, 1982. van der Meer, 1994. Fuiman and Delbos, 1998. Hasegawa, 1998).
[0015] Using similar methodologies, the optomotor response has also been used as an experimental tool to test the following biological principles and properties in fish:
[0000] i. Wavelength sensitivity (Anstis et al. 1998).
ii. Visual acuity (Naeve, 1984; Pankhurst, 1994; van der Meer, 1994; Herbert and Wells, 2002; Herbert et al., 2002, 2003).
iii. Flicker fusion frequency/motion detection (Schaerer and Neumeyer, 1996).
iv. Ontogeny of visual systems (Neave, 1984. Kawamura and Washiyama, 1989. Pankhurst, 1994. Masuda and Tsukamoto, 1998).
v. Schooling behaviour (Shaw and Tucker, 1965. Kawamura and Hara, 1980. Fuiman and Delbos, 1998. Masuda and Tsukamoto, 1998. Veselov et al. 1998).
vi. Rheotactic behaviour (Harden-Jones, 1963. Veselov et al. 1998).
vii. Environmental conditions necessary to induce the optomotor response (Takahashi et al. 1968. Teyke and Schaerer, 1994).
viii. Effect of pollutants on behavioural changes (Richmonds and Dutta, 1992).
ix. Optomotor response in trawling nets (He and Wardle, 1988. Tang and Wardle, 1992.).
x. Rates of oxygen consumption (Dabrowski, 1986; Lucas et al., 1993; Wardle et al. 1996).
[0016] However, the present inventors have realised that the known systems for inducing optomotor response in fish are not suited to commercial fish farming applications. In particular, the moving parts required by known systems are not suitable for immersion in water and are not suitable for scaling up to the dimensions that would be required for commercial fish farming applications. Furthermore, such systems are complex and require regular maintenance.
[0017] Accordingly, in a general aspect, the present invention provides a moving visual stimulus to fish by operation in sequence of a series of light output members.
[0018] Preferably, in a first aspect, the present invention provides an enclosure for fish, defining a space within which the fish can swim, the enclosure having a series of light output members disposed along a path, said light output members being operable to provide a moving visual stimulus along the path by output of light in sequence from the series of light output members, thereby influencing the swimming behaviour of the fish.
[0019] Preferably, in a second aspect, the present invention provides an apparatus for influencing the swimming behaviour of fish, the apparatus having:
[0000] a plurality of light output modules each providing one or more light output members, said modules being for arrangement so as to organise the light output members in a series along a path;
control means for controlling the light output members wherein each light output module is adapted for at least partial submersion in water and the control means is capable of controlling the light output members to provide a moving visual stimulus along the path by output of light in sequence from the series of light output members.
[0020] Preferably, in a third aspect, the present invention provides an enclosure for fish, defining a space within which the fish can swim, the enclosure having an apparatus according to the second aspect.
[0021] Preferably, in a fourth aspect, the present invention provides a method of stimulating an optomotor response in fish including locating the fish in an enclosure having a series of light output members disposed along a path, said light output members being operated to provide a moving visual stimulus along the path by output of light in sequence from the series of light output members thereby to influence the swimming behaviour of the fish.
[0022] Preferably, in a fifth aspect, the present invention provides a method of stimulating an optomotor response in fish including locating the fish in an enclosure according to the first or third aspects, and operating the light output members to provide a moving visual stimulus along the path by output of light in sequence from the series of light output members thereby to influence the swimming behaviour of the fish.
[0023] Preferred and/or optional features will now be set out. These are applicable either independently or in any combination to any of the aspects of the invention, unless the context demands otherwise.
[0024] Preferably, the series of light output members is disposed at an outer perimeter of the enclosure, the fish swimming space being located internally of the series of light output members. In this way, the fish are able to swim in a space that is enclosed not only by the enclosure but also (e.g. wholly or in part) by the series of light output members.
[0025] Additionally or alternatively, another series of light output members or said series of light output members is disposed at an inner perimeter of the enclosure, the fish swimming space being located externally of the series of light output members. In this way, the fish are able to swim around the series of light output members. It will be understood that it may be beneficial to locate one or more series of light output members in each position, so as to provide one or more moving visual stimulus or stimuli to the fish that is visible from a large proportion of the space within which the fish can swim.
[0026] The light output members themselves are intended to remain stationary with respect to the enclosure. In this way, it is not necessary to move the light output members in order to achieve a moving visual stimulus. Instead, it is the sequential output of light along the series of light output members, in use, that allows the production of the illusion of a moving visual stimulus.
[0027] The enclosure may be of any desired shape, provided that fish are free to swim within the space enclosed by the enclosure. For example, the enclosure may be circular or cylindrical, oval, racetrack-shaped, toroidal or another smooth or curved shape that defines a closed swimming route for the fish. Preferably, the series of light output members forms a substantially closed path to define a substantially continuous swimming route for the fish. In this way, the series of light output members may assist in encouraging advantageous swimming behaviour substantially all around the fish swimming route.
[0028] Preferably, the enclosure has boundaries (e.g. walls) that permit the flow of water through them. For example, the boundaries may include a cage, mesh or net for submersion in a body of water such as saltwater or freshwater (e.g. a lake, inlet, sound, loch, sea loch, coastal water or other body of water). The use of caging, mesh or netting is of course known in commercial fish farming context in order to keep the fish in a desired location. Allowing water to flow through the boundaries is useful in maintaining a clean environment for the fish, since it allows waste products from the fish to be conveyed (via gravity and/or water currents) out of the enclosure.
[0029] Preferably, the light output members are disposed on the fish swimming space side of the cage, mesh or net, so as substantially not to illuminate the cage, mesh or net. This can be important, in order to provide the illusion to the fish that there is a moving visual stimulus. Illumination of stationary objects such as the boundaries of the enclosure is thereby desirably avoided.
[0030] Preferably, the enclosure has a lateral dimension (e.g. length or width) of at least 10 m, preferably at least 30 m, more preferably at least 50 m and most preferably at least 70 m. Similarly, the path length of the series of light output members is preferably at least 30 m, or at least 90 m, more preferably at least 150 m and most preferably at least 210 m.
[0031] Preferably, the series of light output members is operable to provide a series of moving visual stimuli, i.e. more than one moving visual stimulus moving in a coordinated way. This is of interest in order to provide the moving visual stimulus to as many fish as possible. For example, the light, output members may be operated so that, at any one time instant, about half are outputting light and about half are not, in a series of moving visual stimuli around the enclosure.
[0032] Preferably, the light output members are spaced apart by a separation dependent upon the fish body length, e.g. the average fish body length. For example, the light output members may have a minimum separation of one to two times fish body length, e.g. about 1.5 body lengths.
[0033] Preferably, the enclosure has a plurality of light output modules, each module providing one or more of said light output members. The modules provide a structure to allow the connection of individual light output members. In use, the light output module is adapted for at least partial submersion in water. This can be of assistance in providing a light output in deep water in situations where illumination provided from a source above the surface may not be appropriate.
[0034] Preferably, individual light output modules are operable independently of each other. The independent operation of the individual light output modules allows control of the moving visual stimuli around the enclosure.
[0035] Additionally or alternatively, individual light output members of a light output module are operable independently of the other light output members of the light output module. Individual control of each light output member allows the moving visual stimulus to be provided by a light output module along the path. Furthermore, individual control of each light output module allows the moving visual stimulus to be provided by a combination of light output members of different light output modules.
[0036] Preferably, the light output modules are elongate and are for arrangement along the path. Preferably, the light output module is disposed with its elongate axis substantially upright, so as to provide a light output of greater upright extent than lateral extent. This allows the moving visual stimulus to be provided by more than one light output module at once, if necessary, whilst restricting the lateral extent of the moving visual stimulus. Furthermore, the elongate nature of the light output module allows the moving visual stimulus also to be elongate. This vertical extent of the moving visual stimulus is useful in providing the moving visual stimulus to as many fish as possible in the enclosure.
[0037] Alternatively, the light output modules are elongate along the said path. The moving visual light stimulus may be provided by the operation in sequence of light output members along the light output module. Furthermore, a moving light stimulus of greater vertical extent may be obtained from an assembly of light modules by operation in sequence of light output members on different light output modules. The series of light output modules may be a substantially upright stack of modules, each module elongate along the said path.
[0038] Preferably, the height of the light output modules is at least 1 m. The total height may be up to 10 m. If necessary, several (e.g. 3 or more) light output modules may be assembled to give this height. Typically, the height is around 1.5-2 m minimum and 3-6 m maximum.
[0039] For salmonid species, the optimal swimming speed is in the region of 1.0 BL/s ((body lengths per second) Houlihan and Laurent, 1987; East and Magnan, 1987; Totland et al. 1987; Christiansen et al. 1989; Christiansen and Jobling, 1990; Christiansen et al. 1992; Jobling et al., 1993; Jørgensen and Jobling, 1993) and for carangid species (e.g Seriola sp.) the optimal swimming speed is in the region of 1.6 BL/s (Yogata and Oku, 2000). These optimal speeds (in BL/s) will typically remain the same irrespective of enclosure size (unless the enclosure is restrictively small and adds extra “turning costs”). For example, for a 30 cm salmonid the absolute speed equates to around 30 cm/s and for a 30 cm Japanese Kingfish ( Seriola sp.) it is in the region of 48 cm/s. The visual stimulus speed preferably matches the optimal swimming speed, e.g. at least 1 BL/s.
[0040] Preferably, the visual stimulus has a brightness of at least 10,000 millicanela (mCd), and may be at least 50,000 mCd. For example, the brightness may be 72,000 mCd (approximately 70 lumens.
[0041] Preferably, the light output member is one or more (preferably a plurality) of light sources such as LEDs. LEDs provide a relatively cheap and reliable light source.
[0042] Alternatively, each light output module has at least one light source and at least one light guide, the light guide being operable to guide light from the light source for directing the light towards the fish. The light guide may guide light from the light source by reflection, e.g. total internal reflection. Most preferably, the light guide is operable to output light substantially uniformly along its length. Preferably, the light guide is elongate.
[0043] Preferably, in use, the light source is located above the light guide so that, in use, the light source is located above the water level. This can be of assistance in preventing corrosion of the electrical contacts in the light source and may provide the light source with a longer useful life. Preferably, the light source is one or more (preferably a plurality) of LEDs.
[0044] The inventor considers that green light (approx. 525 nm wavelength) is the optimal colour to use. This is based on the optical properties of water; yellow-green light is absorbed less in turbid littoral water and blue-green light penetrates to deeper depths. Evidence also suggests that the retinal pigments of salmonid fishes are most sensitive to green light.
[0045] Preferably, the control means is operable to vary the number and/or speed and/or brightness and/or lateral extent of the moving visual stimulus or stimuli. In this way, the nature of the moving visual stimulus can be adapted to be most suited to the fish in the enclosure. For example, as the fish grow and increase in average body length, the optimum absolute swimming speed for that population of fish will change. In that case, the control means may operate so that the speed of the moving visual stimulus also increases, preferably at the same rate.
[0046] The present inventors have realised that the invention has wider application than simply encouraging fish to swim at their optimum swimming speed. The invention may also be used to guide fish along a predetermined path. This is possible if the predetermined path has a suitable series of light output members alongside it. Guiding fish in this way has useful applications in size grading of fish. It also has useful applications in harvesting fish or other manipulation of the fish in such a way as to reduce the stress applied to the fish. This results in an improvement in the quality of the fish product.
[0047] Accordingly, the method preferably further includes the step of guiding the fish along a predetermined branch path using a moving visual stimulus produced via a branch series of light output members along said branch path.
[0048] Preferably, the enclosure is located in a body of water subject to water current, said current flowing through the enclosure. Typically, the enclosure defines a substantially continuous, closed loop swimming route for the fish. In this situation, the series of light output members is preferably operated to provide a visual stimulus moving at a speed relative to the enclosure, said speed varying around the closed loop according to the local speed of the water current relative to the enclosure. More preferably, the speed of the moving visual stimulus is controlled to be substantially uniform relative to the water current speed along the closed loop. In this way, the optimum swimming speed of the fish relative to the water can be maintained around the swimming route for the fish.
[0049] For the avoidance of doubt, it is here noted that, preferably, the invention is not a method of treatment of the animal body by therapy. Preferably, the advantages provided by the invention are in the nature of improving the efficiency of commercial aquaculture and of improving the quality of fish flesh in the product of that industry.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] Embodiments of the invention will now be described, by way of example, with reference to the drawings, in which:
[0051] FIG. 1 shows a schematic representation of an apparatus according to an embodiment of the invention.
[0052] FIG. 2 shows a graph illustrating test results obtained using an embodiment of the invention.
[0053] FIGS. 3A and 3B show further graphs illustrating test results obtained using an embodiment of the invention.
[0054] FIG. 4 shows a graph illustrating test results obtained using an embodiment of the invention.
[0055] FIGS. 5A and 5B show further graphs illustrating test results obtained using an embodiment of the invention.
[0056] FIG. 6 shows a graph illustrating test results obtained using an embodiment of the invention.
[0057] FIG. 7 shows a graph illustrating test results obtained using an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0058] FIG. 1 shows a schematic representation of an apparatus according to an embodiment of the invention, set up for use on an enclosure 12 for holding fish. In the drawing, the apparatus 10 includes a control computer 14 with suitable control leads 16 attached to a series 18 of light output modules. Each light output module 20 has a light source 22 at its upper end with a light guide 24 suspended below the light source, in light communication with the light source.
[0059] In the drawing, only eight light output modules are shown. However, in the test set-up described below, 24 such light output modules were arranged around the enclosure 12 .
[0060] The light sources 22 are LED light sources. Preferably, they have several LEDS packed into a housing. Such an arrangement is able to make use of the fact that LEDs are available at relatively low cost and that they are relatively robust light sources.
[0061] Suitable light sources are 5 mm ultrabright LEDs that typically emit about 12000 mCd at 3.5V, 20 mA. These are housed in a cylindrical, plastic-moulded LED unit. The light sources are arranged in a concentric ring facing directly down and through the length of the light guide.
[0062] Each light guide 24 is a 60 cm tall, 14 mm wide clear acrylic polymer rod (e.g. cylinder), co-extruded with an 8 mm wide reflective strip disposed within the rod, parallel with the principal axis of the rod. Light input at the top of the light guide is guided along the length of the rod. The reflective strip causes a portion of the light to be reflected outwardly from the rod. The light output modules are oriented so that the reflective strip faces towards the centre of the enclosure 12 . The reflective strip is disposed within the rod such that the light output from the light output module falls only gradually along the length of the light guide. Ideally, the light output is substantially uniform along the length of the light guide. In an alternative embodiment, the light guide has a light source disposed at each end, to improve the uniformity of illumination provided by the light output module.
[0063] In use, the light output modules are controlled using the computer 14 using a Labtech Notebook program via a PCI board (Measurement Computing DIO24H). Each light output module is caused to emit light by powering the LEDs in light source 22 . This powering is carried out in sequence along the series. In FIG. 1 , the light output modules that are not emitting light are shown with hatched light guides.
[0064] The time for which each light output module emits light is controlled so that, in this example, a moving visual stimulus is provided that consists of three adjacent light output modules. Movement of the visual stimulus is caused by de-powering one of the light output modules at one side of the group of three light output modules and powering up the next light output module in the series at the other side. In this way, the visual stimulus is caused to move in the direction of arrow A in FIG. 1 .
[0065] The use of more than one light output module at a time to produce the moving visual stimulus reduces the ratio of the speed:width of the stimulus. This reduces the apparent jerkiness of the movement of the stimulus.
[0066] Depending on various factors (e.g. flow regime, prior history of the fish etc) the stimulus or stimuli may move either in a clockwise or anti-clockwise direction.
[0067] As will be clear to the skilled person, appropriate modification of the control software allows the speed, direction and width of the moving visual stimulus to be varied. Furthermore, suitable control allows the creation of a series of moving visual stimuli. These parameters are set according to the fish to be contained within the enclosure.
[0068] The enclosure 12 illustrated in FIG. 1 is a cylindrical tank filled with water (not shown). The light guides 24 are immersed in the water but the light sources 22 sit above the light guides, out of the water. The enclosure may, however, use netting, caging or mesh for its outer perimeter.
[0069] For commercial fish farming applications, the enclosure should be of a suitable size and shape to allow fish to sustain optimal swimming speed (without overly tight turning angles). The inventors have found that the best results are gained when fish are held in circular enclosures (e.g. circular seacages or tanks) and are not impeded by any physical object that would otherwise create complex and inefficient swimming behaviour.
[0070] The light output modules are arranged so that the spacing between adjacent light guides is 1.5 body lengths or less. For example, if the body length of the fish of interest is 30 cm, then the light output modules are preferably spaced 45 cm apart or less in the direction of movement of the moving visual stimulus. The light output modules may be arranged as shown in FIG. 1 , or two or more light output modules may be arranged one above the other to provide more than one series of light output modules, in order to increase the height of the moving visual stimulus.
[0071] To induce optimal swimming speeds in farmed fish, the inventors have realised that several factors are considered before setting the rotational velocity of the optomotor stimulus. These are set out below.
Curved Swimming Path
[0072] Fish that do not swim along a straight path will encounter an extra cost as a result of the centripetal force that is required to maintain a curved swimming trajectory (Weihs, 1981). Optimal swimming speed will therefore depend upon 1) fish body length, 2) the radius of the holding facility (or fish swimming radius) and 3) the rotational velocity of the visual stimuli. By calculating the extra swimming cost that is required to maintain a curved swimming path (Weihs, 1981), the optimal swimming speed of fish (of known length) in a facility of a given size can be controlled by adjusting the rotational velocity of the visual stimuli.
[0073] For example, if a relatively large species of fish is contained in a relatively small seacage and incurs a 15% cost as a result of curvi-linear swimming, the speed of the optomotor stimuli must be reduced by 15% from the known “straight line” optimal swimming speed of the species.
[0074] Curvi-linear costs of more than 20% reflect that fish are turning sharply on a regular basis and linear (i.e. aerobic “low cost” swimming) is no longer maintained. Under these conditions, the benefits of sustained swimming might not be gained. The size of any holding facility should therefore be scaled appropriately for the size of fish it contains.
Water Currents
[0075] Water currents may incur an extra cost of swimming and must be considered in the context of optimal swimming speed. For example, if a 30 cm fish has an optimal swimming speed of 1 body length per second (BL/s) and is under the influence of a unidirectional 30 cm/s current for 50% of the time (e.g. in a seacage), the “straight line” optimal optomotor speed should be reduced to a speed approximating 0.5 BL/s.
[0076] Alternatively, the speed of the optomotor stimulus may be varied around the enclosure, in order to account for the local water current speed relative to the light output members.
Start-Up Speed
[0077] When the apparatus is first activated or the lighting speed is adjusted, it can be important to ensure that the set speed is reached over several hours (i.e. progressively) and not immediately. Fish should be allowed to adapt slowly to any change in the moving stimulus otherwise confusion occurs and fish will lag behind the stimulus (i.e. do not swim at their optimal swimming speed).
Lighting Wavelength and Intensity
[0078] The light intensity of the moving visual stimuli should be sufficiently high to override stationary visual stimuli (e.g. seacage netting) and penetrate background turbidity and the wavelength of the lights should match the photoreceptor wavelength sensitivity of the given farmed fish's eye. Optimal lighting wavelength and intensities improve the behavioural optomotor response of the fish.
EXAMPLES
[0079] Behavioural trials were conducted on horse mackerel ( Trachurus trachurus ) and Atlantic salmon ( Salmo salar L.) to assess whether fish swimming behaviour (i.e. speed and direction) could be controlled using embodiments of the invention, as illustrated in FIG. 1 and described above.
Behavioural Monitoring of Mackerel
[0080] A CCD, video camera was mounted 1.3 m above the circular tank and connected to a computer equipped with a frame grabber (Visionetics VFG-512 BC) capable of digitizing and analysing single video frames with a resolution of 256×256 pixels at 10 frames per second. The geometric centre of a flat, black, oval (1.5 cm×3 cm) target, glued with Vetbond™ to the dorsal nasal region of a single fish in a group, was determined using a customized software programme and its x, y coordinate transmitted, via the RS-232 port, to a data acquisition package (Labtech Notebook). Fish positional (x, y) data was stored on the hard drive for later calculations of swimming speed (i.e. the cumulative distance swum in body lengths per second).
Mackerel Test 1
[0081] A single horse mackerel (Fork Length (FL)=18 cm) was tracked over a 7 hour period to initially assess the efficacy of the optomotor apparatus in controlling fish swimming speeds.
[0082] FIG. 2 indicates that the single fish routinely swam at about 1 BL/s when the optomotor stimulus was stationary but its swimming speed could be controlled in an increasing and decreasing direction using relatively large stepwise changes in optomotor speed. It should be noted that this size of fish struggled to swim at the highest optomotor speed (1.6 BL/s) in the enclosure used because it had to turn continuously to keep up with the stimulus. For this reason the inventors decided that future experiments should only examine the behavioural (and physiological) responses of fish with FL<18 cm.
Mackerel Test 2
[0083] A single 13.5 cm long horse mackerel (within group of three (13-15 cm) individuals) was tracked over a 6 day period to assess:
[0000] 1) The temporal responsiveness of fish to the lighting optomotor stimulus.
2) An initial insight into optimal protocols for control over the swimming speed of fish using the non-mechanical optomotor device.
[0084] The results are shown in FIG. 3 . FIG. 3 shows the effect of moving visual (i.e. optomotor) stimuli on the swimming speed ( FIG. 3A ) and directional orientation ( FIG. 3B ) of horse mackerel (FL=13.5 cm). The bold line indicates the relative speed of the optomotor stimulus.
[0085] Note that directional bias (in FIG. 3B ) is defined by Herbert and Wells (2002) and indicates preferred swimming direction. A directional bias value in the region of 0% indicates that there is no preference for swimming direction (and hence in this test no optomotor response). Directional bias values of greater than +25% indicates a positive optomotor response because the fish is swimming in the same direction as the moving visual stimulus. Negative directional bias values indicate that the fish was swimming in the opposite direction of the moving visual stimulus.
[0086] FIG. 3 indicates that the non-mechanical optomotor device is highly successful in controlling the swimming speed of schooling horse mackerel. The optomotor device raised sustained routine swimming speed from 0.25 BL/s to 1.5 BL/s. Furthermore, the graphs illustrate that group swimming speeds can only be controlled when small (vs. large) stepwise increases in optomotor speed are made over prolonged periods. The small stepwise increase in optomotor speed consistently resulted in an increase in swimming speed ( FIG. 3A ) and positive optomotor responses (i.e. directional bias>25%) ( FIG. 3B ). When fish are held in groups, it is clear that a large and sudden increase in optomotor speed results in poor optomotor responses and non-directional responses.
Behavioural Monitoring of Salmon
Salmon Test 1
[0087] A lighting device for influencing fish swimming behaviour was installed into a 1.2 m diameter fish tank. The lighting device consisted of 48 individual light emitting units and light guiding members, which were arranged vertically and spaced evenly around the outer circumference of the tank.
[0088] The individual light emitting units consisted of a cylindrical plastic unit housing a single, ultra-bright green, 3 mm light-emitting diode (LED). The light emitting unit was positioned on top of a Luxaura™ cylindrical light guide member (20 cm in length and 13 mm in diameter) (www.luxaura.com). Each light guide member was provided with a reflective strip, disposed parallel with the principal axis of the cylinder. Light input from a light emitting unit at the top of the light guide was guided along the length of the cylinder, and the reflective strip caused a portion of the light to be reflected outwardly from the cylinder. The light guide members were oriented so that the reflective strip faced towards the centre of the tank.
[0089] Each light emitting unit was connected to a computer via a PCI DIO-96H interface board (Measurement Computing Inc, USA) and the sequential firing pattern of the units was controlled by a customised Labtech program operating on the computer. Tests were conducted without any other source of light; the light emitting units were the sole source of visible and non-infra-red light.
[0090] The tank was filled with freshwater up to the uppermost level of the light guides (i.e. the light emitting units were not submerged). Water temperature was held at 10.0° C. with a cooling unit and water flow was both minimal and non-directional.
[0091] The experimental tank was equipped with a CCD video camera (Monacor), four infra-red floodlights and a tracking system (Lolitrack, Loligo, Denmark) for direct quantification of fish behaviour under relatively dark conditions. The tracking system operated at 10 Hz and recorded the position (x, y coordinates) of solitary fish for subsequent calculations of fish swimming speed and directional orientation.
[0092] The light stimulus consisted of 4 evenly spaced blocks of light around the tank (with each block consisting of 4 light emitting units and light guiding members being turned “on”). A moving light stimulus was generated around the tank by sequentially firing the lighting blocks at speeds of 0 (stationary control), 0.5, 1.0 and 1.5 body lengths per second (BL/s).
[0093] A single Atlantic salmon parr (weight=21.3±6.6 g; fork length=12.4±1.2 cm) was tracked over 4 days (24 hours at each of the four lighting speeds 0, 0.5, 1.0 and 1.5 BL/s) to assess the efficacy of the optomotor apparatus in controlling salmon swimming speeds and directional orientation.
[0094] FIG. 4 indicates that the moving light stimuli influenced the swimming behaviour of solitary Atlantic salmon in terms of both swimming speed and directional orientation in the absence of water currents. Contrary to the response of solitary horse mackerel (see FIG. 2 ), solitary salmon do not swim with the lights at all times. Solitary salmon often remain inactive for prolonged periods of time, but the moving light stimuli is shown to influence the behaviour of Atlantic salmon during active periods.
[0095] FIG. 4 shows that lights moving at 1 BL/s induce solitary salmon to swim at faster speeds during active periods. Lights moving at 0.5 and 1.0 BL/s induce solitary salmon to swim in the direction of the moving lights during active periods. Solitary salmon showed no directionality in the response to either stationary light or lights moving at 1.5 BL/s.
Salmon Test 2
[0096] Four large-scale lighting devices were installed into four, 3 m diameter tanks at the Marine Environmental Research Laboratory, Machrihanish, Argyll, and a growth trial was carried out using Atlantic salmon smolts under low water flow conditions.
[0097] The customised lighting apparatus in each tank consisted of a power supply, a signal sequencer box and four junction boxes (positioned at regular intervals on the outside of the tank) which controlled the manner in which light was emitted from an array of 72 light emitting units and light guiding members (spread at regular intervals and aligned vertically within the outer perimeter of the tank).
[0098] Each light emitting unit consisted of four, green, ultra-bright LEDs encased in a cylindrical plastic shell. Each tank was equipped with 4 junction boxes to minimise the number of individual cables running between the tank and the sequencer box. In effect, 18 light emitting units were connected by individual cables to one junction box on the side of the tank but only one compact (18 core) cable ran from each junction box to the sequencer. Each light emitting unit was connected to the top of an acrylic light-guiding rod (1 m in length and 22 mm in diameter). According to the downward angle of the LEDs, light was guided down the length of the acrylic rod but was refracted outwards and towards the centre of the tank as a result of bevelled grooves at 5 cm intervals.
[0099] Software on a PC was used to control the speed of the moving light stimuli as well as the number of lights “on” in each lighting block but, once each lighting program was downloaded to the signal sequencer, the PC could be disconnected and the lighting apparatus operated on a stand-alone basis.
[0100] The tanks were covered in thick black plastic and the tests were conducted without any other source of light; the light emitting units were the only source of visible light. There was negligible directional flow of water in the tanks as fresh salt water was provided at a minimal rate of 35 L/min. A rate of 35 L/min was sufficient to maintain good water quality (e.g. high oxygen levels etc.).
[0101] In order to observe and quantify fish swimming behaviour, four underwater video cameras were installed into the tank and video sequences were recorded by a DVD recorder connected to a video quad processor.
[0102] A 28 day growth trial was carried using 500 Atlantic salmon smolts (density=7.23-7.39 kg/m 3 ) in each of the four tanks and lighting stimulus speed was set to either 0 (stationary control), 0.5, 1.0 or 1.5 BL/s. Growth estimates were obtained from the difference in weight and length of 225 tagged fish at the beginning and end of the trial. Food conversion ratios were obtained by monitoring the amount of feed delivered (kg) per incremental increase in fish biomass (kg) over the 28 day period. A change in condition factor [(weight/length 3 )×100] was used to indicate a shift in body shape.
[0103] The results are shown in FIGS. 5 , 6 and 7 . FIG. 5 shows the effect of different light stimulus speeds on the weight-specific growth rate and length-specific growth rate of Atlantic salmon smolts exposed over a 28 day growth trial. Data are mean±95% confidence intervals. The asterix “*” indicates a significant difference from the 0 BL/s control group (P<0.05).
[0104] FIGS. 5A and 5B indicate that the moving light stimulus improved the rate at which salmon grew in terms of both weight ( FIG. 5A ) and length ( FIG. 5B ). Weight-specific growth was improved by 9-14% and length-specific growth by 12-25%. 1 BL/s appeared to be the optimal speed setting for weight specific growth (13.8% improvement) and 0.5 BL/s for length-specific growth (24.7% improvement).
[0105] FIG. 6 shows the effect of different light stimulus speeds on the food conversion ratio (FCR) of Atlantic salmon smolts exposed over a 28 day growth trial. Note that feeding efficiency is improved (i.e. less food is consumed per unit weight gain) with lower FCR values. FIG. 6 indicates that moving light improved the feed conversion efficiency of Atlantic salmon. Typically, FCR was reduced (i.e. feeding efficiency improved) as lighting speed increased. Feed conversion was improved by 2, 9 and 11% with lighting stimulus speeds of 0.5, 1.0 and 1.5 BL/s respectively. Moving light adjusted the condition factor (i.e. body shape) of smolts. Smolts typically became more slender and streamlined compared to the O BL/s controls.
[0106] FIG. 7 shows the effect of different light stimulus speeds on the mean swimming speed of Atlantic salmon smolts exposed over a 28 day growth trial. Data are mean±95% confidence intervals. FIG. 7 indicates that moving light increased fish swimming speed and therefore influenced the swimming behaviour of Atlantic salmon smolts under commercial rearing conditions. Although smolts were not active at all times, mean swimming speed was increased by 2, 32 and 9% with lighting stimulus speeds of 0.5, 1.0 and 1.5 BL/s.
[0107] Modifications of these embodiments, further embodiments and modifications thereof will be apparent to the skilled person on reading this disclosure and as such are within the scope of the invention.
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Christiansen, J. S., Rings, E. and Jobling, M. (1989). Effects of sustained exercise on growth and body composition of first-feeding fry of Arctic charr, Salvelinus alpinus (L.). Aquaculture, 79: 329-335.
Christiansen, J. S., Svendsen, Y. S. and Jobling, M. (1992). The combined effects of stocking density and sustained exercise on the behaviour, food intake, and growth of juvenile Arctic charr ( Salvelinus alpinus L.). Can. J. Zool., 70: 115-122.
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Davison, W. (1989). Training and its effects on teleost fish. Comp. Biochem. Physiol. 94A:1-10.
Davison, W. (1997) The effects of exercise training on teleost fish, a review of recent literature. Comp. Biochem. Physiol., 117A: 67-75.
East, P. and Magnan, P. (1987). The effect of locomotor activity on the growth of brook trout, Salvelinus fontinalis Mitchill. Can. J. Zool. 65: 843-846.
Fuiman, L. A. and Delbos, B. C. (1998). Developmental changes in visual sensitivity of red drum Sciaenops ocellatus . Copeia, 4: 936-943.
Greer Walker, M. and Pull, G. (1973). Skeletal muscle function and sustained swimming speeds in the coalfish Gadus virens L. Comp. Biochem. Physiol., 44A: 495-501.
Hammer, C. (1994). Effects of endurance swimming on the growth of 0- and 1-age group of whiting, Merlangius merlangus , Gadidae. Arch. Fish. Mar. Res. 42: 105-122.
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Hasegawa, E. (1998). Study of measurement of spectral sensitivity under scotopic conditions using optomotor reaction in fishes. Bull. Japanese Soc. Sci. Fish., 64: 626-630.
[0128] He, P. and Wardle, C. S. (1988). Endurance at intermediate swimming speeds of Atlantic mackerel, Scomber scombrus L., Herring, Clupea harengus L., and Saithe, Pollachius virens L. J. Fish Biol., 33: 255-266.
Herbert, N. A., Macdonald, J. A., Wells, R. M. G. and Davison, W. (2003) A difference in optomotor behaviour of two Antarctic nototheniid fishes is correlated with the presence of a choroid rete mirabile and Root effect. Polar Biol. 26: 411-415. Herbert, N. A. and Wells, R. M. G. (2002) The effect of strenuous exercise and P-adrenergic blockade on the visual performance of rainbow trout, Oncorhynchus mykiss . J. Comp. Physiol. B. 172: 725-731. Herbert, N. A., Wells, R. M. G. and Baldwin, J. (2002). Correlates of choroid rete development with the metabolic potential of various tropical reef fish and the effect of strenuous exercise on visual performance. J. Exp. Mar. Biol. Ecol. 275: 31-46. Hinterleitner, S., Huber, M., Lackner, R. and Wieser, W. (1992). Systemic and enzymatic responses to endurance training in two cyprinid species with different life styles (Teleostei: Cyprinidae). Can. J. Fish. Aquat. Sci. 49: 110-115. Houlihan, D. F., Laurent, P. (1987). Effects of exercise training on the performance, growth, and protein turnover of rainbow trout ( Salmo gairdneri ). Can. J. Fish. Aquat. Sci. 44: 1614-1621. Iguchi, K., Ito, F., Ogawa, K., Matsubara, N., Yodo, T. and Yamasaki, T. (2002). Reduction of transport stress of ayu by obligated schooling. Fish. Sci. 68: 849-853. Jobling, M., Baardvik, B. M., Christiansen, J. S. and Jørgensen, E. H. (1993). The effects of prolonged exercise training on growth performance and production parameters in fish. Aquaculture International 1, 95-111. Johnston, I. A. and Moon, T. W. (1980). Exercise training in skeletal muscle of brook trout ( Salvelinus fontinalis ). J. Exp. Biol., 87: 177-194. Jørgensen, E. H. and Jobling, M. (1993). The effects of exercise on growth, food utilisation and osmoregulatory capacity of juvenile Atlantic salmon, Salmo salar . Aquaculture, 116: 233-246. Kawamura, G. and Hara, S. (1980). The optomotor reaction of milkfish larvae and juveniles. Bull. Japanese Sci. Fish., 46: 929-932. Kawamura, G. and Washiyama, N. (1989) Ontogenetic changes in behaviour and sense organ morphogenesis in largemouth bass and Tilapia - nilotica . Trans. Am. Fish. Soc., 118: 203-213. Lackner, R., Wieser, R., Huber, M. and Dalla Via, J. (1988). Responses of intermediary metabolism to acute handling stress and recovery in untrained and trained Leuciscus cephalus (Cyprinidae, Teleostei). J. Exp. Biol. 140: 393-404.
[0141] Leon, K. A. (1986). Effect of exercise on feed consumption, growth, feed conversion, and stamina of Brook trout. Progressive Fish Culturist 48: 43-46.
Lucas, M. C., Johnstone, A. D. F and Tang, J. (1993). An annular respirometer for measuring aerobic metabolic rates of large, schooling fishes. J. Exp. Biol., 175: 325-331. Masuda, R. and Tsukamoto, K. (1998) The ontogeny of schooling behaviour in the striped jack. J. Fish Biol., 52: 483-493. Milligan, C. L., Hooke, G. B. and Johnson, C. (2000). Sustained swimming at low velocity following a bout of exhaustive exercise enhances metabolic recovery in rainbow trout. J. Exp. Biol., 203: 921-926. Nahhas, R., Jones, N. V. and Goldspink, G. (1982). Growth, training and swimming ability of young trout ( Salmo gairdneri R.) maintained under different salinity conditions. J. Mar. Biol. As. U.K., 62: 699-708. Neave, D. A. (1984) The development of visual acuity in larval plaice ( Pleuronectes platessa L.) and turbot ( Scophthalmus maximus L.). J. Exp. Mar. Biol. Ecol., 78: 167-175. Pankhurst, P. M. (1994) Age-related changes in the visual acuity of larvae of New Zealand snapper, Pagurus auratus . J. Mar. Biol. Assoc. U.K., 74: 337-349. Pener-Salomon, H. (1972) The optomotor response of the fishes Acanthbrama terrae - sanctae and Barbus canis at different light intensities. Israel J. Zool., 21: 113-122. Richmonds, C. and Dutta, H. M. (1992) Effect of malthion on the optomotor behaviour of bluegill sunfish, Lepomis macrochirus . Comp. Biochem. Physiol., 102C: 523-526. Schaerer, S. and Neumeyer, C. (1996) Motion detection in goldfish investigated with optomotor response is “colour blind”. Vision research, 36: 4025-4034. Shanghavi, D. S. and Weber, J. M. (1999). Effects of sustained swimming on hepatic glucose production of rainbow trout. J. Exp. Biol. 202: 2161-2166. Shaw, E. and Tucker, A. (1965). The optomotor reaction of schooling carangid fishes. Anim. Behav., 13: 330-336. Sanger, A. M. (1992). Effects of training on axial muscle of two cyprinid species: Chondrostoma nasus (L.) and Leuciscus cephalus (L.) J. Fish Biol. 40: 637-646. Takahashi, M., Murachi, S. and Karakawa, Y. (1968). Studies on the optomotor reaction of fishes. I. Examination of the conditions necessary to induce the reaction of the Japanese Killifish, Oryzias latipes Temminck et Schlegel. J. Fac. Fish. Anim. Husb. Hiroshima Univ., 7: 193-207. Tang, J. and Wardle, C. S. (1992). Power output of two sizes of Atlantic salmon (Salmo salar) at their maximum sustained swimming speeds. J. Exp. Biol., 166: 33-46. Teyke, T. and Schaerer, S. (1994) Blind mexican cave fish ( Astyanax hubbsi ) respond to moving visual stimuli. J. Exp. Biol., 188: 89-101. Teyssedre, C. and Moller, P. (1982). The optomotor response in weak-electric Mormyrid fish: Can they see? Z. Tierpsychol., 60: 306-312. Totland, G. K., Kryvi, H., Jødestøl, K. A., Christiansen, E. N., Tangerås, A. and Slinde, E. (1987). Growth and composition of the swimming muscle of adult Atlantic salmon ( Salmo salar L.) during long-term sustained swimming. Aquaculture, 66: 299-313. Van Der Meer, H. J. (1994). Ontogenetic change of visual thresholds in the cichlid fish Haplchromis sauvagei . Brain. Behav. Evol., 44: 40-49. Veselov, A. E., Kazakov, R. V., Sysoyeva, M. I. and Bahmet, I. N. (1998). Ontogenesis of rheotactic and optomotor responses of juvenile Atlantic salmon. Aquaculture, 168: 17-26. Wardle, C. S., Soofiani, N. M., O'Neill, F. G., Glass, C. W. and Johnstone, A. D. F. (1996) Measurements of aerobic metabolism of a school of horse mackerel at different swimming speeds. J. Fish Biol., 49: 854-862. Weihs, D. (1981). Effects of swimming path curvature on the energetics of fish motion. Fish. Bull. 79, 171-176. Yogata, H. and Oku, H. (2000). The effect of swimming exercise on growth and whole-body protein and fat contents of fed and unfed fingerling yellowtail. Fish. Res. 66: 1100-1105. Young, P. S. and Cech, J. J. (1993a). Effects of exercise conditioning on stress responses and recovery in cultured and wild young-of-the-year striped bass, Morone saxatilis . Can. J. Fish. Aquat. Sci., 50: 2094-2099.
[0165] Young, P. S. and Cech, J. J. (1993b). Improved growth, swimming performance, and muscular development in exercise-conditioned young-of-the-year striped bass ( Morone saxatilis ). Can. J. Fish. Aquat. Sci., 50: 703-707.
Young, P. S. and Cech, J. J. (1994a). Optimum exercise conditioning velocity for growth, muscular development, and swimming performance in young-of-the-year striped bass ( Morone saxatilis ). Can. J. Fish. Aquat. Sci., 51: 1519-1527. Young, P. S. and Cech, J. J. (1994b). Effects of different exercise conditioning velocities on the energy reserves and swimming stress responses in young-of-the-year striped bass ( Morone Saxatilis ). Can. J. Fish. Aquat. Sci., 51: 1528-1534. | An enclosure, method and apparatus for influencing the swimming behaviour of fish is disclosed. The enclosure defining a space within which the fish can swim, said enclosure having a series of light output members disposed along a path, said light output members being operable to provide a moving visual stimulus along the path by output of light in sequence from the series of light output members thereby to influence the swimming behaviour of the fish. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is entitled to the benefit of and incorporates by reference essential subject matter disclosed in International Patent Application No. PCT/DK2007/000433 filed on Oct. 5, 2007 and German Patent Application No. 10 2006 047 879.7 filed Oct. 10, 2006.
FIELD OF THE INVENTION
[0002] The invention concerns a flow adjustment valve with a valve housing comprising a flow channel, in which is arranged a throttle unit with an adjustable throttle element and a shut-off unit comprising a shut-off element blocking the flow channel in a closed position, the shut-off element being actuatable from the outside by means of a handle.
BACKGROUND OF THE INVENTION
[0003] Such a flow adjustment valve is, for example, known from WO 01/71289 A1.
[0004] In liquid-filled systems, such as heating and refrigeration systems, such a flow adjustment valve is used to set a hydraulic balance between different sections of the system. For this purpose, the throttle unit is set so that with given pressure conditions a certain flow through the flow adjustment valve can take place. This flow is then the flow that is allocated to the corresponding section of the system. Usually, such a flow adjustment valve is provided with two pressure measuring outputs, by means of which a pressure difference across a throttle can be determined, this pressure difference again being convertible into a flow. The throttle can be a constant throttle. However, it is also possible to use the throttle unit as throttle. In this case, additionally to the pressure difference, information about the position of the throttle element or the opening width of the throttle unit is required.
[0005] In many cases, however, the flow adjustment valve is also used as shut-off valve, to enable shutting off the corresponding section of the system, if maintenance work is required.
[0006] With the flow adjustment valve known from WO 01/71289 A1, the shut-off element that is formed as a ball, can be rotated by means of a handle to a closed position, in which it blocks the flow channel, or to an open position, in which a passage through the shut-off element is brought to overlap the flow channel.
[0007] The handle has an opening, through which a tool can be inserted, by means of which the throttle element can be set.
[0008] When, once, such a flow adjustment valve has been set, a further setting will usually not be required. Changes of the setting usually only occur in connection with changes in the system. For this reason, such a flow adjustment valve is often located in inaccessible positions, for example in a canal, under a roof, or the like. However, this location makes it difficult for an installer to reach the flow adjustment valve.
BRIEF SUMMARY OF THE INVENTION
[0009] The invention is based on the task of simplifying the handling of the flow adjustment valve.
[0010] With a flow adjustment valve as mentioned in the introduction, this task is solved in that the throttle element can also be activated by the handle.
[0011] With such an embodiment, it is no longer required for the installer to handle a tool, that is, to insert it into the flow adjustment valve, to set the throttle element. On the contrary, the handle can be used, which is accessible from the outside anyway. Thus, the handle has a double function. On the one side it can be used to bring the shut-off unit into a closed state, so that the corresponding section of the system is shut-off. On the other side, the handle can be used to set the flow.
[0012] It is preferred that the handle and the shut-off element are mutually connectable. With this embodiment, it is possible to perform the activation of the shut-off element and the activation of the throttle element independently of one another. At least, the throttle element can be adjusted by means of the handle, without causing the shut-off element to move at the same time. This further simplifies the handling.
[0013] Preferably, the throttle element is arranged at a spindle, which is located adjustably in a tappet, to which the shut-off element is connected. Via the tappet the handle acts upon the shut-off element, when the handle activates the shut-off element. If only the throttle element has to be adjusted, the handle only acts upon the throttle element, namely via the spindle. In this case, a coupling between the handle and the shut-off element is disconnected.
[0014] It is advantageous, if the spindle engages the tappet via a threaded pair. This is particularly the case, if the shut-off element is the ball of a ball valve. When the handle is rotated without having an active connection to the shut-off element, the rotation will axially displace the spindle in the tappet, so that the position of the throttle element changes. When, however, the handle has been brought to engage the tappet, so that an active connection exists between the handle and the shut-off element, the spindle will be turned together with the handle. As, however, because of the simultaneous rotation of the tappet by means of the handle, a relative rotation between the spindle and the tappet does not occur, the position of the throttle element will remain unchanged, when the shut-off unit is activated. After the blocking or after the discontinuation of the blocking, a new setting of the throttle unit is not required. The once chosen setting is maintained, independently of, how often the shut-off unit is activated. It is not significant either, if, when closing or opening the shut-off unit, the handle is rotated by one fourth, three fourth, five fourth of a circle or by other angles. In any case, the setting of the throttle element is maintained.
[0015] Preferably, the handle is translatorically displaceable, a movement in a first direction creating an active connection to the shut-off element and a movement in a second direction, which is opposite to the first direction, disengaging the active connection. This is a relatively simple way of creating and disengaging the active connection between the handle and the shut-off element. Also in inaccessible places the installer can simply displace the handle, if he wishes to activate the shut-off unit or merely to adjust the throttle unit.
[0016] It is preferred that the handle is a twist handle, which is rotatably and axially displaceably arranged at the valve housing. In order to activate the shut-off device, the handle must be axially displaced. Then, it can be rotated to activate the shut-off device. If, however, only an adjustment of the throttle unit is desired, the handle is axially displaced in the opposite direction, so that it only adjusts the throttle element, but does not activate the shut-off element.
[0017] Preferably, a blocking device is provided, with which the handle can be blocked in a position, in which it is in active connection to the shut-off element. Usually, it is endeavoured to keep a once made adjustment of the throttle unit, so that the throttle unit cannot be adjusted by mistake. This is simply achieved in that the handle is brought into an active connection to the shut-off element and blocked in this position. In this case, only the shut-off device is actuatable, the throttle unit, however, cannot be displaced.
[0018] It is preferred that the blocking device comprises a prestressed spring arrangement, which activates the blocking device in the position of the handle, in which it is in active connection to the shut-off element. When the setting of the throttle unit has taken place, the handle can simply be displaced to the active connection to the shut-off unit, which activates the blocking device. For example, under the influence of the prestressed spring arrangement, it can snap into a holder. An automatic disconnection of the blocking device is then not possible. On the contrary, an installer has to actively disconnect blocking device.
[0019] Preferably, in the blocked state, the handle covers a fixing nut. In this case, it is not possible to dismount the handle from the flow adjustment valve. The fixing nut is covered by the handle itself. This further secures the throttle unit from being displaced by unauthorized persons.
[0020] Preferably, a closed position indication is arranged at the handle. In many cases, the angle position of the handle will not indicate, whether or not the shut-off device blocks the passage through the flow channel. A closed position indication, however, can indicate the corresponding state.
[0021] It is preferred that the closed position indication is activated by the displacement of the handle. If the handle is merely used to displace the throttle unit, the handle can be rotated at will, without making the closed position indication visible. If, however, the handle has been displaced, the closed position indication shows whether or not the shut-off element blocks the flow channel.
[0022] Preferably, the shut-off element is actuatable via a torque application surface, which is covered by the handle, when the handle is mounted. Thus, it is also possible to realise a blocking of the section of the system, when the handle has been dismounted and is missing. Also this is a measure performed by many installers to prevent an unwanted adjustment of the throttle unit. If then a blocking of the section of the system is required for a short while, because there has been an emergency, the torque application surface, for example a normal hexagon, provides the opportunity of utilizing the blocking function of the flow adjustment valve by means of another tool.
BRIEF SUMMARY OF THE DRAWINGS
[0023] In the following, the invention is described on the basis of a preferred embodiment in connection with the drawings, showing:
[0024] FIG. 1 is a side view of a flow adjustment valve, partially in section I-I according to FIG. 3 ,
[0025] FIG. 2 is a sectional view II-II according to FIG. 3 , and
[0026] FIG. 3 is a top view of a flow adjustment valve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] A flow adjustment valve 1 comprises a valve housing 2 , in which a flow channel 3 is arranged.
[0028] In the flow channel 3 is arranged a shut-off unit with a shut-off element 4 in the form of a ball, the ball having a passage 5 , so that in the position shown in FIG. 1 the flow adjustment valve is open. In the position shown in FIG. 2 of the shut-off element 4 , the passage 5 is arranged transversally to the flow channel 3 . Here, the flow adjustment valve 1 is blocked. The shut-off element 4 interacts with a valve seat 6 .
[0029] The shut-off element 4 is unrotatably connected to a tappet 7 . When the tappet 7 is rotated, also the shut-off element 4 is rotated to release or block the flow channel 3 .
[0030] The tappet 7 has an inner thread 8 , into which a spindle 9 with an outer thread 10 is screwed. On the spindle 9 is fixed a throttle element 11 that is displaceable in parallel to the rotation axis 12 by a rotation of the spindle 9 . A displacement of the throttle element 11 will more or less release the passage 5 through the shut-off element 4 .
[0031] In relation to the tappet 7 , the spindle 9 is sealed by a sealing 13 . Together with the shut-off element 4 , the throttle element 11 forms a throttle unit.
[0032] At its upper end, the spindle 9 has a diameter expansion 14 , which is provided with an outer toothing that engages an inner toothing 15 , which is formed in a handle 16 . The handle 16 is held on the valve housing 2 by means of a union nut 17 .
[0033] The inner toothing 15 makes the connection between the diameter expansion 14 of the spindle 9 and the handle 16 , which is formed as a twist handle, unrotatable. However, in the axial direction the spindle 9 is displaceable in relation to the handle 16 , which is used for two purposes. Firstly, it is possible to displace the spindle 9 in the axial direction in relation to the twist handle 16 , when the throttle element 11 is adjusted. Secondly, however, it is also possible to displace the twist handle 16 in relation to the valve housing 2 to make an extension 18 of the handle 16 engage the tappet 7 .
[0034] In FIG. 1 the handle 16 is in a position, in which it is not coupled with the tappet 7 . In this case the rotation of the handle 16 will merely rotate the spindle 9 in the tappet 7 . As the tappet 7 is held in a stationary manner in the valve housing 2 , the rotation of the handle 16 will then cause a displacement of the throttle element 11 and thus an adjustment of the free cross-section of the passage 5 .
[0035] FIG. 2 shows a situation, in which the handle 16 has been displaced in the direction of the valve housing 2 , so that the extension 18 engages the tappet 7 . In this situation, the handle 16 is rotatably coupled with the shut-off element 4 . In this situation, a rotation of the handle 16 will only cause a corresponding rotation of the shut-off element, that is, a blocking or a release of the flow channel 3 .
[0036] When the handle 16 rotates, the spindle 9 will also rotate, as the diameter extension 14 still engages the inner toothing 15 . As, however, at the same time also the tappet 7 rotates, a relative rotation between the spindle 9 and the tappet 7 does not occur. Thus, the axial position of the spindle 9 in the tappet 7 and thus also the position of the throttle element 11 in the passage 5 does not change during a rotation of the handle 16 . This means that the setting of the throttle arrangement 5 , 11 is maintained.
[0037] In the direction of the valve housing 2 , the handle 16 has an apron 19 , which covers the union nut 17 , when the handle 16 is in the position shown in FIG. 2 , that is, when the handle 16 is in active connection to the shut-off element 4 .
[0038] The handle 16 has one or more spring elements 20 , which are prestressed radially outwards. The spring element 20 is held in the prestressed state by a circumferential flange 21 , which acts upon an arm 22 of the spring element 20 .
[0039] When the handle 16 has been axially displaced in the direction of the valve housing 2 , the arm 22 engages behind the flange 21 , so that the handle 16 is locked for a return movement away from the valve housing 2 . As, in the locked state, the arm 22 is radially inside the apron 19 , it is not immediately accessible from the outside. A tool has to be used to bend the arm 22 so far outwards that the locking of the handle 16 is released.
[0040] The handle 16 has at least one window 23 , through which numbers or other symbols are visible, which indicate the rotation angle of the handle 16 . Thus, also the position of the throttle element 11 can be determined. FIG. 1 shows a window on the circumference of the handle 16 . FIG. 3 shows a further window 24 on the front side of the handle 16 .
[0041] The window 24 is also used as closed position display. When the handle 16 has been displaced to the position shown in FIG. 2 , in which it engages the shut-off element 4 , a marking 25 will appear in the window 24 , when the handle 16 is rotated to the closed position of the shut-off element 4 . When, however, the handle 16 is in the position shown in FIG. 1 , in which it does not engage the shut-off element 4 , the marking 25 will not appear in the window 24 , regardless of the rotation position of the handle 16 .
[0042] In a manner not shown in detail, the tappet 7 has a torque application surface, which is, however, only accessible, when the handle 16 is dismounted. Thus, it is also possible to activate the shut-off element 4 , when the handle 16 is missing.
[0043] Two measuring outputs 26 , 27 are provided to guide the pressures on both sides of the throttle position formed by the throttle element 11 to the outside. The measuring outputs 26 , 27 are located on a flange 28 , which is rotatably arranged on a pipe stub 29 projecting from the valve housing 2 at approximately right angles to the flow channel 3 . Thus, the measuring outputs 26 , 27 are accessible from several directions.
[0044] While the present invention has been illustrated and described with respect to a particular embodiment thereof, it should be appreciated by those of ordinary skill in the art that various modifications to this invention may be made without departing from the spirit and scope of the present invention. | The invention relates to a flow adjustment valve ( 1 ) comprising a valve housing ( 2 ) having a flow channel ( 3 ) in which a throttle unit ( 4, 11 ) having an adjustable throttle element ( 11 ) and a shut-off unit having a shut-off element ( 4 ) which blocks the flow channel ( 3 ) in a closed position are arranged, the shut-off element ( 4 ) being actuatable from the outside by means of a handle ( 16 ). The aim of the invention is to simplify the handling of a flow adjustment valve of the aforementioned type. For this purpose, the throttle element ( 11 ) can also be actuated by means of the handle ( 16 ). | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. provisional application No. 60/469,256, filed May 9, 2003, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to utility trailers and, in particular, to multi-use lawn cart which may be configured as necessary as a utility trailer, equipment service ramp, work surface and lawn cart.
[0003] Various equipment for use in the yard or with a lawn tractor are known in the art. Lawn carts have been used to aid in manually transporting lawn debris and lawn tools such as rakes, shovels and hoses. Typically, a lawn cart includes an open bin or bed with three sides mounted to a frame supported by two rear wheels and front legs with a handle extending forward. The user lifts the front end of the cart off of the front support legs, pivoting the cart onto the rear wheels to push or pull the cart about the yard.
[0004] Another useful yard tool is a trailer that may be hitched to a lawn tractor and pulled by the tractor about the yard. The lawn tractor minimizes the work and strain of moving the trailer loaded with tools, hoses, or lawn debris such as grass clippings or leaves.
[0005] Maintenance of the lawn tractor, particularly the underside including the blade and mowing deck is often difficult. Prior art jacks have been proposed to lift the front end of the lawn tractor off the ground to provide access to the underside. These jacks often do not provide adequate clearance under the lawn tractor and may be unstable.
[0006] Temporary outdoor work tables may be constructed using a pair of saw horses with a plywood top. If the top is not affixed to the saw horses, it may shift or fall off or may be blown off by the wind.
[0007] All of this equipment requires space to store when not in use, may be costly to buy, and is essentially used for a specialized purpose. There is a need for a multipurpose, multi-use tool that combines the separate functions of these pieces of equipment.
BRIEF DESCRIPTION OF THE INVENTION
[0008] In the practice of one aspect of the present invention, a multi-use lawn cart includes a lawn cart for hauling lawn tools, hoses and debris for example, a removable lawn tractor hitch attached to the multi-use lawn cart for use as a utility trailer, a stable work surface, and a utility ramp/equipment stand with removable ramps to provide easy and stable access to the underside of a lawn vehicle. A utility ramp/equipment stand may also be configured for use with a trailer hitch of a vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The drawings constitute a part of this invention and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
[0010] [0010]FIG. 1 is an upper perspective, exploded view of the multi-use lawn cart with removable lawn equipment ramps and frame configured for use as a stand-alone equipment servicing ramp.
[0011] [0011]FIG. 2 is an upper perspective view of the multi-use lawn cart of FIG. 1 with the ramps and frame engaging the multi-use lawn cart frame.
[0012] [0012]FIG. 3 is a side elevation view of the multi-use lawn cart of FIG. 2 shown in use as an equipment service ramp.
[0013] [0013]FIG. 4 is a multi-use lawn cart of FIG. 3 with the equipment ramps removed to provide access to the underside of the lawn equipment.
[0014] [0014]FIG. 5 is an upper perspective view of the multi-use lawn cart configured for use as a lawn cart/trailer.
[0015] [0015]FIG. 6 is a top plan view of FIG. 5.
[0016] [0016]FIG. 7 is an upper perspective view of a utility ramp configured for use with a trailer hitch and supported by a vehicle.
[0017] [0017]FIG. 8 is a side elevation view of the utility ramp of FIG. 7 shown attached to a vehicle.
[0018] [0018]FIG. 9 is the utility ramp of FIG. 8 with the equipment ramps removed to provide access to the underside of the lawn equipment.
DETAILED DESCRIPTION OF THE INVENTION
[0019] I. Introduction.
[0020] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
[0021] II. Equipment Ramp.
[0022] Referring to FIGS. 1 and 2, an embodiment of the present invention configured as an equipment ramp is generally indicated by reference numeral 10 . Multi-use lawn cart 10 includes a generally rectangularly-shaped frame 12 , a pair of legs 14 connected together with a cross member 16 and a pair of wheel support frames 18 which are secured to the frame 12 and frame cross member 20 by ramp support members 22 . A pair of ramp support bars 24 extend between the inner 26 and outer 28 rails of wheel support frames 18 . A pair of stop bars 30 are secured to the pair of inner 26 and outer 28 rails of wheel support frames 18 . Axles 32 extending from wheels 34 are secured to the surface of cross member 16 .
[0023] A removable ramp frame 40 is designed to releasably engage the ramp support bars 24 . Ramp frame 40 is a generally rectangular frame including a rear frame member 42 , a front frame member 43 , a pair of spaced-apart ramps 44 and a pair of brackets 46 which are sized to engage the ramp support bars 24 . Ramps 44 include inner 48 and outer rails 49 which extend between the front 43 and rear 42 frame members, and a center rail member 50 which is generally centered between rails 48 and 49 and extends between rear frame member 42 and bracket 46 . Rails 48 and 49 may be constructed of one and one-half inch angle iron. The width of ramp frame 40 is sized to fit between the side frame member of frame 12 with the outwardly facing flanges of rails 49 fitting over the side frame members of frame 12 . When the brackets 46 of ramp frame 40 engage ramp support bars 24 , the outside rails 49 of ramp frame 40 engage the upper and inside surfaces of the side members of frame 12 . Ramp frame 40 may also include a handle 52 secured to the front frame member 43 which may be grasped by a user to lift the ramp frame 40 .
[0024] When ramp frame 40 is in place and engaged with the ramp support bar 24 , the ramp frame 40 presents an inclined plane relative to frame 12 . Ramps 44 are spaced to allow alignment with the front 60 or rear 62 tires of a lawn tractor 64 , for example (See FIG. 3). The lawn tractor 64 may be driven up ramps 44 until the front tires 60 roll over stop bars 30 and come to rest against axles 32 and the rear tires 64 rest on top of the end 13 of frame 12 . In this position, the front end of the lawn tractor 64 is supported by legs 14 and ramp support members 22 , while the rear end wheels 62 anchor the end 13 of frame 12 .
[0025] Referring to FIG. 4, while lawn tractor 64 is in the incline position as shown, removable ramp frame 40 may be disengaged from wheel support frame 18 leaving lawn tractor 64 in an inclined position and allow easy access to the underside of the lawn tractor 64 such as the mowing deck 66 . Multi-use lawn cart 10 provides a stable work stand to maintain lawn tractor 64 . In this position, the user has easy access to the blade of the lawn tractor 64 for sharpening or to clean under the mowing deck 66 , for example. When maintenance is completed, the ramp frame 40 may be put back in place and the lawn tractor 64 backed down the ramp for use.
[0026] In the preferred embodiment, the frame 12 , legs 14 and cross members 13 , 16 and 20 may be made of one and one-half inch square steel tubing or other suitable structural material. The inner 26 and outer rails 28 of the wheel support frames may be made using one and one-half inch angle iron. The ramp support member 22 may be made of one inch round steel tubing, for example. All components are welded together to provide a rigid structure. Fasteners may also be used to assemble the various components of multi-use lawn cart 10 .
[0027] The ramp assembly 40 is constructed of one and one-half inch square steel tubing and the front frame member 43 may be constructed of one-inch round steel stock. Brackets 46 may be constructed of one-fourth inch plate steel. Center rail 50 may be positioned and aligned in an inverted “V” and welded in place between rear frame member 42 and bracket 46 .
[0028] All steel parts and welds are properly treated with a rust resistant paint or other coating.
[0029] III. Lawn Cart and Trailer.
[0030] Referring to FIGS. 5 and 6, multi-use lawn cart 10 is shown in a lawn cart, work table configuration. The frame 12 is inverted (compared to FIGS. 1-4) to rest on wheels 34 and supported by removable front legs 70 which are secured at their upper ends by mechanical fasteners 81 (e.g., bolts, nuts and washers) extending through the front leg upper ends and through side brackets 80 . Front legs 70 can be one and one-fourth inch square steel tubing. A plywood or other top 74 may be placed over frame 12 to provide a work surface. Optional sides 76 including side posts 78 adapted to fit within side brackets 80 may also be used to create a lawn cart suitable for hauling lawn debris or for other purposes. The other optional side and the front and rear sides are not shown.
[0031] Side brackets 80 may be welded to frame 12 . Work surface 74 may also include a support frame 75 constructed of two-by-four lumber or other suitable material to add strength to the top 74 .
[0032] A trailer hitch frame 82 may be inserted into the side members of frame 12 and secured therein by mechanical fasteners 81 (e.g., bolts, nuts and washers) to allow the multi-use lawn cart 10 to be fastened to a lawn tractor (not shown). When attached to a lawn tractor, legs 70 may be removed and placed in the cart 10 .
[0033] With the trailer hitch frame 82 removed, a user may grasp the cross member 13 and pivot the cart 10 on wheels 34 to easily move the cart 10 for use as a manual lawn cart.
[0034] IV. Receiver Hitch Utility Ramp.
[0035] Referring to FIGS. 7-9, a trailer hitch mounted utility ramp 100 is shown. Hitch mounted utility ramp 100 includes a hitch frame 102 , a pair of removable ramps 104 and a pair of forward wheel stops 106 .
[0036] Hitch frame 102 includes a tongue 108 for engaging the hitch 110 of a vehicle 112 . Tongue 108 is secured to a generally rectangularly-shaped frame 114 , wheel support frames 116 , braces 118 and wheel stops 120 . Hitch frame members 108 , 114 , 116 and 118 are preferably constructed of square steel tubing.
[0037] Ramps 104 includes inner 122 , outer 124 and center 126 rails secured to front 128 and rear 130 frame members. A C-shaped bracket 132 is sized to fit over the rear frame member 134 of wheel support frame 116 and generally align ramps 104 with wheel support frames 116 .
[0038] With the ramps 104 in place engaging wheel support frame 116 , a lawn tractor 64 may be driven up the ramps 104 over wheel stops 120 until the front wheels 60 encounter forward wheel stops 106 . In this position, the front wheels 60 of tractor 64 are resting between forward wheel stops 106 and wheel stops 120 . Wheel stops 120 prevent the tractor from inadvertently rolling down the ramp 104 or off of wheel support frames 118 .
[0039] With tractor 64 in the inclined position and front wheels 60 engaging the wheel stops 106 and 120 , the ramps 104 may be disengaged from wheel support frames 118 to allow easy access to the underside of tractor 64 while providing a stable platform. The user may perform maintenance and/or repair to the underside components of lawn tractor 64 . When the work on tractor 64 is completed, ramps 104 may be replaced and the lawn tractor 64 backed off the ramps 104 .
[0040] It will be appreciated that various other configurations and embodiments may fall within the scope of the present invention. While certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown. | A combination ramp and cart device includes a main frame and a pair of wheel support frames mounted thereon. In a ramp configuration the wheel support frames extend upwardly from the main frame and support respective front and back ends of ramp frames, which are removably mounted on the main frame. In a cart configuration the wheel support frames depend downwardly from the main frame and a pair of legs are mounted on the main frame to support same. In a cart configuration of the device, the main frame also mounts a trailer hitch frame. In another aspect of the invention, a hitch-mounted ramp device includes a hitch frame adapted for mounting on a vehicle and a pair of ramps adapted for mounting on the hitch frame. | 1 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a variable-speed scroll-type refrigeration compressor.
DESCRIPTION OF THE PRIOR ART
[0002] Document FR 2 885 966 describes a scroll compressor, also known as a scroll pump, comprising a sealed enclosure defined by a barrel defining a suction volume and a compression volume, one on either side of a body contained within the enclosure. The barrel defining the sealed enclosure comprises a refrigerant gas inlet.
[0003] An electric motor is located inside the sealed enclosure, with a stator on the outside, fixed relative to the barrel, and a rotor in a central position connected to a crankshaft-like drive shaft which has a first end driving an oil pump supplying oil from a sump in the bottom of the enclosure to a lubrication way in the center of the shaft. The lubrication way comprises lubrication ports for each guide bearing of the drive shaft.
[0004] The compression volume contains a compression stage comprising a fixed volute fitted with a scroll engaged in a scroll on a moving volute, the two scrolls defining at least one compression chamber of variable volume. The second end of the drive shaft is fitted with an eccentric which drives the moving volute in an orbital movement to compress the aspirated refrigerant gas.
[0005] From a practical point of view, the refrigerant gas arrives from the outside and enters the sealed enclosure. Some of the gas is drawn directly into the compression volume, while the rest of the gas passes through the motor before being drawn into the compression stage. All of the gas reaching the compression stage, either directly or first passing through the motor, is drawn by the compression stage into at least one compression chamber defined by the two scrolls, entering at the edge of the compression stage, and as the gas is carried towards the center of the scrolls it is compressed by the diminishing volume of the compression chambers due to the movement of the moving volute relative to the fixed volute. The compressed gas passes out from the center part into the compressed-gas receiving chamber.
[0006] Depending on the internal flow configuration of this type of compressor, the refrigerant gas entering the compressor can entrain oil, the oil coming from, for example, leaks from bearings or from the gas licking up the surface of the oil in the sump.
[0007] It should be observed that the proportion of oil in the refrigerant gas varies depending on the speed of rotation of the rotor of the electric motor.
[0008] Thus, when the rotor is turning slowly, the amount of oil circulating with the refrigerant gas is low, which can lower the performance of the compressor and reduces the lubrication of its various parts.
[0009] On the other hand, when the rotor is turning fast, the proportion of oil in the refrigerant gas leaving the compressor can become excessive. The direct consequence of this excessive proportion of oil in the gas is less efficient heat exchange by the exchangers situated downstream of the compressor. This is because the oil droplets contained in the gas tend to become deposited on the heat exchangers and form a layer of oil on them.
[0010] In addition, an excessive proportion of oil in the gas can also drain the oil sump. This could lead to destruction of the compressor.
[0011] Document U.S. Pat. No. 6,322,339 describes a way of improving the low-speed performance of a variable-speed compressor without harming its efficiency at high speed. The approach is to increase the amount of oil introduced into the gas stream at low speeds only.
[0012] Document U.S. Pat. No. 6,322,339 thus describes a variable-speed scroll-type refrigeration compressor comprising an oil injection line supplied with oil from oil contained in a sump in the bottom of the enclosure, the injection line being designed to inject oil into the compression volume.
[0013] The oil injection line comprises a valve housed in the sealed enclosure and movable between an open position allowing oil to be injected into the compression volume, and a closed position preventing the injection of oil into the compression volume, the valve being subjected to the action of a compression spring that tends to keep it in its open position.
[0014] The compression spring is designed to keep the valve in its open position as long as the pressure difference between the two sides of the valve is less than or equal to the spring's elasticity. As soon as this pressure difference becomes greater than the elasticity of the spring, the valve is moved to its closed position, preventing oil being injected into the compression volume.
[0015] It should be observed that the elasticity of the spring requires calibration to allow the valve to be moved to its open position as soon as the speed of rotation of the drive shaft falls below a predetermined value, and to its closed position as soon as the speed of rotation of the drive shaft rises above a predetermined value.
[0016] This sort of oil injection line has disadvantages as outlined below.
[0017] This calibration of the elasticity of the compression spring acting on the valve is complex and cannot be performed accurately. As a result, the means employed in document U.S. Pat. No. 6,322,339 are complex and cannot be used to accurately control the injection of oil into the compression volume.
[0018] Furthermore, the elasticity of the compression spring can vary over time. The means used in document U.S. Pat. No. 6,322,339 do not therefore keep the performance of the compressor constant.
[0019] Another disadvantage with this type of oil injection line is the fact that particles can insinuate themselves between the walls of the housing in which the valve slides, and the valve itself. These particles can interfere with the operation of the valve and therefore with that of the oil injection line.
[0020] In addition, locating the valve inside the barrel means that the valve is difficult to maintain. In particular, it is difficult to replace the compression spring or clean out the housing in which the valve slides.
[0021] Document JP 06 185479 describes a more accurate means of controlling the injection of oil into the compression volume.
[0022] Document JP 06 185479 describes a variable-speed scroll-type refrigeration compressor comprising an oil injection line supplied with oil from oil contained in a sump in the bottom of the enclosure and designed to inject oil into the compression volume, the oil injection line comprising a solenoid valve having a core that can be made to move by, a magnetic field, between a first position allowing oil to be injected into the compression volume and a second position preventing or limiting the injection of oil into the compression volume. The solenoid valve is on the outside of the sealed jacket of the compressor and comprises an oil inlet port supplied with oil by a supply pipe extending partly out of the sealed enclosure and connected to an outlet port of an oil pump located inside the oil sump, and an oil outlet port connected to an injection pipe extending partly outside of the sealed enclosure and leading into the compression volume.
[0023] The refrigeration compressor also comprises control means designed to move the solenoid valve core between its first and second positions.
[0024] The presence of the solenoid valve in the oil injection line gives more precise control over the injection of oil into the compression volume, because the calibration to a given value of the magnetic field which is intended to move the solenoid valve core can be performed accurately via control means.
[0025] However, the arrangement of the supply and injection pipes, which are at least partly outside of the sealed jacket, can lead to rupturing of the pipes as a result of unforeseen impacts or stresses during maintenance of the compressor.
[0026] This arrangement of the supply and injection pipes also necessitates creating openings in the sealed jacket of the compressor for the pipes to pass through. Creating such openings can allow leaks of refrigerant fluids into the atmosphere and therefore increase greenhouse gas emissions.
[0027] The purpose of the present invention is to solve these problems by providing a variable-speed scroll-type refrigeration compressor that is structurally simple and allows easy maintenance of the oil injection line, while allowing precise control over the injection of oil into the compression volume, reducing greenhouse gas emissions, and enhancing the protection of the compressor against external impacts and stresses.
SUMMARY OF THE INVENTION
[0028] To this end, the present invention relates to a variable-speed scroll-type refrigeration compressor comprising:
a sealed enclosure defining a suction volume and a compression volume, one on either side of a body contained within the enclosure, the enclosure comprising a refrigerant gas inlet, an oil injection line supplied with oil from oil contained in a sump in the bottom of the enclosure and designed to inject oil into the compression volume, the oil injection line comprising a solenoid valve having a core that can be made to move by a magnetic field, between a first position allowing oil to be injected into the compression volume and a second position preventing or limiting the injection of oil into the compression volume, and control means for moving the solenoid valve core between its first and second positions,
said compressor being characterized in that the solenoid valve has a body attached to the wall of the sealed enclosure and containing the core,
and in that the control means are designed to move the solenoid valve core between its first and second positions, in response to the compressor speed and/or the refrigerant gas delivery temperature.
[0032] The attachment of the solenoid valve to the wall of the sealed enclosure allows easy maintenance of the solenoid valve because the latter is easily accessible from the outside of the compressor.
[0033] Moreover, this attachment of the solenoid valve to the wall of the sealed enclosure avoids the creation of openings in the sealed jacket for the passage of the supply and injection pipes, and avoids having at least some of these pipes on the outside of the sealed jacket. This enhances the protection of the injection pipe and hence of the compressor against external impacts and stresses and reduces greenhouse gas emissions.
[0034] Advantageously, the body of the solenoid valve comprises a first body portion attached to the wall of the enclosure and a second body portion attached removably to the first body portion, outside of the sealed enclosure, the second body portion containing the solenoid valve core. This structure of the solenoid valve body further facilitates the maintenance of this solenoid valve.
[0035] The control means are preferably designed to move the solenoid valve core to its first position when the compressor speed is below a predetermined value or when the refrigerant gas delivery temperature is above a predetermined value.
[0036] In another embodiment of the invention, the control means are designed to move the solenoid valve core to its first position when the refrigerant gas delivery temperature is above a predetermined value and the compressor speed is below a predetermined value.
[0037] In accordance with another feature of the invention, the control means are designed to move the solenoid valve core to its second position when the compressor speed is above a predetermined value.
[0038] In accordance with yet another feature of the invention, the compressor comprises an electric motor having a stator and, integral with a crankshaft-like drive shaft, a rotor, a first end of which drives an oil pump supplying oil from the sump in the bottom of the enclosure to a way formed in the central part of the shaft, said compressor being characterized in that the oil injection line is supplied with oil by the oil pump which is driven by the first end of the drive shaft.
[0039] The solenoid valve advantageously comprises at least one oil inlet port supplied with oil by a supply pipe located inside the sealed enclosure and connected to an outlet port of the oil pump which is driven by the first end of the drive shaft, a first oil outlet port opening inside the sealed enclosure, and a second oil outlet port connected to at least one injection pipe located inside the sealed enclosure and opening into the compression volume. The pipes are advantageously subjected to small pressure differentials (that is, less than 3 bar) compared with the pressure in the low-pressure enclosure of the compressor (around 5 to 20 bar). This means that low-pressure pipe can be used.
[0040] The solenoid valve core is preferably movable, by a magnetic field, between a closed position of the first oil outlet port in which all the oil entering the solenoid valve through the oil inlet port is directed to the second oil outlet port, and an open position of the first oil outlet port in which all or nearly all the oil entering the solenoid valve through the oil inlet port is directed to the first oil outlet port.
[0041] Thus, whatever position the solenoid valve core is in, all of the oil arriving from the oil pump and entering the solenoid valve is redirected into the sealed enclosure and/or into the compression volume. With these arrangements the invention avoids increasing the delivery pressure of the oil pump, which would use more energy.
[0042] In another embodiment of the invention, the solenoid valve comprises an annular chamber connecting together the inlet and outlet ports of the solenoid valve.
[0043] The head losses in the second oil outlet port and in the injection pipe are advantageously much greater than those in the first oil outlet port.
[0044] In yet another embodiment of the invention, the solenoid valve comprises a pipe connecting the second oil outlet port to a connection port formed in the solenoid valve and leading into a bore formed in the solenoid valve and containing the core of the latter, the bore being connected to a chamber which in turn is connected to the oil inlet port and the first oil outlet port, and in that the core is designed to close the connection port when it is in its open position.
[0045] The injection pipe preferably comprises an injection nozzle at that end of the pipe which opens into the compression volume.
[0046] In accordance with another feature of the invention, the end of the injection pipe that opens into the compression volume is inserted into a through-bore formed inside the body separating the compression and suction volumes.
[0047] A pin is advantageously inserted in the end of the injection pipe that leads into the compression volume in such a way as to compress the injection pipe against the walls of the bore formed inside the body, the pin comprising an injection passage allowing oil to be injected into the compression volume. The pin is preferably a roll pin or a coiled pin.
[0048] In accordance with another feature of the invention, the compression volume comprises a fixed volute fitted with a scroll engaged in a scroll of a moving volute driven with an orbital movement, the moving volute bearing against the body separating the compression and suction volumes.
[0049] That end of the bore formed in the body which is directed towards the moving volute preferably comes to an open end outside of the area swept by the moving volute during its orbital movement.
[0050] Alternatively, that end of the bore formed in the body which is directed towards the moving volute comes to an open end within the area swept by the moving volute during its orbital movement.
[0051] Advantageously, the moving volute comprises at least one through-port designed to connect, during at least part of the movement of the moving volute, the end of the injection pipe that opens into the compression volume to a volume defined at least partly by the fixed and moving volutes.
[0052] However, the invention will be understood clearly with the help of the following description, referring to the labeled schematic drawing showing, as non-restrictive examples, a number of embodiments of this scroll compressor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0053] FIG. 1 is a longitudinal section through a first compressor.
[0054] FIGS. 2 and 3 are enlarged sections through a solenoid valve in a first embodiment of the invention in which the valve is shown in its closed and open positions, respectively.
[0055] FIGS. 4 and 5 are enlarged sections through a solenoid valve in a second embodiment of the invention, showing the valve in its closed and open positions, respectively.
[0056] FIG. 6 is a longitudinal section through a second compressor.
[0057] FIG. 7 is a partial longitudinal section through a third compressor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0058] In the following description, the same parts are given the same reference signs in the different embodiments.
[0059] FIG. 1 shows a variable-speed scroll-type sealed refrigeration compressor occupying a vertical position. However, the compressor according to the invention could occupy an inclined position, or a horizontal position, without significant modification to its structure.
[0060] The compressor shown in FIG. 1 comprises a sealed enclosure defined by a barrel 2 whose top and bottom ends are closed by a cap 3 and a base 4 respectively. Weld seams may for example be used to assemble this enclosure.
[0061] The intermediate part of the compressor is occupied by a body 5 that defines two volumes, a suction volume situated beneath the body 5 , and a compression volume located above the latter. The barrel 2 comprises a refrigerant gas inlet leading into the suction volume to bring the gas to the compressor.
[0062] The body 5 serves as a mounting for the refrigerant gas compression stage 6 . This compression stage 6 comprises a fixed volute 7 fitted with a fixed scroll 8 which faces downwards, and a moving volute 9 bearing against the body 5 and fitted with a scroll 10 which faces upwards. The two scrolls 8 and 10 of the two volutes fit one inside the other to create compression chambers of variable volume. Gas is admitted into the compression stage from the outside, the compression chambers 11 having a variable volume which decreases from the outside towards the interior, when the moving volute 9 moves relative to the fixed volute 7 . The compressed gas escapes from the centre of the volutes through an opening 12 in the fixed volute 7 leading to a high-pressure chamber 13 , from which it is discharged by a connector 14 .
[0063] The compressor comprises an electric motor situated inside the suction volume. The speed of the electric motor can be varied by means of a variable-frequency electric generator.
[0064] The electric motor comprises a stator 15 with a rotor 16 in its center. The motor is attached to the barrel 2 by a collar 17 passing around the stator 15 and connected by tabs 18 to the barrel 2 .
[0065] The rotor 16 is connected to a drive shaft 19 with its top end off-center in the manner of a crankshaft. This top end is engaged in a sleeve part 20 of the moving volute 9 . When turned by the motor, the drive shaft 19 drives the moving volute 9 in an orbital movement.
[0066] The bottom end of the drive shaft 19 drives an oil pump 21 which supplies oil from a sump 22 defined by the base 4 to a lubrication way 23 formed inside the central part of the drive shaft.
[0067] The scroll compressor also comprises an oil injection line supplied with oil by the oil pump 21 driven by the bottom end of the drive shaft 19 . The oil injection line is designed to inject oil into the compression volume, and more particularly between the fixed 7 and moving 9 volutes.
[0068] The oil injection line comprises a solenoid valve 25 comprising a body 26 attached to the wall of the barrel 2 near the base 4 .
[0069] As shown more particularly in FIGS. 2 and 3 , the body of the solenoid valve 25 comprises a first body portion 26 a attached to the wall of the barrel 2 and a second body portion 26 b attached removably to the first body portion 26 a outside of the barrel 2 .
[0070] The solenoid valve 25 comprises an oil inlet port 27 supplied with oil by a supply pipe 28 arranged inside the barrel and connected to an outlet port of the oil pump 21 . The solenoid valve also comprises a first oil outlet port 29 opening into the barrel 2 and a second oil outlet port 30 connected to first and second injection pipes 31 , 32 located inside the barrel and each leading into the compression volume. The oil inlet and outlet ports are formed in the first body portion 26 a and lead into an annular chamber 33 formed in the first body portion 26 a . This annular chamber 33 allows the oil inlet and outlet ports of the solenoid valve to be connected to each other.
[0071] The solenoid valve comprises a metal core 34 housed in a bore 35 formed in the second body portion 26 b and movable by a magnetic field, generated by a coil (not shown in the figures) surrounding the core 34 , between a closed position allowing oil to be injected into the compression volume, and an open position which prevents or limits the injection of oil into the compression volume.
[0072] More specifically, the core 34 of the solenoid valve is movable between a closed position of the first oil outlet port 29 shown in FIG. 2 , in which all the oil entering the solenoid valve via the oil inlet port 27 is directed to the second oil outlet orifice 30 via the annular chamber 33 , and an open position of the first oil outlet port 29 shown in FIG. 3 in which all or nearly all the oil entering the solenoid valve through the oil inlet port 27 is directed to the first oil outlet port 29 .
[0073] When the core is in its open position, all or nearly all the oil entering the solenoid valve is directed to the first oil outlet port 29 because the head losses in the second oil outlet port 30 and in the first and second injection pipes 31 , 32 are much greater than those in the first oil outlet port 29 .
[0074] It should be pointed out that the core 34 of the solenoid valve 25 is also subjected to the action of a compression spring 45 housed between the bottom of the bore 35 and the core 34 . This compression spring helps to move the core 34 to its closed position.
[0075] It should be observed that the ends of the first and second injection pipes 31 , 32 leading into the compression volume are inserted into through-bores 36 , 37 , respectively, formed in the body 5 separating the compression and suction volumes. The bores 36 , 37 are approximately parallel to the compressor axis.
[0076] As shown in FIG. 1 , the open ends of the bores 36 , 37 directed towards the moving volute 9 are outside of the surface swept by the latter in its orbital movement. In another embodiment, either or both of the open ends of the bores 36 , 37 directed towards the moving volute may be within the surface swept by the latter.
[0077] The first and second injection pipes 31 , 32 each comprise an injection nozzle at their end directed into the compression volume.
[0078] Each injection nozzle takes the form of a pin 38 inserted in the end of the corresponding injection pipe 31 , 32 directed towards the body 5 . This arrangement of the pins 38 allows the first and second injection pipes 31 , 32 to be compressed against the walls of the corresponding bores 36 , 37 , respectively. The result is that the first and second injection pipes 31 , 32 are held firmly in the body 5 .
[0079] Each pin 38 comprises an injection passage allowing oil to be injected into the compression volume. The pins 38 are advantageously roll pins or coiled pins.
[0080] The compressor comprises control means for moving the core 34 of the solenoid valve 25 to its closed position when the speed of the compressor is less than a predetermined threshold value and moving the core of the solenoid valve to its open position when the speed of the compressor is above this predetermined value.
[0081] The control means are more particularly constructed to modify the magnetic field generated by the coil of the solenoid valve in response to the speed of the electric motor of the compressor in such a way as to allow the core 34 to move between its open and closed positions as the speed of the motor either exceeds or falls below, the predetermined value.
[0082] The operation of the scroll compressor will now be described.
[0083] When the scroll compressor according to the invention is started, the rotor 16 turns the drive shaft 19 and the oil pump 21 pumps oil from the sump 22 into the supply pipe 28 . The oil then enters the oil inlet port 27 of the solenoid valve 25 . As long as the speed of the compressor is below the predetermined threshold value, the core 34 of the solenoid valve is in its closed position, and oil that has entered the solenoid valve is therefore directed to the second oil outlet port 30 via the annular chamber 33 , and thence into the first and second injection pipes 31 , 32 . The oil is finally injected into the compression volume through the injection nozzles.
[0084] It should be observed that the end of the bore 37 directed towards the moving volute 9 can be closed by the latter for at least part of the orbital movement of the moving volute. This closing off of the end of the bore 37 directed towards the moving volute 9 not only lubricates the interface between the body 5 and the moving volute, but also regulates the amount of oil injected into the compression volume.
[0085] When the speed of the compressor exceeds the predetermined value, the control means move the core 34 of the solenoid valve to its open position. As a result, all or nearly all the oil entering the solenoid valve through the oil inlet port 27 is directed to the first oil outlet port 29 , because head losses in the second oil outlet orifice 30 and in the first and second injection pipes 31 , 32 are much greater than those in the first oil outlet port 29 . As a result, all or nearly all the oil that has entered the solenoid valve falls by gravity into the oil sump 22 .
[0086] The compressor according to the invention allows the amount of oil present in the compression volume, and therefore the proportion of oil in the refrigerant gas to be increased only when the speed of the compressor is low and below the predetermined threshold value. The present invention improves the low-speed performance of the variable-speed compressor without reducing its efficiency at high speed.
[0087] In another embodiment of the invention, shown in FIGS. 4 and 5 , the solenoid valve 25 has a pipe 40 connecting the second outlet port 30 to a connection port 41 formed in the second body portion 26 b . The connection port 41 leads into the bottom of the bore 35 containing the core 34 of the solenoid valve.
[0088] The connection port 41 leads to an annular chamber 42 formed inside the first body portion 26 a via a passage running between the bore 35 and the core 34 . The oil inlet port 27 and the first oil outlet port 29 connect with the annular chamber 42 .
[0089] In this embodiment of the invention, the core 34 is movable between a first closed position in which the first oil outlet port 29 is closed and the connection port 41 is open, as shown in FIG. 4 , and a second position in which the first oil outlet port 29 is open and the connection port 41 is closed, as shown in FIG. 5 .
[0090] In the first position of the core 34 shown in FIG. 4 , all the oil entering the solenoid valve through the oil inlet port 27 is directed towards the second oil outlet port 30 via the annular chamber 42 , the connection port 41 and the pipe 40 .
[0091] In the second position of the core 34 shown in FIG. 5 , all of the oil entering the solenoid valve through the oil inlet port 27 is directed towards the first oil outlet port 29 and falls by gravity into the oil sump 22 .
[0092] As in the embodiment described previously, the control means are designed to move the core 34 of the solenoid valve 25 to its first position when the speed of the compressor is below a predetermined threshold value, and move the core of the solenoid valve to its second position when the speed of the compressor is above this predetermined value.
[0093] FIG. 6 shows a second scroll compressor. The only difference between this and that shown in FIG. 1 is that the control means MC are designed to move the solenoid valve core 34 to its closed position when not only the delivery temperature of the refrigerant gas is above a predetermined value but also compressor speed is below a predetermined value, and to move the solenoid valve core to its open position when compressor speed is above a predetermined value. For this purpose the control means have a temperature sensor to measure the refrigerant gas delivery temperature at the connector 14 .
[0094] In another embodiment, the control means MC are designed to move the solenoid valve core 34 to its closed position when the refrigerant gas delivery temperature is above a predetermined value, and to move the solenoid valve core to its open position when the refrigerant gas delivery temperature is below a predetermined value.
[0095] FIG. 7 depicts a third scroll compressor. This differs from that shown in FIG. 1 in that the ends of the two bores 36 , 37 directed at the moving volute 9 open within the area swept by the latter during its orbital movement, in that these two bores are not oriented parallel to the compressor axis but obliquely inwards relative to this axis, and in that the moving volute 9 comprises first and second through-ports 43 , 44
[0096] The first and second through-ports 43 , 44 are designed to connect together, during at least part of the movement of the moving volute, the ends of the first and second injection pipes 31 , 32 directed towards the compression volume with a volume defined at least partly by the fixed 7 and moving 9 volutes.
[0097] It goes without saying that the invention is not limited to the embodiments described above by way of example of this scroll compressor. On the contrary, it encompasses all variants thereof. For instance, the bores 36 , 37 could be oriented obliquely outward away from the compressor axis, or the number of injection pipes could be other than two. | The compressor includes a sealed housing defining a suction volume and a compression volume respectively provided on either side of a body contained in the housing, an oil injection circuit supplied with oil from an oil contained in a casing and adapted for injecting oil into the compression volume, the oil injection circuit comprising an electrovalve including a body attached to the wall of the sealed housing and a core movable under the action of a magnetic fluid between a closing position for injecting oil into the compression volume and an opening position preventing or limiting the injection of oil into the compression volume. The compressor includes a control means for moving the core of the electrovalve between the opening and closing positions based on the compressor speed and/or on the cooling gas discharge temperature. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to a new electronic weft or filling thread monitoring device for shuttleless looms or weaving machines, such as gripper shuttle and rapier weaving machines. Generally, such a monitoring device serves for stopping the loom as soon as the weft thread breaks or is prematurely released from the gripper member during insertion into the weaving shed.
A gripper shuttle weaving machine provided with an optical weft thread monitoring apparatus is shown and described in U.S. Pat. No. 3,489,910, by way of example. Swiss Pat. No. 489,642 discloses a device for monitoring the weft thread on gripper shuttle weaving machines, said device comprising a preferably weft contacting sensor arranged on the picking side of the machine between supply spool and weaving shed, and circuitry determining a monitoring interval in which part of the weft insertion period is supervised. Such circuitry comprises a control member located near the end of the gripper shuttle race and producing a control pulse determining the end of the monitoring interval when the gripper shuttle passes the control member. The latter may be mounted near or within a gripper shuttle catch box. Preferably this control device is arranged ahead of the catch box since its mounting within the same is not possible without engineering changes and thus is not generally practicable. However, with such preferred arrangement, the control pulse appears so early that the monitoring interval is terminated prior to the stoppage of the gripper shuttle and weft or filling thread. As a consequence, the thread is no longer monitored during the last phase of its travel, i.e. after the gripper shuttle has passed the control device. This last phase may comprise a time interval of ten milliseconds or more. Now in order to reduce this non-monitored time interval, the control or controlling pulse, as disclosed in the aforementioned Swiss patent, may be delayed by a constant amount such that the monitoring interval is prolonged by the same amount.
However, the duration of such last phase of the filling insertion period depends upon the type of weaving machine, the adjustment and the working conditions thereof, and in particular the type of filling yarn. Thus it is desirable that the amount of such time delay should be fixed according to circumstances. By way of example, the optimal delay may be in the range from six to twelve milliseconds. The delay may be set by shifting and adjusting the control device generating a controlling pulse along the path of the gripper shuttle. However, such measure requires additional expenditure of mechanical means and, moreover, generally is impracticable due to lack of space. Furthermore, special measuring equipment is required for checking the correct setting, so that only trained personnel is able to perform the setting.
SUMMARY OF THE INVENTION
Thus, it is a main objective of the invention to provide, for an electronic weft or filling monitor mounted on a shuttleless weaving machine, indicating means enabling an operator to easily and optimally adjust the final point of the monitoring interval.
It is a further object of the invention to provide, for an electronic filling monitor comprising a signal channel producing a thread travel signal and trigger circuitry generating a controlling signal or pulse defining the duration of the monitoring interval, a variable delay circuit for adjusting the termination of the control signal.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent upon consideration of the following detailed description thereof which refers to the annexed drawings wherein:
FIG. 1 shows a first embodiment of the new weft thread monitoring device and cooperating indicator circuitry, in block diagram;
FIG. 2 is a block schematic of a second embodiment of the indicator circuitry;
FIG. 3 is a block diagram of a further double indicator circuitry, and
FIG. 4 is a pulse diagram illustrating the mode of operation of the double indicator circuitry shown in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1 the components comprised by the weft thread monitor SW, --without indicator circuitry--, as far as they are essential for understanding the invention, are characterized by numerals 1-15, whereas the indicator circuitry AS1 comprises the components 16-20.
The weft thread monitor SW is mounted on a weaving machine (not shown) and may be designed in an essentially known manner. A thread sensor 1 acted upon by weft or filling thread F is preferably located on the picking side of the machine between supply spool and selvedge. Thread sensor 1 may comprise a conventional piezoelectrical, capacitive, triboelectrical or optoelectrical transducer and produces a sensing signal shaped as an irregular alternating or noise potential when the thread is traveling. A series circuitry comprising amplifier 2, rectifier 3, smoothing circuit 4 and pulse shaper 5 is connected to thread sensor 1. The components 1-5 form a signal processing channel or signal channel furnishing a thread travel signal or pulse F'. The output terminal of signal channel 1-5 is connected to a negating or inverting input of an AND-gate 14. This negating input receives the thread travel signal F' shaped as a rectangular pulse which is prematurely terminated when weft thread F breaks or comes to a standstill.
Blocks 6-13 represent trigger circuitry serving for producing a controlling pulse K'. Firstly, trigger circuitry 6-13 comprises first and second trigger pulse sources 6 and 9, respectively. Normally, the first trigger pulse source 6 is periodically tripped by an element synchronously rotated by the drive shaft of the weaving machine and may be designed as an induction coil cooperating with a rotating permanent magnet, or may be a proximity switch actuated by a rotating magnetic lug. Thus, in each working cycle of the weaving machine a first trigger pulse is generated which defines the start of the monitoring interval. The second trigger pulse source 9 is normally mounted near the path of the rapier or gripper shuttle on the weft receiving or catch side of the machine and furnishes a second trigger pulse at the end of the weft insertion. The second trigger pulse essentially defines the end of controlling pulse K' and thus the end of the monitoring interval.
A series connection of a pulse amplifier 7 and a pulse shaper 8 and a pulse amplifier 10 and a pulse shaper 11 is operatively connected to each of the trigger pulse sources 6 and 9, respectively. Pulse shaper 11 is followed by a delay circuit 12 which is adjustable with respect to the duration of its delay v and acts upon the trailing edge of the second trigger pulse produced by pulse shaper 11. The outputs of pulse shaper 8 and delay circuit 12 are connected to the not particularly referenced set input and reset input, respectively, of a RS-flipflop 13 forming the end or output stage of the trigger circuitry 6-13 and furnishing a controlling pulse K' which is supplied to the not negating input of AND-gate 14. In order to obtain correct operation of the weaving machine free of improper stoppages, the end of controlling pulse K' should be adjusted by means of delay circuit 12 such that it occurs, with orderly weft insertion, some, e.g. three milliseconds prior to the end of thread travel pulse F'. Such a safety interval ts between the end of controlling pulse K' and thread travel pulse F' is advantageous in view of the unavoidable deviations of the duration of the thread travel pulse F' during normal operation of the weaving machine.
Delay circuit 12 may be designed as a monostable circuit or monoflop. Delay v may be varied continually by adjusting the time constant of the monoflop defining the duration of the output pulse of delay circuit 12, by means of a variable resistor or potentiometer. Alternatively the time constant may be varied in steps when desirable.
In case the setting of delay circuit 12 and the operation of the weaving machine are correct, AND-gate 14 having an inverting input produces no switching pulse which might actuate switching device 15, since AND-gate 14 remains blocked for controlling pulse K' due to a thread travel pulse F' supplied to the inverting input of AND-gate 14. However, such a switching pulse 14' is generated when thread travel pulse F' terminates prior to control pulse K' as a consequence of a thread break, thus stopping the weaving machine.
Circuitry AS1 provided for indicating the setting of weft thread monitor SW comprises a series connection of RS-flip-flop 16, integrator 17, comparator or threshold stage 18, pulse stretching stage 19 and indication device 20. The circuits 16-18 designed for producing a timing pulse 18' provide a timing circuitry.
The set input of RS-flipflop 16 is connected to the output of RS-flipflop 13 of trigger circuitry 6-13, whereas the reset input is connected to the output of pulse former 5 of signal channel 1-5. In case delay circuit 12 is set such that controlling pulse K' ends prior to thread travel pulse F', RS-flipflop 16 of indicator circuitry AS1 furnishes a short difference pulse 16' of duration t for each weft insertion. Now indicator circuitry AS1 is designed in such a manner that only difference pulses 16' are indicated whose duration t surmounts the duration ts of the safety interval of e.g. three milliseconds. For this purpose difference pulse 16' is transformed into a triangle pulse 17' by integrator 17. The threshold of comparator 18 following integrator 17 is set such that the latter generates a timing pulse 18' whose duration is shorter than the duration t of difference pulse 16' by the amount ts of the safety interval. Thus, when the difference pulse 16' is longer than the safety interval ts, the duration t-ts of timing pulse 18' equals the time interval between the end of thread travel pulse F' and the end of the preceding controlling pulse K', diminished by the safety interval ts. However, when difference pulse 16' is equal to or shorter than the safety interval ts, no timing pulse 18' is produced. In the first event indication device 20 is actuated, however, no indication occurs in the second event. Pulse stretching stage 19 has the sole purpose to stretch timing pulse 18' such that safe indication and reading is ensured. Pulse stretching stage 19 may produce an indicator pulse of 500 milliseconds, by way of example.
Setting may be performed by means of delay circuit 12 with the weaving machine operating. To begin with, a short delay v is chosen such that the control pulse K' terminates immediately prior to thread travel pulse F', and an indication appears on each weft insertion. Thereafter, the delay v is increased to such an extent that indicator device 20 is actuated only occasionally within a series of weft insertions. With such a setting, the mean time difference between the end of controlling pulse K' and the end of thread travel pulse F' is about three milliseconds, i.e. the duration of the safety interval ts fixed by comparator 18.
Continuous or repeated response of indication device 20 in indicator circuitry AS1 indicates that delay v is set too short on delay circuit 12, or that the duration of difference pulse 16' t is too long.
The indicator circuitry AS2 shown in FIG. 2 may be used in place of indicator circuitry AS1 shown in FIG. 1. Circuitry AS2 comprises timing circuitry 21,22, pulse stretching stage 23 and indication device 24 equipped with a light emitting diode 25 or other indication means.
The timing circuitry 21,22 comprises a first monostable circuit or monoflop 21 and an AND-gate 22 having an inverting or negating input. Pulse stretching stage 23 may be designed as a monostable circuit or monoflop furnishing, upon actuation, an indicator pulse 23' whose duration may be in the range from about 200 to 1000 milliseconds.
The setting process beings as mentioned above, by adjusting delay circuit 12 to a short delay v, whereupon the weaving machine is started. With such adjustment, controlling pulse K' may terminate, by way of example at a time interval t=5 milliseconds prior to thread travel pulse F'.
The first monostable circuit 21 is tripped by the rear or trailing edge of controlling pulse K' and generates a safety pulse 21' of a duration of e.g. three milliseconds. The safety pulse 21' is compared with the negated or inverted thread travel pulse F' in AND-gate 22. Assuming the interval t between the end of pulse K' and the end of pulse F'--or the end of inverted pulse F'--is five milliseconds, then this means that the pulse F' and F' terminate two milliseconds after safety pulse 21'. In this event or generally when t>ts, no timing pulse 22' and no indication will occur.
Now when the delay v at delay circuit 12 is gradually increased and a certain setting is attained, light emitting diode 25 will continually or repeatedly respond during successive weft insertions. Thereupon, delay v is adjusted in such a manner that within a rather long series of weft insertions light diode 25 only occasionally responds. Thereupon, the setting process is finished. In this event, the time interval t between the end of controlling pulse K' and the end of thread travel pulse F' is substantially equal to the duration ts of the safety pulse 21'.
With reference to FIG. 2, the following may explain that procedure. By increasing the delay v, the safety pulse 21' is moved as far to the right side that it overlaps the rear edge of thread travel pulse F' or rising edge of inverted pulse F'. Thus, a timing pulse 22' is generated whose duration equals ts-t as long as the thread travel pulse F' ends within safety pulse 21'. Timing pulse 22' is stretched to e.g. 500 milliseconds in pulse stretching stage 23, and the stretched indicator pulse 23' causes light emitting diode 25 to flash up for the same time interval. By carefully reducing delay v by means of delay circuit 12 the trailing edge of safety pulse 21' is made to coincide with the edge of thread travel pulse F' or F', and the setting process is finished.
During this procedure, the weft thread monitor SW, FIG. 1, does not produce a switching pulse 14' since controlling pulse K' terminates prior to thread travel pulse F'--provided no weft break occurs accidentally during the setting procedure.
Continuous or repeated response of indication device 24 in indicator circuitry AS2 signals that delay v of delay circuit 12 is set too long, or the duration t is too short, that means t<ts.
The double indicator circuitry shown in FIG. 3 consists of two parallel circuits, one of which AS3 comprises the components 26-30 and the second AS2 the components 21-24. This second circuit or circuitry AS2 is identical with the one shown in FIG. 2 and thus need not be here further explained in detail. The function of indicator circuitry AS3 corresponds to that of indicator circuitry AS1, however, these circuits are different in design.
Indicator circuitry AS3 as shown in the upper half of FIG. 3 comprises a pulse expanding circuit 26, a monostable circuit or monoflop 27, an AND-gate 28, a pulse stretching stage 29 and an indication device 30 equipped with a light emitting diode 31. Pulse expanding circuit 26, monostable circuit 27 and AND-gate 28 form a timing circuit 26-28. The components 29 and 30 may be designed like the components 23 and 24, respectively, of indicator circuitry AS2, FIG. 2 and FIG. 3. Pulse expanding circuit 26 is supplied with controlling pulse K' which is expanded by a second safety interval t's whose duration, e.g. five milliseconds, should be somewhat greater than the duration ts of the first safety interval pertinent to circuitry AS2. The expanded control pulse 26' is supplied to monostable circuit 27, in which the trailing edge of pulse 26' trips a supplemental pulse 27' of e.g. 10 milliseconds duration. The supplemental pulse 27' is supplied to one input of AND-gate 28, the other input of which receives the thread travel pulse F'. AND-gate 28 produces a timing pulse 28' of duration t-t's only when supplemental pulse 27' begins prior to the trail of thread travel pulse F', i.e. if t>t's. In this event, light emitting diode 31 flashes up to provide an indication.
The mode of indication of the double indicator circuitries AS2,AS3 shown in FIG. 3 is illustrated by FIG. 4, where the magnitude of the time interval t between the end of controlling pulse K' and the end of thread travel pulse F' is plotted along the abscissa. Response of the indicator circuitries AS2,AS3 is represented by ordinate values 1.
It is obvious from FIG. 4 that indicator circuitry AS2 responds when t<ts, whereas AS3 responds when t>t's. Within the range ts<t<t's neither indicator circuitry responds, indicating the correct setting of weft thread monitor SW.
It should be noted that only positive values of t are importent to the setting procedure when the weaving machine is working, since with negative values a switching pulse 14' is produced and stops the machine.
As an alternative, t's may be chosen smaller than ts; in this event, the correct setting of the weft thread monitor SW is indicated by both light emitting diodes 25,31 flashing up.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously embodied and practiced within the scope of the following claims. ACCORDINGLY, | The invention is concerned with an electronic device enabling an operator to easily and correctly adjust the time interval in which the weft insertion in shuttleless looms fitted with an electronic weft or filling thread monitor is to be monitored. A safety interval of some milliseconds' duration is provided at the end of said time interval taking into account the unavoidable fluctuations of the weft insertion period. | 3 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to elemental analyzers and particularly an analyzer which employs a reagent assembly which is easily removable from the combustion chamber.
[0002] A determination of concentration of elements, such as carbon, hydrogen, sulfur, and nitrogen, in an organic sample is desirable for a variety of reasons. In recent years, the food market in particular has become interested in determining the amount of protein in an organic sample, which can be determined by the nitrogen content. Further, the sulfur content, as well as the carbon-to-hydrogen ratio, is desirable in the characterization of coal and coke samples, as are the carbon, hydrogen, and nitrogen ratios in a variety of other organic materials.
[0003] Elemental analyzers are commercially available from the Assignee of the present application, Leco Corporation of St. Joseph, Mich., which manufactures CHN analyzers, which are sold under the trademark TRUSPEC®. The analyzer may employ a variable volume ballast chamber of the type disclosed in U.S. Published Application 2004/0171165 A1 (now U.S. Pat. No. ______), the disclosure of which is incorporated herein by reference. The analyzer disclosed in this published application generally is used for the macro analysis of samples of from about 0.25 grams in size. The combustion system in such an analyzer uses a generally U-shaped quartz combustion tube of the type also disclosed in U.S. Pat. No. 4,622,009, the disclosure of which is incorporated herein by reference. The combustion tube includes a first vertically extending leg which receives a crucible for combustion of a sample and a second vertically extending leg downstream coupled to the first leg and which includes reagents that can serve several purposes. These include scrubbing undesirable products of combustion, enhancing the complete combustion of difficult samples, and/or the removal of excess reagents, such as oxygen. The selection of the reagent is dependent upon the characteristics of the application.
[0004] Generally, the analysis of elemental carbon, hydrogen, sulfur, and nitrogen is well known and is discussed in several references, including Methods in Microanalysis , Vol. 1, Mirra Osipovna Korshun, 1964, Instrumental Organic Elemental Analysis , R. Belcher, 1977; and Organic Elemental Analysis Ultramicro, Micro, and Trace Methods , Wolfgang J. Kirsten, 1983. U.S. Pat. No. 4,525,328 discloses an analyzer employing a fixed volume ballast chamber, which collects analytes in an approximately 4.5 L chamber for subsequent analysis. The amount of combustion oxygen used in filling the fixed ballast chamber is significant, and an analysis takes a significant amount of time for the combustion and ballast chamber filling. Also, the byproducts of combustion, i.e., the analyte gases, are somewhat diluted in the relatively large volume ballast chamber. The 2004/0171165 A1 application discloses a variable volume ballast chamber with a movable piston and a combustion detector, such that, during combustion of a sample, the chamber is only filled with byproducts of combustion until the completion of combustion is determined by the combustion detector. Typically, a significantly smaller volume than that of the fixed volume ballast chamber is captured in a more concentrated form of analyte which subsequently can be ejected from the variable volume ballast chamber by controlling a movable piston.
[0005] With the variable volume ballast chamber system disclosed in the above-identified published patent application, a large or macro analysis sized sample of 0.10 grams or more are employed. It is desired to provide an analyzer which utilizes a smaller samples, if possible, and conduct an analysis on-the-fly (i.e., detection of the sample during the combustion event as opposed to storing a combustion sample and providing an aliquot sample from a ballast chamber). One difficulty with an on-the-fly analysis system is that, for such micro analysis utilizing a helium carrier gas, an influx plug of excess oxygen is employed to fully combust the sample, and the remaining oxygen must be eliminated prior to detection by flowing the gaseous byproducts of combustion through a reduction reagent, such as copper wire strips.
[0006] In the U-shaped combustion tubes used in analyzers, such reagents are packed in the downstream leg of the U-shaped combustion tube and it is necessary after several analyses, which can be anywhere from less than 100 to about 1000 samples, to remove the fused and contaminated reduction reagent from the combustion tube and replace it with new reagents. This requires complete disassembly of the furnace and frequently replacement of the combustion tube itself inasmuch as the reagent packed in the quartz tube tends to melt and stick as a plug in the combustion tube itself. Since combustion takes place at a temperature of nearly 1000° C., this requires considerable time, expense, and manpower, since the furnace must first be cooled, opened, the combustion tube disassembled, and frequently a new combustion tube with a new reagent installed.
[0007] Thus, there exists a need for an improved system which allows for on-the-fly micro analysis, i.e. 2 mg to 10 mg samples, utilizing a combustion system which allows for the easy replacement of the reducing reagent.
SUMMARY OF THE INVENTION
[0008] The system of the present invention satisfies this need by providing a reagent assembly for a combustion furnace having a combustion tube. The reagent assembly employs a reagent tube which is packed with a reagent and is concentrically positioned in the combustion tube. The reagent tube is sealably and removably coupled to an open end of the combustion tube such that, when the reagent is depleted, the reagent tube can be easily removed without disassembly of the furnace or changing the combustion tube.
[0009] In one embodiment of the invention, the reagent tube is top loaded into one leg of a U-shaped combustion tube. In another embodiment, in order to reduce dead volume in the combustion flow path, the reagent tube is inserted into a second tube having an inner diameter greater than the outer diameter of the reagent tube such that a flow path exists between the annular space between the outer wall of the reagent tube and the inner wall of the second tube. The second tube is generally cylindrical and has a closed floor at one end and is inserted into the leg of the combustion tube with the outer diameter of the second tube having a diameter smaller than the inner diameter of the combustion tube. The reagent and second tubes are sealably mounted to the combustion tube such that byproducts of combustion are forced in a tortious flow path, which includes the concentric space between the combustion tube and the outer surface of the second tube then between the space between the inner surface of the second tube and the outer surface of the reagent tube and subsequently upwardly through the open end of the reagent tube to an exit port.
[0010] In all embodiments, the reagent tube is packed with reagents and is coupled to a fitting which is easily removed from the combustion furnace and combustion tube and which allows the reagent tube containing an exhausted reagent to be removed from the top of the combustion tube, thereby eliminating the need to remove and/or replace the entire combustion tube from the furnace once the reagent has been expended. In a preferred embodiment of the invention, the fitting includes a twist-lock cap associated with the reagent tube to facilitate its removal. Such a system thereby allows for on-the-fly micro analysis of a sample which utilizes a reagent to remove the excess oxygen and allows the reagent to be replenished as necessary without the time and effort required by existing systems.
[0011] These and other features, objects and advantages of the present invention will become apparent upon reading the following description thereof together with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a fragmentary cross-sectional view of a resistance combustion furnace and combustion assembly including the reagent assembly of the present invention;
[0013] FIG. 2 is an enlarged fragmentary exploded cross-sectional view, partly broken away, of the reagent assembly of the present invention;
[0014] FIG. 3 is an exploded fragmentary perspective view of the combustion furnace and reagent assembly of the present invention;
[0015] FIG. 4 is an exploded perspective view of the twist-off cap assembly of the reagent assembly of the present invention;
[0016] FIG. 5 is a perspective view of the mounting block to which the cap is secured; and
[0017] FIG. 6 is a flow diagram of an analyzer embodying the top-loading reagent assembly of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Referring initially to FIG. 1 , there is shown an analytical furnace 10 embodying a reagent assembly 100 of the present invention. Furnace 10 is a resistance heating furnace including a generally U-shaped quartz combustion tube 20 having a generally cylindrical vertically extending first or combustion leg 22 , a transverse coupling conduit 24 , and a vertically upwardly extending second or reagent leg 26 . The combustion tube, thus, generally has cylindrical sections 22 and 26 which are joined by the transverse conduit 24 . The furnace 10 can generally be of the type disclosed in U.S. Pat. No. 4,622,009, the disclosure of which is incorporated herein by reference, which heats a sample 36 dropped by a sample load assembly 30 of the type disclosed in U.S. Pat. No. 6,291,802, the disclosure of which is incorporated herein by reference, through an oxygen lance and sample introduction tube 32 into a crucible 34 . Crucible 34 can be of the type disclosed in U.S. Pat. No. 6,270,727, the disclosure of which is incorporated herein by reference.
[0019] Combustion crucible 34 is held in place by a suitable quartz porous plug 35 which allows the byproducts of combustion to flow downwardly through the leg 22 in the direction indicated by arrow A in FIG. 1 . The tube 32 , in addition to providing a sample drop pathway, serves as an oxygen lance for the introduction of combustion oxygen to the open mouth of the cup-shaped crucible 34 during combustion. The furnace 10 is employed in a micro analysis system in which, after the sample 36 is introduced into the crucible and furnace, which has been heated to approximately 1000° C., a helium carrier gas flows through the combustion chamber 20 until a plug or aliquot of oxygen is introduced through lance 32 , for a period of about 5-10 seconds in one embodiment, to complete the combustion of the 1 to 50 mg sample 36 held within crucible 34 to completely combust the sample. The helium carrier gas then carries the byproducts of combustion through the transverse conduit 24 and upwardly, as indicated by arrow A, into the open mouth of the reagent tube 110 of the reagent assembly 100 .
[0020] Reagent tube 110 , as seen in FIGS. 1 and 2 , is also made of quartz and has an open lower end 112 with an inwardly tapered section 114 holding the reduction reagent 42 in place. Reagent tube 110 is generally cylindrical and includes an annular mounting flange 116 at its open upper end 117 ( FIG. 3 ). Flange 116 rests upon an annular surface 154 of mounting block 150 and is sealed to the mounting block 150 by an O-ring seal 152 , as best seen in FIG. 2 .
[0021] In a preferred embodiment of the invention, the open end 112 of quartz reagent tube 110 had a diameter of about 0.5 inches, while the inner diameter of tube 110 was approximately 0.75 inches, and had a wall thickness of about 3 mm. The outer diameter of tube 110 is approximately 1 inch. The tapered end 114 was tapered at an angle of approximately 20° over a length of approximately 0.70 inches while the overall length of tube 110 was approximately 9.25 inches. The flange 116 has a diameter of 1.2 inches, and tube 110 fits within the circular opening 153 of mounting block 150 with flange 116 engaging the annular surface 154 ( FIG. 5 ) of block 150 .
[0022] Within the inner removable reagent tube 110 , there is packed the reagent comprising in a preferred embodiment, as seen in FIG. 1 , copper wool 40 forming a plug at the tapered lower end 114 of the reagent tube 110 . Above the copper wool plug 40 there is placed the reduced copper reagent 42 itself comprising finely chopped copper wire sticks which are prepared by placing the sticks in a vacuum furnace with hydrogen to scavenge all the oxygen from the copper. The reagent is commercially available from Leco Corporation of St. Joseph, Mich.
[0023] Tube 110 is concentrically and removably mounted within the second leg 26 of combustion tube 20 by a twist-off sealed locking cap 140 removably mounted to mounting block 150 , which is affixed to furnace wall 12 as described in greater detail below. Although the reagent tube can be dimensioned to reduce the dead space between its outer diameter and that of the inner diameter of the combustion tube leg 26 , in one embodiment, dead space is reduced by the use of an optional second concentric tube 120 as now described.
[0024] The generally cylindrical quartz outer tube 120 has a closed lower end or floor 122 which rests on the bottom surface 23 of the leg 26 of combustion tube 20 , as best seen in FIG. 2 . The quartz tube 120 has a length of about 9 inches and, when resting on the floor of the combustion tube, leg 26 does not extend fully to the top of the reagent tube but rather leaves an open annular space 124 ( FIG. 2 ) above the top edge 125 of tube 120 in the area between the inner wall 27 of combustion tube leg 26 and the outer wall 115 of reagent tube 110 .
[0025] The outer diameter of the second or outer tube 120 is about 1.18 inches as compared to the inner diameter of 1.25 inches of the combustion tube leg 26 , thereby leaving an annular space for the flow of combustion gases in the direction of arrow A around the outer surface of inner tube 120 and the inner surface 27 of combustion tube leg 26 into the annular space 124 , which is sealed by an O-ring seal 28 sealing the combustion tube section 26 to the furnace wall 12 , as best seen in FIG. 2 . The gases, therefore, are forced to flow downwardly in a second annular space 128 between the outer diameter of reagent tube 110 and the inner diameter of outer tube 120 . The inner diameter of outer tube 120 is approximately 1.063 inches, such that a gap of approximately 0.0315 inches is formed between the outer wall of the reagent tube 110 and the inner wall of the outer tube 120 , allowing the gaseous byproducts of combustion to flow downwardly, as indicated by arrow A, into the open area 130 below open end 112 of tube 110 and above floor 122 of outer tube 120 . The gas then flows upwardly as indicated by arrow A through reagents 42 into the exit aperture 142 of removable cap 140 .
[0026] Cap 140 is shown in detail also in the exploded view of FIG. 4 and includes a first cylindrical section 141 , which extends downwardly within the open mouth of inner tube 110 , as best seen in FIG. 2 , and is sealed to the inner surface of tube 110 by sealing O-ring 143 . The cap 140 also includes a second, larger diameter annular section 144 which sealably fits within the aperture 153 ( FIG. 5 ) of mounting block 150 and is sealed thereto by an O-ring 145 . Cap 140 includes a mounting flange 146 having a diameter greater than that of section 144 . Flange 146 includes a pair of keyhole-shaped arcuate slots 147 . The outer edge 148 of flange 146 is knurled to allow the cap to twist off from the mounting block 150 , which includes a pair of cap bolts 160 over which the cap 140 can be extended and rotated while pressing downwardly to sealably engage the combustion tube section 26 as well as reagent tube 110 , which is coupled to cap 140 by the interference fit with O-ring 143 during assembly of the unit. A gas elbow 149 of conventional configuration is threadably coupled to the opposite end of aperture 142 to provide an exit flow path 149 ′ for the byproducts of combustion into the remaining components of the analyzer, as shown in FIG. 6 .
[0027] Mounting block 150 , as seen in FIG. 5 , includes blind threaded apertures 151 for receiving the cap bolts 160 , which extend upwardly a distance sufficient for extending through slots 147 in flange 146 of the cap 140 . Mounting block 150 also includes a plurality of apertures 155 for securing the cap to the furnace wall 12 in a conventional manner in sealed engagement by the use of O-ring 28 , as seen in FIG. 2 . The details of this mounting arrangement are not shown in the flow path cross-sectional views of FIGS. 1 and 2 , however, the furnace wall 12 , as seen in FIG. 3 , includes threaded apertures 156 for receiving conventional fasteners, such as cap head screws, which extend through apertures 155 in the mounting block 150 for securing mounting block 150 to the furnace wall 12 . The cap 140 and mounting block 150 are machined of aluminum or other suitable metal to withstand the pressure and temperature of the byproducts of combustion flowing therethrough. Cap 140 includes an annular recess 145 ′, as seen in FIG. 4 , for receiving the sealing O-ring 145 , which forms a double seal with the cap and the seal 152 in cap-receiving recess 153 of mounting block 150 .
[0028] As can be seen in reviewing FIGS. 1-5 , the removable reagent tube 110 of assembly 100 allows the furnace 10 to be employed for combusting several samples until the reagent is exhausted. The furnace can be opened to expose the combustion tube and the cap 140 of the removable reagent assembly. Cap 140 is rotated and lifted to gain access to the reagent holding inner tube 110 , which can be lifted from the combustion tube reagent section 26 while retaining the outer tube 120 in place to allow the easy replacement of the reagent inner tube 110 either by inserting a freshly made and repacked reagent tube or by cleaning out the existing tube external to the furnace and repacking it with reagent materials 40 and 42 . By providing a reagent tube with a flanged upper end and a tapered lower end and having a diameter in cooperation with either the combustion tube leg 26 or the outer tube 120 , the flow of byproducts of combustion through the reagent tube is assured, and an easily replaceable reagent section of the combustion system is provided. This greatly reduces the time, effort, and expense required of the prior art systems, where frequently combustion tube 20 itself had to be replaced.
[0029] The reagent assembly 100 is initially installed by placing the outer tube 120 within the leg 26 of combustion tube 20 , which need not be critically centered in view of the existence of a gap between the outer diameter of reagent tube 110 (or tube 120 ) and the inner diameter of leg 26 of combustion tube 20 , allowing a flow pass of gas therebetween regardless of the precise centering. Similarly, the insertion of reagent tube 110 within the outer tube 120 always allows a generally annular gap therebetween such that the byproducts of combustion will be forced downwardly around the space between the outer or second tube and the reagent tube and then upwardly through the open end of the reagent tube and through the reagent. The overall analyzer, including the unique top-loaded removable reagent assembly 100 of the present invention, is shown in FIG. 6 , which is now briefly described.
[0030] Inlet 31 ( FIG. 6 ) of furnace 10 receives combustion gas (O 2 ) from a source 15 of oxygen which has a flow rate adjusted between 0.5, 1, 3, 5, or 6 L per minute by the selective activation of parallel flow control valves 11 , 13 , and 17 in conduit 16 leading from the supply of oxygen to the inlet 31 of the combustion furnace. The O 2 pressure is monitored by a pressure sensor 18 . The oxygen is jetted into the open mouth of a sample-holding crucible 34 through an oxygen lance 32 to combust the sample. As described above, the byproducts of combustion (i.e., analytes) flow through reagent 42 in reagent tube 110 positioned in leg 26 and from combustion chamber 20 through exit port 149 ′. Conduit 41 transfers the byproducts of combustion through a heater 43 . The byproducts of combustion flowing in conduit 41 then pass through a combustion detector 45 comprising an H 2 O IR cell, which detects the hydrogen content in the gas stream as a result of the combustion of the sample 36 in crucible 34 . The combustion detector 45 is coupled to a CPU, as described in the above identified ′ 165 publication, for storing the detected hydrogen level.
[0031] As seen in FIG. 6 , the byproducts of combustion are forced through a flow path including an anhydrone scrubber 47 and an SO 2 determining IR cell 49 and a CO 2 determining IR cell 50 , all contained within a heated chamber 52 .
[0032] The He carrier gas in conduit 14 then carries the byproducts of combustion through pinch valve 19 in conduit 51 to valve 76 . The sample gas then passes through valve 74 into catalytic reduction heater 78 and through anhydrone scrubber 80 . Conduit 82 carries the sample gas through a 300 cc/minute flow controller 84 into the nitrogen sample inlet port 86 of thermal conductivity module 60 and through the thermal conductivity measurement device 88 , which is coupled to a CPU to provide data relative to the nitrogen concentration detected. After measurement, the gas is then exhausted through an exhaust outlet valve 90 . During the measurement of nitrogen concentration by cell 88 , He carrier gas at T-junction 68 also flows through a flow restrictor 91 to a thermal conductivity reference cell 92 .
[0033] He carrier gas from source 54 flows through filter 56 in conduit 58 to inlet port 59 of thermal conductivity module 60 via the actuation of He valve 62 . The He gas exits module 60 via port 63 , travels through a 12 psi pressure regulator 64 and scrubber 65 into port 66 of thermal conductivity module 60 . Heater 78 is filled with copper (Cu) heated to about 750° C. to remove any remaining oxygen and convert NO to free nitrogen (N 2 ), which subsequently flows through the scrubber 80 , which includes sodium hydrate silicate for removing CO 2 and an anhydrone, which removes water from the gas flow stream.
[0034] The control of the valves and the combustion furnace, as well as the measurement and detection of the concentration of gases, is conventionally controlled by a CPU(not shown). The CPU receives an input signal as to the size of the sample from balance 12 and controls the loading head 30 ( FIG. 1 ) to drop the sample within the combustion chamber. The CPU also controls the application of power to furnace 10 through a suitable power control module. The CPU may be coupled to a printer to print the results of the gas concentrations detected. The CPU is programmed in a conventional manner, to analyze the sample based upon standard ASTM standards utilizing data from the infrared detectors and thermal conductivity detectors shown in FIG. 6 . As is well known after an analysis cycle, the analyzer is purged to condition it for a subsequent analysis.
[0035] It will become apparent to those skilled in the art that various modifications to the preferred embodiment of the invention as described herein can be made without departing from the spirit or scope of the invention as defined by the appended claims. | A reagent assembly for a combustion tube includes a reagent tube which is sealably and removably coupled to the open end of the combustion tube such that, when the reagent in the reagent tube is depleted, it can be easily removed without disassembly of the furnace or changing the combustion tube. The reagent tube includes a twist-lock cap to facilitate removal of the reagent tube. | 6 |
BACKGROUND OF THE INVENTION
[0001] I. Field of the Invention
[0002] The present invention relates to the administration of an educational program. More specifically, the present invention provides a computer-based system for processing registration, tracking and student performance data and generating reports related to a student's performance.
[0003] II. Background of the Invention
[0004] Many professional schools require students to participate in on-the-job training programs generically referred to as clinical rotations or externships. For example, the third and fourth year of most medical school programs involve engaging students in an externship comprising a variety of rotations involving different aspects of the practice of medicine. A typical emergency medicine rotation, for example, consists of 17 clinical shifts, 8 hours of didactic conference, 4 one and one-half hour procedural workshops, and an emergency medical service “ride along”. Students may also be given written tests. During the rotation students are directly supervised by several different attending physicians. The student's final grade for the rotation is based not only on test results, but also on an evaluation of the student's performance during clinical shifts, conferences, workshops and the EMS ride along. Compiling evaluation data from so many sources can be a time-consuming and difficult task.
[0005] Significant difficulties are associated with scheduling students into rotations, collecting evaluation data and processing the evaluation data to give accurate and timely assessments of student progress. This is true for most externship programs, but these problems are particularly acute with respect to medical training because medical schools typically partner with a variety of teaching hospitals, teaching hospitals partner with more than one medical school, and the medical schools partner with each other.
[0006] In view of the foregoing, there is a real need for an effective, timely and efficient method for registering and tracking students, generating evaluation data, collecting the evaluation data, storing the data, and reporting the data on a timely, as needed, basis.
SUMMARY OF THE INVENTION
[0007] Currently there are available a variety of relational database software packages for use on computers. Such software packages are sold by Microsoft, Inc. of Redmond, Wash. under the trademark Microsoft Access and by Borland Software Corporation of Scotts Valley, Calif. under the trademark PARADOX. Oracle Corporation of Redwood Shores, Calif. manufactures very powerful relational database software.
[0008] Relational database software products have various features in common. Generally speaking, they permit users to create a plurality of tables on which data is stored. The tables will generally have common fields and the software uses these common fields to relate the data in one table to the data in another table. Users can develop easy-to-use input screens so that the data input into the database is stored in the proper table. Such software allows the user to develop queries so that data from various tables can be studied. Such queries can then be used to create reports based upon data stored in the tables.
[0009] The present invention utilizes relational database software (or SQL database software) to store evaluation data, analyze evaluation data and generate reports on student performance.
[0010] To access the power of the database software and to provide an efficient scheduling and evaluation system, various types of data must be input, stored and processed by the computer.
[0011] In the context of medical training, medical schools and teaching hospitals are the institutions that provide training. Students typically receive training from several different institutions. Such institutions employ a number of different people who deliver the training. Some of these people are also involved in advisement and evaluation of student performance.
[0012] There is no single course of study undertaken by medical students. Each student's training is, to some extent, unique. Medical schools offer a variety of courses and teaching hospitals offer a variety of rotations for which a student might register. Not all courses and rotations are offered during all sessions. Different institutions have different schedules for courses and rotations. Sometimes the rotations for the various institutions overlap. All of this greatly exacerbates scheduling difficulties. Also, evaluation and reporting becomes more difficult when student performance in multiple courses and rotations from multiple institutions all needs to be evaluated. With careful planning and implementation, the use of a relational database can prove to be very useful.
[0013] In a relational database, data is stored in tables and relationships are created between tables to link data in the different tables together. In the present invention, the tables can be divided into four broad categories. Data related to the institutions, their faculty, the courses or rotations they offer, and the schedules for the courses fall into a first group. The second group of tables contains personal information related to the student. The third group of tables cooperates with the first and second group of tables for scheduling students into classes and rotations. The final group cooperates with the other three groups for evaluating student performance. The power of the relational database makes more efficient scheduling and reporting of performance possible.
[0014] With respect to student evaluation, data generated through the evaluation process can be entered into the tables at the time each separate evaluation is completed. The software can then be used to generate periodic reports based upon the data input into the database or selected portions thereof. Such reports can be given to the student and any of the institutions involved in training the student. Some of the data will be in the form of test results. Some of the data will also relate to the performance of the student during clinical shifts, conferences, workshops or the like. Anecdotal data or other comments can be included in the evaluation, stored in the database and presented in reports.
[0015] In view of the foregoing, it should be clear that a principal object of the present invention is to provide an effective system for registering students, collecting evaluation data on student performance, storing said data, processing said data and reporting said data.
[0016] Another object of the present invention is to provide a system for collecting and storing data on a real-time or near real-time basis to improve the accuracy and efficacy of the registration and evaluation processes.
[0017] Another object of the present invention is to provide a comprehensive registration system along with an efficient and timely system for evaluation of student performance.
[0018] Still another object of the present invention is to provide a system which permits the efficient production of periodic performance reports.
[0019] Another object of the present invention is to provide performance reports that are both timely and capable of delivering an effective and clear assessment of overall performance as well as particular areas of performance that have been evaluated.
[0020] These and other objects of the present invention will become more clear from the following detailed description of the preferred embodiments, particularly when read in conjunction with the drawings which form a part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a chart showing a plurality of tables which make up a relational database of the present invention.
[0022] [0022]FIG. 2 is a student profile form for entering and reviewing biographical data related to a student.
[0023] [0023]FIG. 3 is a form for entering and reviewing evaluation data related to student performance.
[0024] [0024]FIG. 4 is a form for entering and reviewing a data log relating to procedures performed by the student
[0025] [0025]FIG. 5 is a form for entering data related to student performance on a test.
[0026] [0026]FIG. 6 is a form for reporting student performance; and
[0027] [0027]FIG. 7 is a form for reviewing grade information for a student.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The principal advantages of the present invention are derived from the use of a computerized relational (SQL) database to record, store and report registration data and evaluation data. The database consists of a collection of tables. Each table has a unique name. The tables share a key data element that is used to link the tables together.
[0029] Proper design of the database is essential. The place to begin is with an assessment of what training is to be offered and what student performance data needs to be reported. Once this assessment is complete, an outline of data points that are necessary to properly register students and produce the desired student performance reports can be created. With this outline in hand, one can consider how the necessary data will best be collected and can organize a table structure for the database accordingly.
[0030] The present invention provides a mechanism for efficiently collecting and reporting data related to student registration and performance. This invention can be applied to a variety of educational programs. To meet the disclosure requirements of the patent laws, the example used to describe the invention will relate to the registration and the evaluation of medical students.
[0031] [0031]FIG. 1 shows a preferred table structure for the registration and evaluation system of the present invention. This table structure includes four general information tables. These are tables 10, 12, 14 and 16.
[0032] Table 10 is used to store general information related to medical schools. Information in this table includes the name of the school, address information, and the like. Each school has a Unique School ID used to associate information in other tables with a particular school.
[0033] Table 12 is used to store information related to hospitals. Such information includes the name, address, phone number and the like for the hospitals. Each hospital is assigned a Unique Hospital ID. The Hospital ID is used to associate information in table 12 with data in other tables.
[0034] Table 14 is used to store general information related to faculty members. Each faculty member is given a unique ID which is used to relate the data in table 14 to the data in other tables. Table 14 also includes such data as the name of each faculty member, the degrees they hold, their specialty, the position they hold, their e-mail address and the like. The institutions (i.e., schools or hospitals) with which the faculty member is affiliated is also listed in table 14 using the Unique School ID and Hospital ID. When entering the School ID in table 14, table 10 serves as a look-up table. Similarly, table 12 serves as a look-up table when completing the Hospital ID field in table 14.
[0035] Table 16 is used to store personal information related to students. Each student is assigned a Unique Student ID. Information such as the student's name, sex, address, phone number, and e-mail address are associated with the Student ID in table 16. Table 16 also lists the student's proposed area of specialty and advisor as well as the student's start date, end date and graduation year. The School ID of the school the student attends is listed in table 16. Again, table 10 serves as a look-up table when completing this field of table 16. Table 16 is also used to store a unique user name and password for the student. The student uses the user name and password when registering for courses or checking grades.
[0036] In a medical training program, a number of different courses are offered. Data related to the various courses offered are stored in a catalog table 18. Each course is assigned a Course ID. Each course is associated with a school using the School ID for the school offering the course. Table 18 also includes data related to the course number, the name of the course, the course director, an indication of whether the course is required, a description of the course, the stat date and end date of the course and the limit on the number of students who can participate in the course. Table 18 also includes a Site ID that defines the site where the course is offered.
[0037] The Site ID is used to link the course to the hospitals where the course rotation is offered. This is done using table 20. More specifically, table 20 uses the Site ID, Course ID and Hospital ID fields to link the individual courses (i.e., rotations) to the hospitals where various rotations are offered. The site director's name and e-mail address are also listed in table 20.
[0038] Table 20 is also used to link the courses and hospitals to other important scheduling data. For example, table 22 contains data related to the starting and ending dates of various sessions. Each session has a Unique Session ID. Table 24 associates this date information using the Session ID with a site using the Site ID and Session ID fields.
[0039] Registration of students is based upon virtually all the tables described above. Specific registration information is stored in table 26. Table 26 associates a Student ID with a Course ID, the site at which the course is offered and the start date and end date for the courses. In this context, the student registers using a drag-and-drop process. Courses having available space are listed. The student selects from those listed. Data related to the student's selection is listed in table 26.
[0040] One aspect of table 26 that is significant to the evaluation process is that a Unique Register ID is associated with a specific student. The Register ID is used to associate the evaluation data with the student.
[0041] In the system of the present invention, evaluation cards are used to initially record evaluation data related to student performance. Certain data is recorded in table 28 related to each card. This data includes a Unique Card ID, the evaluation date, the Faculty ID of the faculty member performing the evaluation, a case number associated with the evaluation card, and a review field. The cards typically include a plurality of grades and a comment section. The grades are stored along with the Card ID in table 30. The comments are stored along with the Card ID in table 32. Using the Faculty ID, the card is associated with the particular faculty member performing the evaluation. The card is associated with the student using the Register ID.
[0042] Effective medical training requires that student's experience a variety of procedures. Therefore, the system of the present invention provides a procedure log for each student. Table 34 is used to store a list of procedures performed by a student. Specifically, table 34 does this by associating the one or more Procedure ID of each procedure performed by the student with the Register ID of the student who performed the procedure.
[0043] Two other tables are shown in FIG. 1. These are drop-down tables 36 and 38. Table 36 is used to list all of the available specialties. When specialty data is entered in table 16 for a new faculty member, the person inputting the data chooses from the list provided in table 36. Similarly, table 38 lists the various positions a faculty member can hold. When someone is entering data related to a faculty member in table 14, and more specifically in the Position ID field of table 14, the position information in table 38 is used.
[0044] Those skilled in the art will recognize that other tables can be added or additional fields can be added to the tables shown. For example, if written pre-tests, and mid-term tests, or final examinations are included as part of the system, one or more tables can be used to associate grades on these tests with a particular student.
[0045] Those skilled in the art will recognize that data can be directly entered into a table and the tables can be viewed to review the data. However, the tables are not easy to use either for data input or data review. Data entry forms are, therefore, created to provide an easy and logical way to input data into the tables. These forms also provide an attractive, easy-to-read mechanism for reviewing the data. These forms can be created once the table structure of the database has been determined.
[0046] The forms include a plurality of fields that correspond to the fields of the tables. The fields of the forms can be designed to restrict the data that can be entered and to assist the data entry process. Some fields, such as those related to biographical information or for comments, will typically be free-text fields where the data is typed in free form. Other fields of the forms are more limited. Some are just boxes to be checked, others include drop-down lists so that the user must select from the list. Proper form design will minimize typing and the time required to input the data.
[0047] FIGS. 2 - 5 are examples of such forms. The form shown in FIG. 2 is used to input and display much of the data for table 16. FIG. 3 shows the evaluation forms used to collect and display data related to daily evaluations. FIG. 4 shows the form used to collect and display data related to the procedures performed by the student. FIG. 5 is a form that might be used to collect and display data related to the student's performance on a final examination.
[0048] The manner in which information can be entered or reviewed will now be discussed with reference to FIG. 3. As indicated above, FIG. 3 is an example of a form that can be used to enter data related to a student's performance. The form is specifically used to record a faculty assessment of a student's performance during a hands-on procedure. Data entered using the form shown in FIG. 3 is stored in tables 28, 30 and 32. Similarly, data displayed in the form shown in FIG. 3 comes from these three tables. The form includes the identity of the faculty member who performed the evaluation, the date of the evaluation, the case number of the case evaluated and an indication of whether the case was reviewed by the faculty member. All of the data ends up in table 28. The form of FIG. 3 also includes an evaluation of student performance in three areas: attitude, collection of information, and synthesis of the information. The student's grades in these three areas are recorded in table 30. The form of FIG. 3 also includes an area for comments and a box to check if the comment is private. This date is recorded in table 32. A faculty member can quickly and easily complete the form shown in FIG. 3 using a computer associated with the database. Preferably the computer will have a mouse and a keyboard. Using the mouse, the faculty member selects his name from the drop-down menu next to the word “faculty”, the date is automatically supplied. If necessary, the date can be changed by the faculty member using the keyboard. The faculty member then uses the mouse to “click” the “reviewed” box and the appropriate grade associated with “attitude”, “collection” and “synthesis”. The faculty member can type in any comments and “click” the “private” box if the comments are not to be shared. The whole data entry process using the form of FIG. 3 takes less than a minute.
[0049] [0049]FIG. 6 is an example of a report that might be given to a student related to the assessment of the student's performance during a rotation. The report provides a summary listing the number of evaluation cards (see FIG. 3) completed, the number of cases completed, the averages of the grades on assessments of attitude, collection and synthesis related to clinical procedures, an overall average of the assessments, and a final grade for the rotation. The report in FIG. 6 also shows the grade on a final examination and how the clinical evaluations and final examination grade were weighted to arrive at the overall grade for the rotation.
[0050] [0050]FIG. 7 is an example of a report that can be created by the database. Such a report might be used by course director of a particular rotation to review the performance of the students currently enrolled. The report lists the students by name, the start date of the students, the school they attend and their grade.
[0051] The most important function of the database is to assemble the data that has been collected in an organized fashion to produce such reports. Such reports can be summary reports (see FIG. 7) or far more detailed reports. Standard reports can be created and, in the example, distributed to the student during the course of the rotation to provide a more “real-time” progress report so that remedial actions can be taken to improve performance. The school where the student is enrolled, or anyone else who has a need for such a report can also be supplied with standard or, as explained further below, specially designed reports.
[0052] One of the benefits of a relational database is that, in addition to standard reports, the data can be analyzed using queries. Queries allow the user to look at particular pieces of data in many different ways. Queries can be used to perform record retrieval and updates, perform calculations, append data to tables, or summarize data in one or more tables. Using queries, a user with a question can specify the criteria for a search and then automatically sort and display all records matching the criteria. For example, with the database shown in the drawings and described above, a query can be used to generate a list of all students interested in emergency medicine by searching the “specialty” field of table 16. The query can then easily be modified to generate a report of all students interested in emergency medicine also having particular grades using not only the “specialty” field on table 16, but also data from table 30.
[0053] The database can be equipped with other features. Such features include password protection schemes having different security levels for different users. To ensure security of student data, a faculty member may be permitted to enter data only related to an evaluation conducted by the faculty member, but restricted from reviewing, or editing, or printing other data. The database can also be coupled to other software for data entry purposes. For example, voice recognition software can be used for data entry rather than or in addition to a keyboard and mouse. The database can also be used in conjunction with an e-mail system to deliver an electronic version of periodic reports as opposed to a hard copy. The database can also be used to track and evaluate trends in faculty evaluations through the use of appropriate queries and reports.
[0054] The database described above is, of course, a tool which assists in the registration and evaluation processes. A description of one way to use the system as part of a comprehensive evaluation process will now be provided.
[0055] During student orientation, a new record is started for each student by entering biographical information using the form shown in FIG. 2. The student, using a computer, then registers for a rotation based upon data stored in tables 10-24. A Registration ID is assigned and associated with the Student's ID of the student, the Course ID of the rotation, the name of the rotation, the hospital site at which the rotation is to take place and the start and end dates of the rotation. This data is stored in table 26. At this same time, a 50 question pre-test may be taken by the student, graded using the system, and a report can be generated by the system and sent by e-mail to the student.
[0056] During the rotation, the student works a plurality of shifts. An attending physician, who is a faculty member, directly supervises the student's clinical activities during each shift. The faculty member, at the end of each shift, completes an evaluation card (see FIG. 3). The evaluation card requires the faculty member to grade the student's abilities in interpersonal relations (i.e., attitude), data acquisition and data synthesis. The faculty member can also provide comments in a free-text form. Entry of this evaluation data can be completed in less than a minute because most data is entered using drop-down lists or by marking “option buttons”. At the same time, the faculty member can identify procedures performed by the student using the form shown in FIG. 4. To reduce data entry time, a drop-down list is used to enter the procedures performed.
[0057] As a student progresses through the rotation, the daily evaluations are used to follow the student's progress. Each student may request to review the evaluations completed to date with one of the directors of the program. Reports can be easily generated from the daily evaluation data for review at such a meeting. Alternatively, such reports can be e-mailed to the student. A student can review his or her evaluation data using the user name and password entered for the student in table 16.
[0058] At the end of the rotation students are typically given a final exam. The examination is scored by marking incorrect answers using the form shown in FIG. 5. The database automatically calculates and stores the final grade. See FIG. 5.
[0059] As should be clear from the foregoing, the present invention provides a mechanism for registering students and evaluating student performance which is easy to use, thorough, efficient and capable of providing timely periodic reports related to student performance. The description set forth above is not intended to be limiting. Instead, it is intended to provide a sufficient understanding to enable those skilled in the art to practice the invention. Those skilled in the art will be able to make modifications without deviating from the invention which is defined by the following claims. | A method for registering students in courses and generating, collecting, processing and reporting student performance is provided. The process involves the use of a database including information related to institutions, the courses they offer and their faculty to register students for courses periodically inputting student performance data into the database and using the database to analyze the data and provide periodic reports related to student performance. | 6 |
FIELD OF THE INVENTION
[0001] The present invention addresses the problem of understanding and controlling the flow of information in networks, with the aim of spreading or preventing spreading of information in said networks. The invention involves analyzing the structure of a given network, based on the measured topology (the nodes of the network and the links between them). The networks in question may be any kinds of networks, but the invention is particularly applicable in communication networks.
TECHNICAL BACKGROUND
[0002] There exist many methods for defining well connected clusters in a network; but only the regions-analysis method disclosed in the applicant's earlier Norwegian patent applications NO 20035852 and NO 20053330 has been shown to have direct utility for understanding and controlling spreading of information on the network. Specifically, in NO 20035852 we have presented a basic method for analyzing networks. This method is valid whenever the links of the network may be viewed as symmetric—i.e., whenever flow of information over a link may (at least approximately) be assumed to be equally likely in either direction on the link. A principal output of this method is the assignment of each node to a region (well connected cluster) of the network. The analysis predicts that information spreading will be relatively faster within regions than between them. Hence knowledge of these regions is useful for controlling the spread of information—that is, either hindering the spread of harmful information (such as computer viruses) or aiding the spread of useful information. Geoffrey Canright and Kenth Engφ-Monsen, “Roles in Networks”. Science of Computer Programming, 53 (2004) 195-214, is a research article which describes the analysis method in detail.
[0003] Geoffrey Canright and Kenth Engφ-Monsen. “Spreading on networks: a topographic view” to appear in Proceedings, European Conference on Complex Systems, 2005 (ECCS05) and Geoffrey S. Canright and Kenth Engφ-Monsen, “Epidemic spreading over networks: a view from neighbourhoods”, Telektronikk 101, 65-85 (2005) are further research articles which demonstrate that our definition of regions is indeed extremely useful for understanding how information is spread over a network. Also, in the last paper mentioned, we present methods for modifying the structure of a given network, towards the goal of either helping or hindering information flow. Results of some limited tests of these design methods are presented, which are also described in the Norwegian patent application NO 20053330. The test results reported in the last paper indicate that design and modification techniques that are based on our regions analysis can significantly affect the rate of information spreading.
[0004] One shortcoming of our region analysis method is that there has not so far been found any useful way to refine the analysis, i.e., to define subregions within each region. That is, the method allows one to sort the nodes of the networks into a number of regions, defined by their being well connected internally. However, the number of such regions is determined by the analysis, and hence is not subject to any choice by the user of the analysis. Also, for a sufficiently well connected network, the method can give the answer that the network is composed of a single region. Thus, if a user of this approach wishes to examine smaller subregions than those given by the analysis, new methods are needed. In many cases, it is desirable to be able to iteratively refine the analysis, defining sub-subregions, etc.
[0005] M. Girvan and M. Newman, “Community structure in social and biological networks”, Proc. Natl. Acad. Sci. USA, 99 (2002), pp. 8271-8276 describes a method for network analysis which also breaks down a given network into well connected clusters. The Girvan-Newman method has the advantage that the breakdown may be refined as many times as wished, giving subregions, sub-subregions, etc. However, the Girvan-Newman method has no demonstrated connection to the important practical problem of understanding the spreading of information.
[0006] Another shortcoming of the region analysis method as described in NO 20035852 is that it can be too demanding in terms of computing power when handling large graphs. An important technical aspect of the regions-analysis method is the calculation of the steepest-ascent graph (SAG) for a given network. This graph is used to assign nodes uniquely to regions. We have discovered, in working with multi-million-node graphs, that it is important to be able to calculate this SAG in an efficient manner. Specifically, we found that an ordinary approach to calculating the SAG in such cases might take several hundred years to complete—thus rendering the whole approach practically impossible.
[0007] Finally, we note that a highly desirable feature of any method of network analysis is the possibility for visualizing the resulting structure (as given by the analysis). There has been, and continues to be, a huge volume of work on the problem of visualizing networks. However, the problem of finding a good visualization which presents our ‘regional’ view of a network is largely unsolved.
[0008] An overview of current techniques for visualization og graphs may be found in Giuseppe Di Battista, Peter Eades, Roberto Tamassia, and Ioannis G. Tollis, Graph Drawing: Algorithms for the Visualization of Graphs, Prentice Hall PTR, Upper Saddle River, N.J., USA (1998).
SUMMARY OF THE INVENTION
[0009] Thus, a principal objective of the present invention is to provide a method and device for network analysis that solves the shortcomings of prior art methods as mentioned above. The analysis method of the present invention is based on the use of the steepest ascent graph (SAG).
[0010] The method according to the present invention for analysis and visualization of a network, said network including a number of nodes inter-connected by links, is as defined in the appended claim 1 . Specifically, the method includes at least the steps of mapping the topology of the network, calculating an Adjacency matrix A of said network, from said Adjacency matrix A extracting a neighbour list for each node in the network, calculating an Eigenvector Centrality (EVC) score for each node, from said neighbour list and EVC score identifying the neighbour of the node with the highest EVC score, and creating a matrix à with entries for each link in the network, in which the entry for a given link is set to 1 if it is a link between a node and its neighbour with the highest EVC score, said matrix à being the Steepest Ascent Graph (SAG) of the network.
[0011] The invention also includes a device, a computer program product and a computer readable medium as claimed in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention will now be given a detailed description, in reference to the appended drawings, in which:
[0013] FIG. 1 shows a simple test graph with 16 nodes,
[0014] FIG. 2 shows the same graph with contour lines removed,
[0015] FIG. 3 shows the subregions of the test graph in FIG. 1 ,
[0016] FIG. 4 shows the sub-subregions obtained by further refinement of the largest subregion in FIG. 3 ,
[0017] FIG. 5 is a schematic tree visualization of the test graph in FIG. 1 ,
[0018] FIG. 6 is a visualization of the Gnutella network using prior art technique,
[0019] FIG. 7 shows the steepest-ascent graph of the same network,
[0020] FIG. 8 is another prior art visualization of the Gnutella network, taken at another point in time,
[0021] FIG. 9 is the corresponding visualization using the steepest-ascent approach,
[0022] FIG. 10 shows the graph in FIG. 8 , but with the nodes colored according to their region membership,
[0023] FIG. 11 is the subregion visualization for the two-region graph of FIG. 9 ,
[0024] FIG. 12 is the same graph with a threshold set for subregion size, i.e. small subregions are not shown,
[0025] FIG. 13 shows the subregion visualization for the one-region graph of FIG. 7 , also with a threshold set on subregion size.
DETAILED DESCRIPTION
Defining Subregions and Refining
[0026] We invoke our topographic picture in order to describe the ideas behind this invention. In this picture, each region is a ‘mountain’, and the eigenvector centrality (EVC) index of each node is its ‘height’. For each region, the top of the mountain is called its Center—this is the highest node in the region. We then note that the steepest-ascent graph gives a picture of the ‘ridge’ structure of the mountain. That is, each link which is retained in the steepest-ascent graph is a link from a node to that node's highest (in EVC) neighbor. These links thus represent the likeliest path for information flow towards or from the Center of the region. Furthermore, there is one such ‘ridge line’ (including lower branches) for each neighbor of the Center.
[0027] Hence we define a subregion as simply that branch of the SAG (which is a tree) which ends at one neighbor of the Center. That is, each neighbor of the Center sits at the head of a subtree of the SAG tree; and we identify each subtree as a subregion. This definition is not arbitrary, since each subtree represents in fact the set of likeliest paths for information flow between the nodes in the subtree and the Center.
[0028] This definition also has the obvious advantage that it allows for iterative refinement. Since a subregion is simply a subtree of the SAG, one can readily define sub-subregions as sub-subtrees. That is, one simply moves ‘down’ the subtree from its head, until the first branching of the subtree. Each branch of the subtree then is defined as a distinct sub-subregion. The extension to even further refinements should be clear from this definition.
[0029] We illustrate the definition of subregions with an example. FIG. 1 shows a simple graph with 16 nodes. ‘Contour lines’ of constant ‘height’ are also shown. It is clear from the figure that a regions analysis gives two regions—one with 12 nodes on the left, and one with 4 nodes on the right. For each region, the Center node is marked with blue color.
[0030] FIG. 2 shows the same graph, with contour lines removed, and with those links lying on the SAG marked with thick lines. Hence the SAG is clearly visible in FIG. 2 .
[0031] Now we define the subregions for each region. For each region, we remove the Centers, and all links connected to them. Those nodes that were neighbors of a Center are now ‘heads’ of their subregion. These nodes are colored black (see FIG. 3 ). Nodes which are at the ‘leaves’ of the tree, ie at the end of a chain of links, are still red. Nodes which are both head and leaf (because they represent a one-node subregion) are black/red. Finally, there is a green node which is neither head nor leaf.
[0032] Each connected subgraph in FIG. 3 is a subregion of the graph of FIG. 2 . Thus we find that there is one subregion with six nodes, one with two nodes, and six subregions with only one node. We note that trials with empirically measured (peer-to-peer) networks have indicated that one can find typically a wide variation in the size of the subregions, and that, even with large empirical networks, one-node subregions are not unusual. Hence FIG. 3 is typical (except for the small size of the whole graph) of the real networks we have examined so far (these having about 1000 nodes).
[0033] The graph of FIG. 1 allows for one further step of refinement. We illustrate this in FIG. 4 , in which we refine the largest subregion of the graph. Refinement consists of removing the head of the subregion, and its links. (If the head has only one neighbor below it, we remove that one also—and so on, until the removed head has multiple neighbors.) There are now three sub-subregions—that is, one for each neighbor of the removed head. The green node is now seen as head of its sub-subregion. The process of refinement is almost completely analogous to the process of defining subregions; also, any further refinements (on larger graphs than that in these Figures) are precisely like the refinement process illustrated here.
[0034] Efficient Calculation of the Steepest-Ascent Graph
[0035] As noted earlier, we found that applying a straightforward algorithm for finding the SAG gave a projected running time of about 200 years for a test graph with 10 million nodes. The problem here was that the entire test graph did not fit in the fast (RAM) memory of a machine with 4 GB of RAM. Hence we had to resort to ‘external-memory’ algorithms, i.e. approaches which only read in a part of the problem at a time, operate on that part, delete it, and then read in the next part. (For a reference on external memory algorithms, see: External Memory Algorithms, pub. American Mathematical Society, Jan. 1, 1999.) Running time is then strongly constrained by the number of read operations for external memory—these operations are many times (orders of magnitude) slower than access times for RAM.
[0036] The present invention solves this problem by giving an algorithm which is optimal in terms of the number of accesses to external memory. That is, our new algorithm reads the neighbor list of each node (which is a column of the adjacency matrix) exactly once. Doing so reduced the running time for our 10-million-node example from (expected) 200 years to 58 hours.
[0037] The method builds on the insight that steepest ascent from any given node is actually determined by (a) its highest neighbor, plus (b) steepest ascent from this neighbor. In other words, for each node, we need only find—once and for all—its single highest neighbor (if there is one—otherwise it is a Center, i.e. a local maximum). Thus, for each node, we find and store that one piece of information, and forget all other links.
[0038] In short, the SAG requires finding and storing exactly one link for each node. This link is found after a single access to the node's neighbor list, and stored in a separate data structure for the SAG.
[0039] In detail, calculation of the SAG begins with several input structures. First of all, we need the adjacency matrix A expressing the topology of the graph (A ij =1 if there is a link between nodes i and j, and 0 otherwise). The 1's in the i'th column (or row) of A thus give the node numbers of those nodes which are neighbors of node i; it is in this sense that we say that we can extract the neighbor list of a node from a column of A.
[0040] We also need a vector e giving the eigenvector centrality (EVC) score e i for each node i. We then use the neighbor list of a given node g, and the EVC scores of these neighbors (taken from the vector e), in order to find the single neighbor h of g that has the highest EVC score. We store this result in a new matrix Ã, by placing a 1 at the entry à gh . The matrix à is in fact the steepest-ascent graph (SAG). It is highly sparse, since it has only one link for each node. Hence it is much more feasible to store all of à in RAM than it is to store all of A (which is typically, in terms of storage requirements, 10-20 times as large as Ã). Of course, one need store only the 1's for any sparse, binary matrix, such as A or Ã; but still the former has many more 1's than the latter.
[0041] The efficiency of this method, in terms of number of read access events for columns of A, is clear. A naïve approach would pick a node g, and then find its highest neighbor h, then find h's highest neighbor, and so on, until a Center is reached. This naïve approach gives immediate region membership information for each chosen node g; but it clearly requires many more read access events in the case that A is externally stored.
[0042] Our method, instead, defers determination of region membership until the entire SAG is stored in Ã. One then determines region membership as follows. One builds a start vector s, such that s i =i. That is, one simply places the node number at that node's entry. Multiplication of s by à sends each node number ‘downhill’ in the SAG tree—for example, in the above notation, multiplication by à will send the number at h to g (and to all other nodes having h as their highest neighbour). Repeated multiplication by à results in a stable vector s*, where the entry in s* for each node g gives the node number of the Center whose region g belongs to. (In the exceedingly rare case that a node belongs to two regions, it will receive the sum of the node numbers for the two Centers—a case that is easily detected.) We note that only a few multiplications by à are needed, as the s vector converges exactly to s* after a number of multiplications equal to the radius of the largest region (measured in number of hops). Typical graphs, even very large graphs, have small radii due to ‘small worlds’ effects.
[0043] A modified version of the procedure detailed in the previous paragraph can be used in the calculation of subregions. First the SAG must be updated in two ways: i)
[0044] Remove the centre node from the tree, causing the SAG to decompose into a number of separate trees, and ii) add self-referencing links to the new root node for each new tree. Subregion membership is then determined by the same procedure given above, applied to each separate tree.
[0045] Visualization
[0046] We describe two methods for visualising the structure of a network, based on the analysis method presented here. We call these two methods ‘Tree visualization’ and ‘Subregion visualization’ respectively.
[0047] Tree Visualization
[0048] For Tree visualization we proceed as follows:
1. First consider each region as an isolated subgraph, ie, ignore inter-region (‘bridge’) links. 2. Find the SAG for each region separately. 3. Use freely available force-balance packages to display the resulting tree structures on the screen. For multiple regions, one can display multiple trees. 4. One can also calculate a ‘net link strength’ between any given pair of subregions-either from the same region, or from distinct regions. One can then use this net link strength to determine which subregions (subtrees) should lie closest to one another in the tree (SAG) representing one region.
[0053] FIG. 5 shows the tree visualization for the graph of FIG. 1 . This figure is only schematic—that is, we have not used any force balance package to lay out the nodes.
[0054] A practical approach to tree visualization is outlined above. Our approach uses freely available software to actually lay out the nodes in the plane; the new idea simply comes from discarding all links other than those in the SAG. In other words, tree visualization involves building the SAG (as outline above), and then simply feeding the SAG as a graph to a force-balance visualization program such as UCINet (UCINet and NetDraw may be downloaded from: http://www.analytictech.com/).
[0055] We offer more realistic examples of tree visualization in FIGS. 6-10 . FIG. 6 shows a snapshot of the Gnutella peer-to-peer file-sharing network, taken in 2001. It has about 1000 nodes. The visualization in FIG. 6 was performed using NetDraw, a component of the network analysis package UCINet. This is thus a state-of-the-art visualization; but it reveals (as is common with large networks) a structureless mess.
[0056] FIG. 7 shows the same graph, laid out again by NetDraw; but the input to NetDraw was the steepest-ascent graph as found by our analysis. We see that our analysis finds only one region; but FIG. 7 reveals a rich internal subregion structure for this one region. In fact, many layers of substructure are already visible in FIG. 7 ; and it is clear that refinement of the subregions will only bring out this substructure even more clearly.
[0057] FIG. 8 shows a different Gnutella snapshot, again with about 1000 nodes, again drawn using the full link structure and NetDraw. FIG. 9 shows that our analysis finds two regions for this snapshot. Again the contrast (compare FIGS. 8 and 9 ) is striking. FIG. 10 is the same layout as in FIG. 8 , but with the nodes colored according to their region membership (as found by our analysis). The point of FIG. 10 is that the two-region structure is partially visible in the layout using the full link structure (assuming one knows how to assign the nodes to regions). Hence FIG. 10 gives some indication of the network's structure—more than does FIG. 8 —but FIG. 9 shows both the two-region main structure, and many levels of substructure, much more clearly.
[0058] There are many subregions for the single region in FIG. 7 , and for each of the two regions in FIG. 9 . Clearly, for a tree structure, all subregions should radiate outwards from the center; but there is no obviously best criterion for determining which subregions are ‘neighbors’ as they are laid out in a ring around the Center. The layouts shown in these two figures used the simple, standard mechanism of force-balance algorithms that every node has a degree of repulsion with respect to every other. Thus the force balance itself was allowed to determine the radial ordering of the subregions. We see that the results of using this simple default method are good.
[0059] It is also possible to use more information to guide the radial ordering of the subtrees. One can define and calculate a measure of ‘net link strength’ (as described in more detail below) between any given pair of subregions, and then use this net link strength to guide in the placement of the subtrees. For example, one can place a fictitious extra link between the respective heads of each pair of subtrees, giving a weight to this link that is determined by the net link strength between the subtrees (subregions). The force balance method will then tend to drive subtrees towards one another if they have a high net link strength between them.
[0060] We note that the use of net link strength may have an advantage with very large graphs. That is, for very large graphs, even the SAG tree structure may be too time consuming to lay out with force balancing. In such a case, using extra inter-head links, with a high link weight compared to the SAG links, is likely to speed up convergence-perhaps considerably.
[0061] Methods for calculating net link strength will be given in the next subsection, since this quantity plays a crucial role in subregion visualization.
[0062] Finally, we emphasize that tree visualization is readily suited for displaying refinements of the subregions. Refinement of a given subregion picture simply gives a new set of subtrees, which may then be handled precisely as for the case of multiple trees from multiple regions. FIG. 4 is (again) a schematic example of one step of refinement, starting from the tree visualization of FIG. 3 .
[0063] Subregion Visualization
[0064] The procedure for Subregion visualization is as follows:
1. First consider each region as an isolated subgraph, i.e., ignore inter-region (‘bridge’) links. 2. Find the SAG for each region separately. 3. For each subregion, determine its size (number of nodes). 4. Choose a threshold size T. Subregions of size smaller than T are not displayed, to save clutter. All subsequent steps apply only to subregions of size ≧T. 5. For each SAG, calculate the net link strength between each pair of subregions. 6. Remove the Center of each region, so that the subregions are decoupled from one another at the Center. Their only remaining coupling is then the pairwise couplings formed by the net inter-subregion link strength; and the resulting structure is no longer a tree. 7. For each region, build a ‘coarse-grained graph’ by representing each subregion as a single node, and using the inter-subregion net link strengths as the links. Display the resulting coarse-grained graphs for each region, using a freely available force-balance package. The displayed size of the nodes in the coarse-grained graphs may be used to indicate the size (number of actual nodes) for the corresponding subregion; and the net link strengths may be displayed using the thickness of the displayed links in the coarse-grained graph.
[0072] Subregion visualization requires a few more steps to explain than does tree visualization. For this reason, we repeat the steps given above, adding further details where appropriate.
1. First consider each region as an isolated subgraph, ie, ignore inter-region (‘bridge’) links. 2. Find the SAG for each region separately. 3. For each subregion, determine its size (number of nodes).
[0076] These three steps are clear.
4. Choose a threshold size T. Subregions of size smaller than T are not displayed, to save clutter. All subsequent steps apply only to subregions of size ≧T.
[0078] It is always useful in visualization to be able to choose a level of resolution, i.e., the level of detail that one wishes to have displayed. Subregion visualization already removes much detail by simply displaying each subregion as a single node. However there can be very large variation in the size of the subregions. For example, the graph of FIG. 7 yields subregions of size ranging from 1 to about 350—with a large number of tiny subregions, and only a few large ones. Furthermore, we expect this kind of distribution to be typical of many real networks. Hence it can be desirable to suppress the display of the many tiny subregions, and focus on the large ones.
5. For each SAG, calculate the net link strength between each pair of subregions.
[0080] In principle, there are many ways to define this net link strength. We give here a formula, based on two ideas: (i) links with high EVC get more weight; (ii) many links give more weight than few links.
[0081] To implement these two ideas, we define the ‘arithmetic link centrality’ for a link between nodes i and j to be the arithmetic average of the two nodes' EVC scores:
[0000]
a
ij
=
(
e
i
+
e
j
)
2
.
(
1
)
[0082] Alternatively, one can define the ‘geometric link centrality’ g ij for a link between nodes i and j to be the geometric average of the two nodes' EVC scores:
[0000] g ij =√{square root over (( e i *e j )}.
[0083] We then define the net link strength between two subregions α and β to be the sum of the link centralities for all links connecting α and β. This gives
[0000]
NLS
(
α
,
β
)
=
∑
i
∈
α
∑
j
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β
a
ij
.
(
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[0084] We note finally that one can violate the instruction in step 1 , for graphs with multiple regions. That is, an even more thorough overview may be obtained by calculating, and including the effects of, all inter-subregion net link strengths—both those between subregions in the same region, and those between subregions in different regions. [Formula (2) is equally valid for a pair of subregions taken from two distinct regions.] This will allow the resulting display to take into account inter-regional relations, so that the final layout reflects most clearly the whole set of relationships. Our default choice is however to treat each region separately.
6. Remove the Center of each region, so that the subregions are decoupled from one another at the Center. Their only remaining coupling is then the pairwise couplings formed by the net inter-subregion link strength; and the resulting structure is no longer a tree.
[0086] Here we see that the subregions are now treated as individual nodes (as far as visualization is concerned). They have a ‘size’ (from step 3 ), and they have internode links with link strengths given as detailed in step 5 . The Center is removed as it does not belong to any subregion; and the aim of subregion visualization is to try to display the subregions (only) and their relationship to one another.
[0087] Thus we end up with a visualization problem with S nodes (for S subregions of size ≧T), and, in general, links of some strength between most pairs of nodes. Thus our coarse-grained graph is in fact a dense graph—it is not sparse, since most of the possible links are present. However, two aspects make this visualization problem much easier than the problem of visualizing the entire network. First, the number S of subregions for a given region is guaranteed to be very much smaller than the number N of nodes in the graph—it is not more than the number of neighbors for the Center of the region (a number much less than N already), and is likely to be much smaller than even that number, if the threshold size T is set to exclude many small subregions. Secondly, there is likely to be large differences in the various net link strengths in the resulting dense graph. These differences make convergence in the force-balance method much easier than it would be if all links had the same, or nearly the same, strength.
7. For each region, build a ‘coarse-grained graph’ by representing each subregion as a single node and using the inter-subregion net link strengths as the links. Display the resulting coarse-grained graphs for each region, using a freely available force-balance package. The node size in the coarse-grained graphs may be used to indicate the number of nodes for the corresponding subregion; and the net link strengths may be displayed using the thickness of the displayed links in the coarse-grained graph.
[0089] All of the techniques needed for this step are publicly available. There are of course other ways (eg, colors) to indicate scalar measures of node size and link strength. We do not exclude any such method here. The essential information that we want to include in this invention is that both the node (subregion) size, and the net (inter-subregion) link strength, can and should be displayed in subregion visualization; they are an important part of the total picture of how the subregions are related to one another.
[0090] FIG. 11 shows the subregion visualization for the two-region graph of FIG. 9 , with threshold T=1—that is, all subregions are shown. For comparison, in FIG. 12 we have set T=10. The reduction in clutter is significant. We note that it is not trivially easy to find correspondences between subregion structures in FIG. 9 and those in FIG. 11 or 12 . We believe that this is because each type of visualization emphasizes different, but useful, structural information about the network under study. That is, the two methods are complementary, rather than redundant.
[0091] Some main features can however be found to correspond. For example, the largest ‘red’ subregion in FIG. 11 corresponds to the entire ‘lower half’ of the red region in FIG. 9 ; we know that the lower half is a subregion, because the Center of that region is at the hub of the upper half. The same kind of correspondence may be found for the blue region.
[0092] For completeness, we show in FIG. 13 the subregion visualization for the one-region graph of FIG. 7 , with T=10. Here again we see one very large subregion, corresponding to the ‘upper half’ of FIG. 7 .
[0093] There are many conceivable applications of the inventive method. We list several here:
Analysis and improvement of information flow in organizations Systems for supporting other kinds of social networks, e.g. online communities Security for computer networks, e.g. virus control Novel strategies for controlling the spreading of diseases among animals and humans Limiting the spread of damage in technological networks, for example power networks
[0099] The method may be performed in a device including a controller and a storage device. The controller may be realized as a server, and the storage device may be a database controlled by the server. The storage device/database is storing setup information regarding each node in a network. The setup information includes information on the connections/interfaces to/from each node. The device may also be interfaced to the network, and be adapted to retrieve this information from the nodes. In other cases this information must be gathered in other ways, e.g. when the nodes in question not are communication nodes. For communication nodes, traffic information may be gathered from each node, such as traffic counts.
[0100] The method according to the present invention may be implemented as software, hardware, or a combination thereof. A computer program product implementing the method or a part thereof comprises a software or a computer program run on a general purpose or specially adapted computer, processor or microprocessor. The software includes computer program code elements or software code portions that make the computer perform the method using at least one of the steps according to the inventive method.
[0101] The program may be stored in whole or part, on, or in, one or more suitable computer readable media or data storage means such as a magnetic disk, CD-ROM or DVD disk, hard disk, magneto-optical memory storage means, in RAM or volatile memory, in ROM or flash memory, as firmware, or on a data server.
[0102] It will be understood by those skilled in the art that various modifications and changes may be made to the present invention without departure from the scope thereof, which is defined by the appended claims. | A method for analysis and visualization of a network is disclosed. The analysis method is based on the use of the steepest ascent graph (SAG). Specifically, the method: (i) uses the SAG to define subregions, in a way that allows iterative refinement; (ii) presents a new and highly efficient way of calculating the SAG; (iii) uses the SAG, and the definitions in (i), as the foundation of a novel method for displaying the structure of the network in a two-dimensional visualization. | 8 |
OBJECT OF THE INVENTION
[0001] The object of the present invention is a new system for reconstruction of the cardiac electric activity from cardiac electric signals recorded with a vector (array) of intracardiac catheters and adequate processing media, for their visualization with position of the cardiac electrical activity. This invention is in the frame of technics for inverse problem in electrocardiography, consisting of estimating the endocardial or epicardial electric sources (transmembrane voltage or current) from remote measurements (intracardiac electrograms) in catheters or electrodes.
FIELD OF THE INVENTION
[0002] The field of the invention is that one of systems for generating and visualizing medical images, specifically, the graphical representation of the electric activity in medical systems used in electrocardiology and cardiac electrophysiology.
PRECEDENTS OF THE INVENTION
[0003] Cardiac arrhythmias are one of the main causes of mortality in the world. Current therapies have their foundamentals on a partial knowledge of the mechanisms of the most usual arrhythmias (atrial and ventricular tachicardias, atrial and ventricular fibrillation, and others), and thouth these therapies reach high levels of effectiveness, the detailed knowledge of a fast arrhythmia (tachyarrhythmia) is the key for creating new anti-arrhythmic therapies or for improving the actual ones.
[0004] Nevertheless, the knowledge of the arrhythmic mechanism in a given patient is limited by the fact that the physical magnitude involved is the electric impulse propagation throughout the cardiac cells. The visualization of electric activity in the internal surface of the heart (endocardium) is troublesome, given that current technology only gives indirect measurements, consisting of electric voltage measured in catheters inside the heart (electrograms). These measurements record the electric field that is induced by the cardiac currents at a given distance of atrial or ventricular walls, and hence, mathematical calculations are required for estimated the numerical values of the cardiac currents in the endocardial surface.
[0005] Intracardiac navigation systems allow the spacial reconstruction of one or several cardiac cavities and a representation of miocardiac electrical activity changes with time, using the electric signal recordings in diverse points and the detection of the spacial location of the catheter from different spatial location media. Currently, several cardiac navigation systems are used to reconstruct the cardiac electric activity in the myocardium from measurements in catheters. The most relevant are the following:
i. Carta System (Biosense, Cordis-Webster). It is probably the most widespread used. It allows to obtain an image (color-coded) of the relative activation time of the endocardium with respect to a reference signal during a stationary rhythm. Its main limitation is it only can be used in stationary rhythms, hence it can not be used in real time for analyzing the nature of non-periodic arrhythmias. More, it requires a time for mapping the electric activity in each patient, between one and three hours, which represents a high cost for the health system ii. Localisa. This system is similar to the preceding one, and it was commertialized by Medtronic. It is no longer commertialized, and its succesor is Navex (n the sense that it uses the same system for spacial detection). iii. Ensite. It is an advanced system allowing the reconstruction of the myocardial electric activation from the recordings in a catheter array. Theoretically, it allows this reconstruction in an instantaneous form, hene being potentially useful for any kind of arrhythmia (periodical or not).
[0009] Probably, the cause for Ensite not having a wider acceptation and use in practice, despite its theoretical advantages, is that it gives an estimation of bioelectrical currents with an associated uncertainty. Improvement of this uncertainty would make a system of this family having a widespread acceptation in the clinical practice. Other problems are the catheters dimensions, its complicated manipulation, its price, and the fact that the accurate information is limited to the proximal zone of the electrode.
[0010] In the current state of technique, several systems are described including the use of catheters for cardiac mapping. Among them, we can consider the patents U.S. Pat. No. 6,892,091, U.S. Pat. No. 5,297,549 y U.S. Pat. No. 5,311,866.
DESCRIPTION OF THE INVENTION
[0011] The system for the reconstruction and visualization of cardiac electric activity, object of the present invention, includes, at least:
a. A set of intracardiac catheters. b. Media for positioning and obtention of the location coordinates of said set. c. Media for auxiliary image (resonance, TAC, ecography) that yields the geometrical coordinates of the cardiac wall, and eventually of some additional electric properties (for instance, necrosis regions). d. Media for processing the signals from the catheters, where said processing methods include, at least, an algorithm based on SVM for the reconstruction of the dual signal problem. e. Media for visualizing the processed signals.
[0017] Where the SVM subsystem includes a statistical learning algorithm that is derived from the structural risk minimization principle. Two of the main advantages of the SVM are regularization and robustness, ideal conditions for the requirements of the inverse problem in electrocardiography.
[0018] The said system generates a plurality of signals whose physical origin is in that system, and they are subsequently used in the method, hence we have that:
Signals v[k] are the voltages measured in the k-th electrode of the catheter set, and they are acquired in the same time instant for all the electrodes. Signal ho[k] is the spacial transfer function, and it can be either estimated by conventional system identification techniques, or obtained from the volume conductor equation for a homogeneous media. Spacial coordinates of each catheter are recorded by means of available media of catheter positioning. Data of the cardiac cavity geometry are obtained with the auxiliar image subsystem, from image fusion techniques from previous medical images, such as magnetic resonance (and variants) or ultrasound echocardiography.
[0023] A second aspect of the present invention is the method for reconstruction and visualization of cardiac activity that includes, at least, the next stages:
(i) A first stage of registering the anatomical cardiac information (resonance, ultrasound) and storing it in digital format. (ii) A second stage of electro-physiological procedure, where a set of catheters are placed inside the cavity, and the catheter locations are recorded with the dedicated subsystem. (iii) A third stage of calculating the distance matrix, with the previous information, storing it in digital format. (iv) A fourth stage of simultaneously recording of the voltages in the catheters v[k], for k successive time instants. (v) For each voltage measurement v[k], the SVM is volved in a digital processing element as follows:
a. The quadratic problem given by measurements v[k] and by the distance matrix is solved in block, and transmembrane currents i[k] are estimated. b. The signal of measurements of estimated voltages v[k] is interpolated, from estimated transmembrane currents in c. Interpolated potentials are checked to correspond with quality to the recorded potentials.
(vi) A sixth stage (optional) of visualization of the reconstructed voltage (with increased resolution) or of the estimated transmembrane current (with increase resolution) for successive time instants.
SHORT DESCRIPTION OF THE FIGURES
[0033] We next describe (very briefly) a series of plots which aim to help to better understand the invention, and that are related with a realization of said invention that is presented as a non-limiting example.
[0034] FIG. 1 . Block diagram of the system for reconstruction and visualization of cardiac electric activity, object of the present invention.
[0035] FIG. 2 . Representation of a unidimensional simulation of the system for reconstruction and visualization of the cardiac electrical activity, object of the present invention.
[0036] FIG. 3 . Reconstruction of the signal of the system for reconstruction and visualization of cardiac electric activity, object of the present invention.
PREFERENTIAL REALIZATION OF THE INVENTION
[0037] The system for reconstruction and visualization of cardiac electric activity, object of the present invention, includes at least:
a. A set of intracardiac catheters. b. Media for positioning for obtention of the location coordinates of said set. c. Metida for auxiliary image (resonance, TAC, echocardiography) yielding the location coordinates for the cardiac wall geometry, and eventually of some additional electrical properties (for instance, necrosed regions). d. Media for processing the signals from the set of intracardiac catheters, where said media include at least an algorithm based on SVM for solving the dual signal problem. e. Media for visualization of the processed signal.
[0043] Where the SVM subsystem consists of a statistical learning algorithm derived from the structural risk minimization principle. Two of the main advantages of the sVM are regularization and robustness, ideal conditions for the requirements of the inverse problem in electrocardiography.
[0044] Said system generates a plurality of signals with physical origin on that system, and they are subsequently used, hence, we have that:
Signals v[k] are the voltages measured in the k-th element of the set of catheters, and they are acquired at the same time instant for all the catheters. Signal ho[k] is the spacial transfer function, and it can be either estimated from conventional system identification techniques, or given by the volume conductor equation for a homogeneous media. Spacial coordinates of each catheter are recorded with the location media of the catheters. Data about the cardiac cavity geometry are obtained with the auxiliar medical image media, thanks to fusion image techniques from previous medical images, such as given by magnetic resonance, or by ultrasound echocardiography.
[0049] In FIG. 1 we can observe the block diagram of the system, where it has been included an interpolation/decimation stage for obtaining an increment in resolution given by a number of sensing catheters.
[0050] A second aspect of the present invention is the method of reconstruction and visualization of the cardiac activity, which includes, at least, the following stages:
(i) A first stage of registering the anatomical cardiac information (resonance, ultrasound, or others) and storing it in digital format. (ii) A second stage of electro-physiological procedure, where a set of catheters are placed inside the cavity, and the catheter locations are recorded with the dedicated subsystem. (iii) A third stage of calculating the distance matrix, with the previous information, storing it in digital format, and building the SVM kernel from it. (iv) A fourth stage of simultaneously recording of the voltages in the catheters v[k], for k successive time instants. (v) For each voltage measurement v[k], the SVM is volved in a digital processing element as follows:
a. The quadratic problem given by measurements v[k] and by the distance matrix is solved in block, and transmembrane currents i[k] are estimated. b. The signal of measurements of estimated voltages v[k] is interpolated, from estimated transmembrane currents i[k]. c. Interpolated potentials are checked to correspond with quality to the recorded potentials.
(vi) A sixth stage (optional) of visualization of the reconstructed voltage (with increased resolution) or of the estimated transmembrane current (with increase resolution) for successive time instants.
[0060] The SVM stage, which is the responsible of restoring the electric cardiac activity, is described more in detail with a set of equations which are necessary for defining said stage.
[0061] i. Signal Model.
[0062] The voltage sensing in catheters, for a given time instant, can be written as:
[0000] lif.f m ( )
[0000] where M represents the distance matrix relating (according to the volume conductor model) the transmembrane current (i m ) with the voltage that is recorded in different points of the cardiac substrate (egm). In matrix form:
[0000] (N)w isvwft. 11 Ppywir. If
[0000] where v is a [K×1] matrix, i is a [L×1] matrix, and H is a [L×K] matrix, with L≧K. Explicitely, we have:
[0000]
[
?
0
⋮
?
]
=
[
?
?
t
ɛ
-
1
]
P
·
[
h
0
r
h
1
r
?
h
K
-
1
]
?
indicates text missing or illegible when filed
[0000] In FIG. 2 we show the unidimensional representation of the electrode measurements recording, where h k is distance matrix M (expressed in vector form) that relates the transmembrane current in each myocite with the voltage measured in the k-th electrode. For electrode k, the captation model can be written as:
[0000]
?
k
=
∑
t
=
0
L
-
1
t
l
h
lk
=
t
T
·
h
k
.
?
indicates text missing or illegible when filed
[0000] where (.) denotes the dot product. This function is also depicted in FIG. 2 . This equation, in conventional notation for signal processing, is defined as:
[0000]
?
[
k
]
=
∑
n
=
0
K
-
1
t
[
n
]
·
h
k
[
n
]
.
?
indicates text missing or illegible when filed
[0000] Given that h k [n] can be expressed as h 0 [n−k], and by defining the impulse response as h[n]=h g [n], the system is perfectly characterized by the convolution between the current and transfer function h[n]:
[0000]
?
[
k
]
-
∑
n
=
0
K
-
1
t
[
n
]
·
h
k
[
n
]
-
∑
n
=
0
K
-
1
t
[
n
]
·
k
[
n
-
k
]
-
t
[
k
]
+
h
[
k
]
?
indicates text missing or illegible when filed
[0000] The problem of cardiac activity reconstruction, as shown next, consists then in finding that current ([ ] better approximating the voltage measured in the exterior points of the volume conductor v[k].
[0063] ii. Signal Model in the Primal Problem
[0064] Be the truncated time series (v k , k=0, . . . , K−1) the set of values of voltage observed as a result of convolving the unknown time series of the myocites currents (l k ,k=0, . . . , K−1) with the known transfer function (h k=0, . . . , K−1) so that the next model is obtained:
[0000]
?
=
?
?
h
k
+
?
=
∑
n
=
0
K
-
1
?
h
n
-
k
+
?
?
indicates text missing or illegible when filed
[0000] Where the problem of current estimation can be expressed as the minimization of:
[0000]
?
=
1
2
?
2
2
+
∑
k
=
0
K
-
1
?
(
?
)
?
indicates text missing or illegible when filed
[0000] Where =[t, . . . l k-1 ] and:
[0000]
L
ε
H
(
e
k
)
=
{
0
,
e
k
≤
ɛ
1
2
δ
(
e
k
-
ɛ
)
2
,
ɛ
≤
e
k
≤
e
C
C
(
e
k
-
ɛ
)
-
1
2
δ
C
2
,
e
k
≥
e
C
[0065] Therefore, the previous functional can be expressed as:
[0000]
J
PSM
=
∑
k
=
0
K
-
1
i
k
2
2
+
1
2
δ
∑
k
∈
I
1
(
ξ
k
2
+
ξ
k
*
2
)
+
C
∑
k
∈
I
2
(
ξ
k
+
ξ
k
*
)
-
1
2
∑
k
∈
I
2
δ
C
2
[0000] Which has to be minimized with respect to (l k ) and ( ( ) k ), constrained to:
[0000]
υ
k
-
∑
j
=
0
K
-
1
i
j
h
k
-
j
≤
ɛ
+
ξ
k
-
υ
k
+
∑
j
=
0
K
-
1
i
j
h
k
-
j
≤
ɛ
+
ξ
k
*
ξ
k
,
ξ
k
*
≥
0
[0000] For k=0, . . . , k=1 and where ( (h) k ) are slack variables or losses, and I 1 , (I 2 ) are the indices of the residuals that can be found in the quadratic (linear) cost zone.
[0066] The solution to the previous optimization problem is given by the saddle point of the corresponding Lagrangian function:
[0000]
L
=
∑
k
=
0
K
-
1
i
k
2
2
+
1
2
δ
∑
k
∈
I
1
(
ξ
k
2
+
E
k
*
2
)
+
C
∑
k
∈
I
2
(
ξ
k
+
ξ
k
*
)
-
1
2
∑
k
∈
I
3
δ
C
2
--
∑
k
=
0
K
-
1
(
?
+
?
)
++
∑
k
=
0
K
-
1
α
k
(
υ
k
-
∑
j
=
0
K
-
1
i
j
h
k
-
j
-
ɛ
-
ξ
k
)
+
∑
k
=
0
K
-
1
α
k
*
(
-
υ
k
+
∑
j
=
0
K
-
1
i
j
h
k
-
j
-
ɛ
-
ξ
k
*
)
?
indicates text missing or illegible when filed
[0067] subject to the following constraints:
[0000]
α
k
(*
)
,
β
k
(*
)
,
ξ
k
(*
)
≥
0
∂
L
∂
i
n
=
0
;
∂
L
∂
ξ
n
(*
)
=
0
[0068] together with Karush-Kuhn-Tucker conditions:
[0000]
{
α
k
(
υ
k
-
∑
j
=
0
K
-
1
i
j
h
k
-
j
-
ɛ
-
ξ
k
)
=
0
α
k
*
(
-
υ
k
+
∑
j
=
0
K
-
1
i
j
h
k
-
j
-
ɛ
-
ξ
k
*
)
=
0
{
β
k
ξ
k
=
0
β
k
*
ξ
k
*
=
0
[0069] Since ( k ; are slack variables, then = , and therefore k k = . By deriving the Lagrangian with respect to the primal variables, we can obtain the dual problem, which is the next stage of the method.
[0070] iii. Signal Model in the Dual Problem
[0071] For the optimization of
[0000]
∂
ɛ
∂
i
n
=
0
:
[0000]
i
n
-
∂
[
∑
k
=
0
K
-
1
(
α
k
-
α
k
*
)
(
∑
n
=
0
K
-
1
i
n
h
k
-
n
)
]
∂
i
n
=
0
⇒
i
n
=
∑
k
=
0
K
-
1
(
α
k
-
α
k
*
)
h
k
-
n
[0000] Using a change of variables and having n j =α j −α j *′, we have:
[0000]
i
^
k
=
∑
j
=
0
K
-
1
h
j
-
k
(
α
j
-
α
j
*
)
=
h
-
k
*
η
k
[0000] which can be expressed in matrix form as:
[0000]
i
^
=
∑
j
=
0
K
-
1
h
j
-
k
(
α
j
-
α
j
*
)
[0000] where h j-k =[1×K], and hence
[0000] î=H (α−α′)
[0000] where H(m,p)=h form with indices {m,p=1, . . . ,K} and hence:
[0000]
[
h
0
,
h
1
,
…
h
K
-
1
h
-
1
,
h
0
,
…
h
K
-
2
⋮
⋮
⋱
⋮
h
1
-
K
,
h
2
-
K
,
…
h
0
]
[0000] Moreover, given that
[0000] ∥ i∥ 2 =i T i ∥i∥ 2 =(α−α*) T H T H (α−α*)
[0000] ∥ i∥ 2 =(α−α*) T K (α−α*)
[0000] K=H T H
Explicitly,
[0072]
K
=
[
h
0
,
h
-
1
,
…
h
1
-
K
h
1
,
h
0
,
…
h
2
-
K
⋮
⋮
⋱
⋮
h
K
-
1
,
h
K
-
2
,
…
h
0
]
·
[
h
0
,
h
1
,
…
h
K
-
1
h
-
1
,
h
0
,
…
h
K
-
2
⋮
⋮
⋱
⋮
h
1
-
K
,
h
2
-
K
,
…
h
0
]
[0000] which can be expressed in a compressed form as
[0000]
K
(
m
,
p
)
=
∑
z
=
1
K
h
m
-
z
h
p
-
z
[0000] where m, p, z are indices taking values in {1, . . . , K}, and taking n=m−p, previous equation can be written as:
[0000]
K
(
n
,
p
)
=
∑
z
=
1
K
h
p
+
n
-
z
h
p
-
z
[0000] so that signal R can be defined as
[0000]
R
k
=
∑
n
=
0
K
-
1
h
k
h
k
+
n
=
h
k
*
h
-
k
[0000] which is the autocorrelation of h k .
On the other hand, in the optimization of
[0000]
∂
L
∂
?
=
0
?
indicates text missing or illegible when filed
[0000] we have that:
1−k∈I 1 :cuadratic zone:
[0000]
1
δ
(
ξ
k
+
ξ
k
*
)
-
(
β
k
+
β
k
*
)
-
(
α
k
+
α
k
*
)
=
0
[0000] *β k (•)= 0 according to KKT, since in the cuadratic zone ξ k (•) =0
*either ξ k or ξ k *; are different than zero, but not at the same time. Therefore:
[0000] ξ k (•)=δα k (•)
[0000] It can be demonstrated that (using α k α k =0)
[0000]
1
2
δ
∑
k
∈
I
1
(
ξ
k
2
+
ξ
k
*
2
)
=
1
2
δ
∑
k
∈
I
1
(
δ
2
α
k
2
+
δ
2
α
k
*
2
)
=
=
δ
2
∑
k
∈
I
1
(
α
k
2
+
α
k
*
2
)
=
δ
2
∑
k
∈
I
1
(
α
k
-
α
k
*
)
2
=
=
δ
2
(
α
-
α
*
)
T
I
I
1
(
α
-
α
*
)
[0000] 2.−k∈I 2 : linear zone. As in the previous case we have:
[0000] β k (•)= 0 por ξ k (•)≠ 0
[0000] then,
[0000] α k (•)=C
[0073] iv. Solution for the Primal Signal Model
[0000] The solution of the primal signal model is depicted in FIG. 1 , where given the initial model:
[0000]
v
k
=î
k
*h
k
+e
k
={circumflex over (v)}
k
+e
k
[0000] whose solution is
[0000] î k =η k *{tilde over (h)} k =η k *h −k
[0000] we get that
[0000] {circumflex over (v)} k =î k *h k =η k *R k h
[0074] v. Dual Signal Model
[0000] Be the set of measurements {v k }, modeled by a nonlinear regression from a set of given locations (k). This regression uses a nonlinear transformation H→H, which maps the set of locations (real scalars) to a Reproducing Hilbert Kernel Space (RKSH) H, or feature space. By choosing an adequate φ, we can build a linear regression model in H, given by:
[0000] v k = w ,φ( k ) + e k
[0000] where w∈H is the weight vector.
[0075] vi. Primal Problem for the Dual Signal Model
[0076] By developing the primal problem, functional is given by:
[0000]
J
DSM
=
∑
k
=
0
K
-
1
w
k
2
2
+
1
2
δ
∑
k
∈
I
1
(
ξ
k
2
+
ξ
k
*
2
)
+
C
∑
k
∈
I
2
(
ξ
k
+
ξ
k
*
)
-
1
2
∑
k
∈
I
2
δ
C
2
[0000] To be minimized with respect to (ω i ) β( k h ), and constrained to:
[0000] υ 1 − w ,φ( l ) ≦ε+ξ 1
[0000] υ−v 1 − w ,φ( l ) ≦ε+ξ 1 *
[0000] By obtaining the Lagrangian and taking the derivatives with respect to primal variables, we get to:
[0000]
w
=
∑
k
=
0
K
-
1
η
k
φ
(
k
)
[0000] Hence, voltage can be expressed as
[0000]
v
k
=
〈
∑
j
=
0
K
-
1
η
j
φ
(
j
)
,
φ
(
k
)
〉
=
∑
j
=
0
K
-
1
η
j
〈
φ
(
j
)
,
φ
(
k
)
〉
[0000] And by using the kernel trick,
[0000]
v
k
=
∑
j
=
0
K
-
1
η
j
(
j
,
k
)
=
∑
j
=
0
K
-
1
η
j
(
j
-
k
)
[0000] This last equality is fulfilled as far as K is given by a suitable Mercer kernel.
[0077] vi. Dual Problem for the Dual Signal Model
[0000] By defining
[0000] G(j,k)= φ(j),φ(k) =k(j,k)
[0000] where the following functional has to be maximized:
[0000]
L
D
=
-
1
2
(
α
-
α
*
)
T
(
G
+
δ
I
)
(
α
-
α
*
)
+
v
T
(
α
-
α
*
)
-
ɛ
1
T
(
α
+
α
*
)
0
≤
α
(*
)
≤
C
[0000] and taking into account the convolutional model, then the voltage recorded in different K points {k=0, . . . , K−1} is
[0000]
v
k
=
∑
j
=
0
K
-
1
i
j
h
j
-
k
[0000] Comparing the equations of v k , and identifying terms, we can express
[0000] K(j−k)=h j-k
[0000] î k =η k
[0000] and then,
[0000] {circumflex over (v)} k =η k * k =η k *h k
[0000] Therefore, taking we find that the convolutive model emerges naturally for the relationship between the impulse response and the sparse signal (some few samples are different from zero). | System and method for the reconstruction of cardiac electrical activation from cardiac electrical signals recorded by intracardiac catheters. The obtained signals are processed using a Support Vector Machine (SVM) algorithm to solve the dual signal problem. Visualization of the solution includes geometric information in such a way that the cardiac electrical activity can be identified and localized. The system and method are described as a preferential application for anti-arrhythmic therapies. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to novel sulfur-containing organopolysiloxanes, to compositions including such polymers and to siloxane elastomers containing sulfur.
2. Description of the Prior Art
Organopolysiloxanes in which the terminal silicon atoms have one or more alkoxy groups attached thereto are known in the art and are useful in the preparation of compositions which are capable of being cured at room temperature to produce rubbery siloxane materials. The preparation of organopolysiloxanes in which terminal silicon atoms have at least two alkoxy groups attached thereto may be prepared, for example, according to the procedure set forth in U.S. Pat. No. 3,161,614. The reference also discloses the preparation of curable compositions including such polymers and curing catalysts such as metal salts of carboxylic acids, titanium esters and amines. As another example, it is noted in U.S. Pat. No. 3,294,729 that mixtures of alkoxy substituted silanes with hydroxylated siloxanes and selected titanium compounds will cure to an elastomeric material upon exposure to atmospheric moisture. It is proposed in U.S. Pat. No. 3,161,614 that the alkoxyl groups of the silane react with the hydroxyl groups of the hydroxylated siloxane to produce alkoxy ended siloxanes which, in turn, are cured to elastomers upon exposure to atmospheric moisture by the action of the catalyst.
It is believed that one of the limiting factors on storage stability of room temperature curable mixtures of alkoxy endblocked siloxane polymers and catalysts is the limited stability of, e.g, methyldimethoxy and trimethoxy siloxy groups at the ends of siloxane polymers.
There exists a need in the art for alkoxy functional group-containing polysiloxanes that exhibit storage stability in the presence of curing catalysts.
SUMMARY OF THE INVENTION
According to the present invention, novel sulfurcontaining organopolysiloxanes are prepared and may be employed in the preparation of storage stable compositions curable to elastomers at room temperature and preferably only upon exposure to atmospheric moisture. The organopolysiloxanes prepared according to the invention are alkoxy functional siloxane polymers characterized by a non-oxygen containing linkage between alkoxysilyl groups and the siloxane polymer chain. As a result of this characteristic, compositions of the invention which include such polymers and curing catalysts should exhibit stability equal to or better than prior compositions including alkoxy functional polymers.
Organopolysiloxanes of the invention include di- and tri-alkoxy functional polymers and may be prepared by reacting, e.g., alkenyl endblocked polysiloxanes with alkoxy mercaptoalkyl silanes. Alternately, the polymers may be formed by reacting, e.g., mercaptoalkyl endblocked polysiloxanes with alkoxy alkenyl silanes. Such addition reactions are readily carried out in the presence of suitable catalytic conditons including use of metal salts of carboxylic acids.
Curable compositions of the invention may optionally include fillers, viscosity aids and crosslinking agents and provide sealants, caulking materials, electrical insulation and the like, which cure rapidly at room temperature to elastomeric materials with non-sticky surfaces. Preferably curable compositions are stable when packaged to exclude moisture in the form of water or water vapor, including atmospheric water vapor, but will cure spontaneously upon exposure to moisture.
DESCRIPTION OF THE INVENTION
This invention relates to novel sulfur-containing organopolysiloxanes consisting essentially of a combination of units selected from dimethylsiloxane units, trimethylsiloxane units, sulfur-containing siloxane units of the formula ##STR1## and pendent sulfur-containing siloxane units of the formula ##STR2## wherein: R and R 1 are the same or different and selected from the group consisting of methyl and ethyl;
x has a value of 2 or 3;
a has a value of 0 or 1;
A and B are the same of different and selected from among the group consisting of divalent radicals of the formulas
--C.sub.m H.sub.2m --
and
--C.sub.n H.sub.2n --
wherein:
m and n are the same or different and have a value of from 2 to 4 inclusive, and trivalent radicals having the formula ##STR3## forming a silacyclopentamer by attachment of the (+) bond to a sulfur atom and the other two bonds to one silicon atom;
R 2 is a monovalent radical selected from the group consisting of alkyl and alkoxy radicals having from 1 to 3 carbon atoms inclusive and phenyl radical;
b has a value of 1 to 2;
R 3 is methyl or ethyl;
c has a value of 0 or 1;
provided that (1) in the divalent radical, no carbon atom is attached to both a silicon atom and a sulfur atom; (2) when A is a trivalent radical, x is 2 and a is 0; (3) when B is a trivalent radical, b is 1 and c is 0; and (4) when B is a divalent radical, b is 2 and c is 1; said organopolysiloxane containing an average of at least two sulfur-containing siloxane units per molecule and no more than 10 mole percent pendent sulfur-containing siloxane units based on the total number of siloxane units in the organopolysiloxane.
Organopolysiloxanes of the invention contain an average of at least about 2 sulfur-containing units per molecule and no more than 10 mole percent siloxane units having "pendent" alkoxy functional sulfur-containing groups based on the total number of siloxane units in the organopolysiloxane.
Curable compositions of the invention include:
(A) a sulfur-containing organopolysiloxane as described above;
(B) a curing catalyst in an amount equal to from 1 to 10 parts by weight per 100 parts by weight of (A);
(C) a filler in an amount of from 0 to 200 parts by weight per 100 parts by weight of (A); and
(D) a cross-linking agent, such as methyltrimethoxysilane, in an amount of from 0 to 10 parts by weight per 100 parts by weight of (A).
Examples of novel polymers of the invention having terminal, alkoxy functional sulfur-containing groups may be represented by the formulas I through VI: ##STR4## wherein: R, R 1 , R 2 , m and n are defined above; and
y has a value of 0 to 1000 and preferably 200 to 800. Those having 37 pendent" alkoxy functional, sulfurcontaining groups may be represented by the formulas VII through XII: ##STR5## wherein: R, R 1 , R 3 , m and n are defined above;
the sum of s and t has a value of 18 to 1000 and preferably 200 to 800; and
t is greater than 2 and no more than a number providing 10 mole percent sulfur-containing siloxane units, based on total siloxane units in the organopolysiloxane.
Polymers of the invention are formed by an addition reaction between a mercapto-containing compound and alkenylcontaining compounds. The addition reaction is catalyzed by conventional means including electromagnetic and particulate radiation energy and, preferably, chemical catalysts such as metal salts of carboxylic acids. Polysiloxane reagent compounds for use in the synthesis of polymers of the invention include, for example, mercaptoorganopolysiloxanes and alkenyl-containing polysiloxanes such as are employed in the manufacture of cured compositions according to U.S. Pat. No. 4,039,504; U.S. Pat. No. 4,070,328; U.S. Pat. No. 4,070,329; U.S. Pat. No. 3,445,419; U.S. Pat. No. 3,816,282; U.S. Pat. No. 3,873,499; German Patent Publication (OLS) No. 2,008,426; U.S. Pat. No. 4,064,027; U.S. Pat. No. 4,066,603; and U.S. Patent Application Ser. No. 663,326, filed Mar. 3, 1976, by Gary N. Bokerman and Robert E. Kalinowski, entitled "Method of Curing Thick Section Elastomers".
Alkoxy mercaptoalkyl silane and alkoxy alkenyl silane reagent compounds for use in synthesis of polymers of the invention are easily prepared by methods well-known in the art.
As noted previously, the addition reactions involved in preparation of the polymers of the invention are readily carried out in the presence of suitable catalytic conditions such as ferric octoate. In some instances, it may be desirable to accelerate the catalytic activity of the metal salts with organic peroxides and hydroperoxides.
The novel polymers of the invention are useful in the preparation of curable compositions in essentially the same manner as prior art organopolysiloxanes having alkoxy groups attached thereto. As such, the curable compositions include the sulfur-containing organopolysiloxane, a curing catalyst, and, optionally, a filler, a viscosity aid, and/or a cross-linking agent.
The catalyst employed to cure the compositions of this invention can be any catalyst capable of causing the reaction of an alkoxysiloxane with water to form a hydroxysiloxane and further causing condensation between an SiOH group and a silicon-bonded alkoxy group or between SiOH groups. If desired, mutual solvents can be used to increase the solubility of the catalyst in the siloxane. One class of catalyst includes metal salts of monocarboxylic acids such as lead 2-ethylhexoate, dibutyltin diacetate, dibutyltin di-2-ethylhexoate, dibutyltin dilaurate, butyltin tri-2-ethylhexoate, iron 2-ethylhexoate, cobalt 2-ethylhexoate, manganese 2-ethylhexoate, zinc 2-ethylhexoate, stannous octoate, tin naphthenate, zirconium octoate, antimony octoate, bismuth naphthenate, tin oleate, tin butyrate, zinc naphthenate, zinc stearate and titanium naphthenate. The stannous carboxylates and certain orthotitanates and partial condensates thereof are preferred.
Another class of catalyst, which is particularly useful to prepare one package compositions, are titanium esters such as tetrabutyltitanate, tetra-2-ethylhexyltitanate, tetraphenyltitanate, tetraoctadecyltitanate, triethanolaminetitanate, octyleneglycoltitanate and bis-acetylacetonyldiisopropyltitanate.
Additional suitable catalysts include amines such as hexylamine, dodecylamine, and amine salts such as hexylamineacetate, dodecylaminephosphate and quaternary amine salts such as benzyltrimethylammoniumacetate and salts of alkali metals such as potassium acetate.
For the purpose of this invention the amount of catalyst is not critical but is normally present in amounts of from 1 to 10 parts by weight per 100 parts by weight of the siloxane.
Fillers can be used in the compositions of this invention, but are not required. The fillers can be both treated and untreated reinforcing fillers, such as fume silica and fume silica having triorganosiloxy groups such as trimethylsiloxy groups on the surface, carbon black or precipitated silica, and extending fillers such as crushed or ground quartz, diatomaceous earth, and calcium carbonate. The curable elastomeric compositions preferably contain filler up to about 200 parts by weight per 100 parts by weight mercaptoorganopolysiloxanes.
Cross-linking agents can be used in compositions of the invention but are not required. Such agents can include silanes of the formula R 4 e Si(OR 5 ) 4-e wherein e has a value of from 0 to 2 inclusive and R 4 and R 5 can be, for example, mononuclear aryl, halogen-substituted mononuclear aryl, alkyl, alkenyl, alkynyl, haloalkyl, haloalkenyl, haloalkynyl, cycloalkyl, cycloalkenyl, and halogen substituted cycloalkyl and cycloalkenyl, and cyano lower alkyl.
Silanes of the above-noted formula are well known in the art and are described, for example, in U.S. Pat. No. 2,843,555. When such silanes are to have solely a cross-linking function, e has a value of 1 or less and the preferred silane is methyltrimethoxy silane. When it is desired that the silane additionally exhibit a potential for chain extension, e has a value of 2 and the preferred silane is dimethyldimethoxysilane.
In addition to use of the above-noted cross-linking agents, it is expected that materials functional as cross-linkers for curable compositions can be excess mercaptoorganotrialkoxysilane and species formed in situ during the preparation of the polymers of this invention. For example, use of a stoichiometric excess of mercaptoorganotrialkoxysilane and metal salt catalyst during formation of a polymer of the invention by condensation of the silane with an alkenylendblocked siloxane is expected to result in the polymers as described herein and in a suitable cross-linking agent of the formula,
(RO).sub.3 Si--C.sub.n H.sub.2n --S--S--C.sub.n H.sub.2n --Si(OR).sub.3
Compositions of this invention cure to elastomers at room temperature upon exposure to moisture in the form of water or water vapor, including atmospheric water vapor.
The following examples are presented for illustrative purposes and should not be construed as limiting the invention.
EXAMPLE 1
This example illustrates preparation of a novel trialkoxy endblocked polymer of the general formula I, and more specifically of the formula ##STR6##
Five hundred grams of linear polydimethylsiloxane having terminal methylphenylvinylsiloxy units with a viscosity of about 2.625 Pa·s and approximately 0.25 weight percent vinyl radical was added to 18.15 g gamma-mercaptopropyltrimethoxysilane in a 1-liter, 3-necked flask and stirred to form a reaction mixture. One-half gram of a 52 weight percent dispersion of ferric octoate in mineral oil was added and the reaction mixture became orange in color. During the reaction, which was allowed to continue for two hours, the mixture became dark brown in color and a slight increase in temperature was noted. The volatiles were stripped off at 150° C. (at less than 1333 Pa pressure) to give a polymer which had a viscosity of 6.3 Pa·s. To a 5 g sample of the polymer, 0.07 g of tetrabutyltitanate was added. The mixture, exposed to the atmosphere at room temperature, formed a surface skin in 5 minutes and was thoroughly cured (0.5 to 1.0 cm thickness) upon standing overnight.
EXAMPLE 2
This example illustrates preparation of a novel trialkoxy endblocked polymer of the general formula I, and more specifically of the formula ##STR7##
Five hundred grams of linear polydimethylsiloxane having terminal gamma-mercaptopropyldimethoxysiloxy units, with a viscosity of about 2.112 Pa·s and approximately 0.84 weight percent --SH group was added to 37 g of vinyltrimethoxysilane, catalyzed with 0.5 g of ferric octoate and allowed to react as in Example 1. The resulting polymer had a viscosity of about 10 Pa·s. A five gram sample catalyzed with 0.07 g of tetrabutyltitanate skinned over in five minutes and was completely cured upon standing overnight when exposed to the atmosphere at room temperature.
EXAMPLE 3
A polymer structurally similar to that of Example 1 was prepared by the method therein set forth but employing 100 g of a linear polydimethylsiloxane having terminal methylphenylvinylsiloxy units (viscosity, 8.968 Pa·s; 0.14 weight percent vinyl groups) and 20.4 g of gamma-mercaptopropyltrimethoxysilane. The mixture was allowed to react for five hours and yielded a polymer having a viscosity of 16.832 Pa·s. A 5 g sample of the polymer, exposed to the atmosphere at room temperature, skinned over in 5-10 minutes upon addition of 0.07 g tetrabutyltitanate. The sample cured open standing overnight at room temperature to give a low durometer composition.
EXAMPLE 4
This example illustrates preparation of a novel dialkoxy endblocked polymer of the general formula II and more specifically of the formula ##STR8## Five hundred grams of the linear polydimethylsiloxane employed in the synthesis of Example 1 was mixed with 16.65 g of (gammamercaptopropyl)methyldimethoxysilane and treated as in Example 1. The resulting polymer had a viscosity of 4.32 Pa·s. A 5 g sample of the polymer skinned over in about 45 minutes when catalyzed with 0.07 g tetrabutyltitanate and cured completely upon standing overnight exposed to the atmosphere at room temperature.
EXAMPLE 5
The synthesis of Example 3 was repeated using 500 g of the linear polydimethylsiloxane, 20.4 g of the silane and 1.0 g of the ferric octoate dispersion. The reaction was allowed to continue for 2.5 hours. A sample of the resulting polymer taken immediately after preparation did not exhibit substantial crosslinking upon catalysis with tetrabutyltitanate. After this polymer was allowed to shelf age for about three days, a 5 gram sample skinned over in 5 minutes upon addition of 0.07 g of the titanate and cured completely upon standing overnight at room temperature. The viscosity of the shelf aged polymer was 26.88 Pa·s and provided cured mixtures which display excellent adhesion characteristics to various surfaces including aluminum and steel.
EXAMPLE 6
The synthesis of Example 5 was repeated using 500 grams of the linear polydimethylsiloxane, 10.2 g of the silane and 0.5 g of the ferric octoate dispersion. After the reaction had proceeded for 45 minutes, 0.5 g of tertiarybutyl hydroperoxide was added with stirring and the reaction was continued for 75 minutes. The resulting polymer had a viscosity of 34.65 Pa·s. A 5 g sample of the polymer skinned over in 5 minutes upon catalysis with tetrabutyltitanate and completely cured upon standing overnight at room temperature.
EXAMPLE 7
The synthesis of Example 6 was repeated except that the peroxide was added initially, rather than after 45 minutes of reaction. The mixture was reacted for 1 hour. The viscosity of the polymer was 29.46 Pa·s and a sample displayed curing characteristics identical to those of the polymer of Example 6.
EXAMPLE 8
This example illustrates the preparation of a novel trialkoxy endblocked polymer of the general formula III, and more specifically of the formula ##STR9## Five hundred grams of a linear polydimethylsiloxane having terminal methylsilacyclopentene units with a viscosity of 0.703 Pa·s and approximately 0.58 weight percent --CH═CH-- was added to 44.0 g gamma-mercaptopropyltrimethoxysilane in a 1-liter flask. One-half gram of a 52 weight percent dispersion of ferric octoate in mineral oil was added along with 0.5 g tertiarylbutyl peroxide. Additional 0.5 g amounts of the peroxide were added to the reaction mixture after 1 and 24 hours of reaction, respectively. A 5 g sample taken after 25 hours of reaction and catalyzed with 0.07 g tetrabutyltitanate skinned over in 45 minutes and fully cured upon standing overnight exposed to the atmosphere at room temperature.
EXAMPLE 9
A curable composition was prepared from the following components:
______________________________________ CompositionComponent (Parts by Weight)______________________________________Polymer of Example 6 140Fume silica filler 14Hydroxy endblocked polymethyl-phenylsiloxane having about 4wt. % silicon-bonded hydroxyl 4Methyltrimethoxysilane 4Diisopropoxy titaniumbis-(ethylacetoacetonate) 2.8______________________________________
The mixture was prepared by mixing under conditions which excluded moisture, and kept in a sealed tube. Samples from the tube were extruded into a molding chase, exposed to atmospheric air, and cured for five days at room temperature. The physical properties of the cured material were as follows:
______________________________________Durometer (Shore A) 42Tensile Strength (MPa) 2.83Elongation (%) 250Tear Strength (kN/m) 3.85Modulus (100%) (MPa) 1.03Modulus (200%) (MPa) 2.14______________________________________
EXAMPLE 10
A curable composition was prepared from the components of Example 9, but using the polymer of Example 1.
The mixture was prepared by mixing under conditions which excluded moisture, and kept in a sealed tube. Samples from the tube were extruded into a molding chase, exposed to atmospheric air, and cured for five days at room temperature. The physical properties of the cured material were as follows:
______________________________________Durometer (Shore A) 44Tensile Strength (MPa) 2.21Elongation (%) 160Tear Strength (kN/m) 3.15Modulus (100%) (MPa) 1.21______________________________________
Numerous modifications and variations in the practice of the invention are expected to occur to those skilled in the art upon consideration of the foregoing description and only such limitations as appear in the appended claims should be placed thereon. | Sulfur-containing organosiloxanes are prepared and can be used in the preparation of storage stable compositions curable to elastomers at room temperature. The organopolysiloxanes are alkoxy functional siloxane polymers characterized by a non-oxygen containing linkage between alkoxysilyl groups and the siloxane polymer chain. The non-oxygen linkage contains sulfur. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to a technology for inspecting a substrate having a fine pattern such as a semiconductor device and liquid crystal for defects, and in particular, relates to a charged particle beam apparatus that inspects a pattern on a substrate for defects by irradiating the substrate with a charged particle beam and detecting a secondary signal generated from the substrate, and to an image detecting method with the charged particle beam apparatus.
BACKGROUND OF THE INVENTION
[0002] An inspection of a semiconductor wafer is taken as an example of substrate for a description below. A semiconductor device is manufactured by repeating a process of transferring a pattern formed on a photo-mask to a semiconductor wafer by lithography processing and etching processing. Quality of lithography processing, etching processing and other processing and an occurrence of foreign matter in a manufacturing process of semiconductor devices have a great influence on fabrication yields of semiconductor devices. Therefore, various devices for inspecting patterns on semiconductor wafers in the manufacturing process are used to detect an occurrence of abnormal conditions or defects in the manufacturing process at an early stage or in advance.
[0003] As methods for inspecting defects present in patterns on a semiconductor wafer, a defect inspection device that irradiates a semiconductor wafer with light and compares circuit patterns of the same type of a plurality of LSIs using optical images, and a defect inspection device that irradiates a semiconductor wafer with a charged particle beam such as an electron beam and detects generated secondary electrons or reflected electrons to convert a signal thereof to images before detecting defects, have been put in practical use.
[0004] Known is a charged particle beam apparatus for defect inspection employing a Scanning Electron Microscope (SEM), which improves throughput thereof by adopting a stage tracking system that makes a charged particle beam scan while a target to be inspected being continuously moved (for example, Japanese Patent Application Laid-Open Publication No. 05-258703). However, the movement direction of the stage and the scanning direction are predetermined and the degree of freedom when an image is acquired is low and therefore, there remain problems of both action to be taken when distortion of an image occurs and difficulty in improving throughput.
SUMMARY OF THE INVENTION
[0005] In a conventional charged particle beam apparatus, as described above, throughput of image acquisition is improved by performing a scan of a charged particle beam while the stage being continuously moved. An object of the present invention is to provide a charged particle beam apparatus that optimizes scanning in accordance with situations and purposes, reduces distortion of images, and improves throughput, image quality, and defect detection rate by controlling deflection of a charged particle beam in the stage tracking system.
[0006] According to an embodiment of the present invention, an inspection apparatus for detecting abnormal conditions of an inspection target by irradiating the inspection target with a charged particle beam and detecting generated secondary electrons includes a stage that moves continuously with the inspection target placed thereon and a deflection control circuit which provides a deflector with a scanning signal that causes the charged particle beam to scan repeatedly in a direction substantially perpendicular to a stage movement axis direction while the charged particle beam being deflected in the stage movement axis direction (the direction of stage movement or the opposite direction thereof) in accordance with a change in movement speed of the stage during movement of the stage.
[0007] According to the present invention, a charged particle beam apparatus that reduces distortion of images and improves throughput, image quality, and defect detection rate by exercising deflection control of a charged particle beam in the movement axis direction in accordance with a change in movement speed of an inspection target can be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a block diagram of a circuit pattern inspection apparatus using a charged particle beam.
[0009] FIG. 2 is a screen diagram exemplifying a screen displayed in an interface display.
[0010] FIG. 3 is a conceptual diagram illustrating control of scanning an inspected substrate with a primary electron beam.
[0011] FIG. 4 is a conceptual diagram illustrating control of scanning the inspected substrate with the primary electron beam.
[0012] FIG. 5 is a conceptual diagram illustrating control of scanning the inspected substrate with the primary electron beam.
[0013] FIG. 6 is a conceptual diagram illustrating control of scanning the inspected substrate with a primary electron beam.
[0014] FIG. 7 is a conceptual diagram illustrating control of scanning the inspected substrate with the primary electron beam.
[0015] FIG. 8 is a conceptual diagram illustrating a control flow of a stabilization function.
[0016] FIG. 9 is a screen diagram exemplifying an interface for monitoring an electron beam scanning adjustment function.
[0017] FIG. 10 is a screen diagram exemplifying an interface for setting/specifying conditions of the electron beam scanning adjustment function.
DESCRIPTION OF THE REFERENCE NUMERALS
[0000]
1 : circuit pattern inspection apparatus
2 : inspection chamber
3 : electron-optical column
4 : optical microscope chamber
5 : image processing part
6 : interface
7 : secondary electron detection part
8 : sample chamber
9 : inspected substrate
10 : electron gun
11 : electron beam induction electrodes
12 : condensing lens
13 : blanking defector
14 : diaphragm
15 : scanning detector
16 : objective lens
17 : reflector
18 : E×B deflector
19 : primary electron beam
20 : secondary electron detector
21 : preamplifier
22 : AD converter
23 : light conversion means
24 : optical transmission means
25 : electrical conversion means
26 : high-voltage power supply
27 : preamplifier driving power supply
28 : AD converter driving power supply
29 : reverse bias power supply
30 : sample stand
31 : X stage
32 : Y stage
33 : rotation stage
34 : position monitor length measuring machine
35 : inspected substrate height measuring device
36 : retarding power supply
40 : light source
41 : optical lens
42 : CCD camera
43 : scanning signal generator
44 : objective lens power supply
45 : storage unit
46 : image processing circuit
47 : defect data buffer
48 : operation part
49 : overall control part
55 : map display part
56 : image display part
58 : image processing instruction area
59 : processing condition setting instruction part
60 : mode switching button
61 : correction control circuit
101 : inspection stripe
102 : chip
103 : cell
104 : plug
201 : deflecting view field
202 : center
203 : monitoring screen
204 : stage speed change display part
205 : Y deflection amount change display part
206 : irradiation interval change display part
207 : speed numeric information display part
208 : distance numeric information display part
209 : interval numeric information display part
210 : condition instruction screen
211 : tracking mode selection part
212 : setting value input part
213 : automatic setting function start button
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0087] An embodiment of the present invention will be described in detail below with reference to drawings.
[0088] FIG. 1 is a block diagram of a circuit pattern inspection apparatus using a charged particle beam and represents a main constitution by a substantially longitudinal sectional view and a functional diagram. A circuit pattern inspection apparatus 1 includes an inspection chamber 2 from which the air is evacuated and a spare chamber (not shown) for transporting an inspected substrate 9 into the inspection chamber 2 , and the spare chamber is constructed such that the air can be evacuated therefrom independently of the inspection chamber 2 . In addition to the inspection chamber 2 and the spare chamber, the circuit pattern inspection apparatus 1 includes an image processing part 5 .
[0089] The inspection chamber 2 mainly comprises an electron-optical column 3 , a sample chamber 8 , and an optical microscope chamber 4 . The electron-optical column 3 includes an electron gun 10 , electron beam induction electrodes 11 , a condensing lens 12 , a blanking deflector 13 , a diaphragm 14 , a scanning deflector 15 , an objective lens 16 , a reflector 17 , an E×B deflector 18 , and a secondary electron detector 20 , and irradiates the inspected substrate 9 with a primary electron beam 19 and detects secondary electrons generated from the inspected substrate 9 .
[0090] The optical microscope chamber 4 is arranged near the electron-optical column 3 inside the inspection chamber 2 and apart from the inspection chamber 2 so as not to be mutually affected. The optical microscope chamber 4 includes a light source 40 , an optical lens 41 , and a CCD camera 42 . The distance between the electron-optical column 3 and the optical microscope chamber 4 is known, and an X stage 31 or a Y stage 32 moves reciprocatingly across the known distance between the electron-optical column 3 and the optical microscope chamber 4 .
[0091] A secondary electron detection part 7 includes a preamplifier 21 for amplifying an output signal from the secondary electron detector 20 , an AD converter 22 for converting an amplified signal from an analog signal into a digital signal, a preamplifier driving power supply 27 and an AD converter driving power supply 28 for driving them respectively, a reverse bias power supply 29 , and a high-voltage power supply 26 for supplying electricity to these power supplies. An amplified digital signal is converted into an optical signal by a light conversion means 23 and the optical signal passes through an optical transmission means 24 and is converted into an electric signal by an electrical conversion means 25 before being sent to a storage unit 45 of the image processing part 5 . Though not shown, an optical image acquired by the CCD camera 42 is also sent to the image processing part 5 in the same manner.
[0092] The image processing part 5 includes the storage unit 45 , an image processing circuit 46 , a defect data buffer 47 , an operation part 48 , and an overall control part 49 . A signal stored in the storage unit 45 is converted into images by the image processing circuit 46 , which also performs various kinds of image processing such as alignment of images that are specific positions apart, normalization of signal levels, and removal of signal noise and performs a comparison operation of image signals. The operation part 48 compares an absolute value of a differential image signal obtained after the comparison operation with a predetermined threshold and judges the image signals to be defect candidates if the differential image signal level is larger than the predetermined threshold before sending positions thereof, the number of defects and the like to the interface 6 . The overall control part 49 controls the image processing and operations before sending such states to a correction control circuit 61 .
[0093] An electron beam image or optical image is displayed in an image display part 56 of the interface 6 . Operation instructions and operation conditions of each part of the circuit pattern inspection apparatus 1 are input from the interface 6 before being sent to the correction control circuit 61 from the overall control part 49 of the image processing part 5 . Conditions of an accelerating voltage, deflection width, and deflection speed when the primary electron beam 19 is generated, timing of capturing a signal by the secondary electron detection part 7 , movement speed of the X stage 31 and the Y stage 32 and the like can be set in the interface 6 optionally or selectively in accordance with purposes. The interface 6 has, for example, a function of display and a distribution of a plurality of detected defects is displayed on a map schematically representing a wafer, with symbols in a map display part 55 . An image acquisition instruction area 57 is a part for issuing instructions to acquire electron beam images or optical images for each detected defect or area. An image processing instruction area 58 is a part for instructing brightness adjustments or contrast adjustments of an acquired image. A processing condition setting instruction part 59 is a part for setting various conditions such as the deflection width, deflection speed, and focal length and focal depth of an objective lens when the inspected substrate 9 is irradiated with the primary electron beam 19 .
[0094] The correction control circuit 61 exercises control so that the accelerating voltage, deflection width, and deflection speed when the primary electron beam 19 is generated, timing of capturing a signal by the secondary electron detection part 7 , movement speed of the X stage 31 and the Y stage 32 , and the like follow instructions sent from the overall control part 49 of the image processing part 5 . The correction control circuit 61 also monitors the position and height of the inspected substrate 9 from signals of a position monitor length measuring machine 34 and an inspected substrate height measuring device 35 , generates a correction signal based on a result thereof, sends the correction signal to a scanning signal generator 43 and an objective lens power supply 44 , and changes the deflection width, deflection speed, and focal length and focal depth of an objective lens so that the primary electron beam 19 is irradiated with on a correct position.
[0095] A diffusion/re-supply type thermal field-emission electron source is used as the electron gun 10 . A stable electron beam current can be secured by using the electron gun 10 , as compared, for example, with a conventional tungsten (W) filament electron source and a cold field-emission electron source and therefore, electron beam images with less fluctuations in brightness can be obtained. Moreover, the electron beam current can be set to be large with the electron gun 10 and therefore, a high-speed inspection described later can be carried out.
[0096] The primary electron beam 19 is withdrawn from the electron gun 10 by applying a voltage to between the electron gun 10 and the electron beam induction electrodes 11 . Acceleration of the primary electron beam 19 is determined by applying a high-voltage negative potential to the electron gun 10 . Accordingly, the primary electron beam 19 travels toward a sample stand 30 with energy corresponding to the potential thereof and is converged by the condensing lens 12 and further thinly narrowed down by the objective lens 16 before being irradiated with on the subjected substrate 9 on the sample stand 30 .
[0097] The blanking deflector 13 and the scanning deflector 15 are controlled by the scanning signal generator 43 that generates a blanking signal and a scanning signal. The blanking deflector 13 can deflect the primary electron beam 19 so that the primary electron beam 19 does not pass through an opening of the diaphragm 14 to prevent irradiation of the inspected substrate 9 with the primary electron beam 19 . Since the primary electron beam 19 is thinly narrowed down by the objective lens 16 , the primary electron beam 19 is caused to scan on the inspected substrate 9 by the scanning deflector 15 .
[0098] A fast inspection speed is required for an automatic inspection apparatus. Therefore, unlike a normal SEM, a low-speed scan of an electron beam of an electron beam current on the order of pA, a repetitive scan, and superposition of respective images are not performed. Also in order to inhibit insulating material from being charged, an electron beam scan needs to be fast and limited to once or several times. Thus, in the present embodiment, an image is formed by performing a scan of a large-current electron beam of, for example, 100 nA, which is about 100 times or more that of a normal SEM, only once. The scan width is set, for example, to 100 μm, one pixel to 0.1 square-μm, and one scan is performed in 1 μs.
[0099] The objective lens power supply 44 is connected to the objective lens 16 . A lens power supply (not shown) is also connected to the condensing lens 12 . Intensity of these lenses is adjusted by the correction control circuit 61 by changing the voltage of the lens power supply.
[0100] A negative voltage can be applied to the inspected substrate 9 by a retarding power supply 36 . By adjusting the voltage of the retarding power supply 36 , the primary electron beam 19 is decelerated so that electron beam irradiation energy to the inspected substrate 9 can be adjusted without changing the potential of the electron gun 10 .
[0101] The inspected substrate 9 is placed on the X stage 31 or the Y stage 32 . A method by which the X stage 31 and the Y stage 32 are put to rest when an inspection is carried out and the primary electron beam 19 is scanned with two-dimensionally and another method by which the X stage 31 is put to rest and the primary electron beam 19 is scanned with in the X direction while the Y stage 32 being moved continuously at a constant speed are known. When a specific and relatively small area is inspected, the former method by which the stages are put to rest for inspection is effective and when a relatively large area is inspected, the latter method by which the stage is continuously moved at a constant speed is effective.
[0102] When an image of the inspected substrate 9 is acquired while one of the X stage 31 and the Y stage 32 being moved continuously, the primary electron beam 19 is scanned with in a direction substantially perpendicular to the direction of movement of the stage and secondary electrons generated from the inspected substrate 9 are detected by the secondary electron detector 20 in synchronization with scanning of the primary electron beam 19 and movement of the stage. Secondary electrons generated by the inspected substrate 9 being irradiated with the primary electron beam 19 are accelerated by a negative voltage applied to the inspected substrate 9 . The E×B deflector 18 is arranged above the inspected substrate 9 , thereby deflecting accelerated secondary electrons in a predetermined direction. The amount of deflection can be adjusted by changing the intensity of magnetic field with a voltage applied to the E×B deflector 18 . An electromagnetic field of the E×B deflector 18 can be made variable in coordination with a negative voltage applied to the inspected substrate 9 . Secondary electrons deflected by the E×B deflector 18 collide against the reflector 17 under predetermined conditions. The reflector 17 serves also as a shield pipe of the scanning deflector 15 of the primary electron beam 19 irradiated with on the inspected substrate 9 and has a conical shape. When accelerated secondary electrons collide against the reflector 17 , second secondary electrons having energy of several V to 50 eV are generated from the reflector 17 .
[0103] In the present embodiment, the position monitor length measuring machine 34 is constructed such that it uses a length measuring machine based on the principle of laser interference in the X and Y directions and measures positions of the X stage 31 and the Y stage 32 while the primary electron beam 19 being irradiated with, to send the positions to the correction control circuit 61 . Moreover, the number of rotations of each driving motor of the X stage 31 , the Y stage 32 , and a rotation stage 33 is sent to the correction control circuit 61 from the respective driver circuit. The correction control circuit 61 can correctly grasp the area or position on which the primary electron beam 19 is irradiated with based on the above data and corrects position displacements of the irradiation position of the primary electron beam 19 . The correction control circuit 61 can also store the area on which the primary electron beam 19 has been irradiated with.
[0104] An optical measuring device using a measurement method other than an electron beam, for example, a laser interference measuring device or a reflected light type measuring device for measuring changes based on the position of reflected light is used as the inspected substrate height measuring device 35 . For example, a method by which the inspected substrate 9 is irradiated with an elongated white light after passing through a slit through a window and, the position of the reflected light is detected by a position detection monitor, and the amount of changes in height is calculated from position fluctuations is known. The inspected substrate height measuring device 35 is mounted on the X stage 31 and the Y stage 32 to measure the height of the inspected substrate 9 . The focal length of the objective lens 16 for thinly narrowing down the primary electron beam 19 is dynamically corrected based on data measured with the inspected substrate height measuring device 35 so that the primary electron beam 19 always focused on an inspected area can be irradiated with. Moreover, by measuring warping and height distortion of the inspected substrate 9 before irradiation of the primary electron beam 19 , correction conditions of the objective lens 16 for each inspection area can be set based on the resultant data.
[0105] FIG. 2 is a screen diagram exemplifying a screen displayed in an interface display. A map display part 55 and an image display part 56 are arranged in a large area of the display screen. A mode switching button 60 is arranged at the bottom and each mode of “Inspect”, “Check defect”, “Create recipe”, and “Utilities” can be selected. The “Create recipe” mode is a mode for setting conditions for automatic inspection. The “Utilities” mode is a mode for invoking an auxiliary function that does not appear in other modes and is not usually used.
[0106] FIG. 3 is a conceptual diagram illustrating control of scanning the inspected substrate 9 with the primary electron beam 19 . FIG. 3A is a plan view of the inspected substrate 9 , FIG. 3B is an enlarged view of an A portion of FIG. 3A , FIG. 3C is an enlarged view of a B portion of FIG. 3B , and FIG. 3D is a relational diagram showing a relationship between a scanning time of the primary electron beam 19 and the position in the X direction.
[0107] As shown in FIG. 3A , the primary electron beam 19 is caused to scan in a direction perpendicular to the direction of movement of the stage while the stage being moved. Since the stage is moving, the primary electron beam 19 travels in the direction of an inspection stripe 101 denoted by arrows in the figure while scanning on the inspected substrate 9 . Each rectangle represents a chip 102 . A final product of it is cut off along boundary lines between rectangles and then is bonded to electric terminals.
[0108] FIG. 3B is an enlargement of one chip 102 enclosed by the A portion in FIG. 3A , and a plurality of cells 103 are arranged therein. If the width of scanning of the primary electron beam 19 is 100 μm and that of the cell 103 is 100 μm or less, one column of the cells 103 will be scanned in one stage movement.
[0109] FIG. 3C is an enlargement of the B portion in FIG. 3B and shows a situation in which a plurality of circuits called plugs 104 is arranged in one cell 103 . The cell 103 is scanned with the primary electron beam 19 in turn like in the order of sampling (1), sampling (2), sampling (3), and generated secondary electrons are detected at the same time before being converted into images.
[0110] FIG. 3D is a relational diagram showing a relationship between the scanning time of the primary electron beam 19 and the position in the X direction, and the scanning time for sampling (1) is defined as a T 1 time (for example, 1 μs) and this is repeated as a time interval between irradiations (hereinafter, referred to as an irradiation interval).
[0111] By controlling the irradiation interval and the irradiation position in the movement axis direction in real time in accordance with an electrification state of the inspection target, precision of transport means, or inspection purposes, quality of inspection images to be detected and throughput of the inspection can be improved. This is called an adjustment function and an example thereof will be shown below.
[0112] A method of carrying out an inspection by continuously moving at a constant speed a stage that moves an inspection target is taken as an example. It is assumed that the stage moves in the Y direction and the primary electron beam 19 is scanned with in the X direction (substantially perpendicular to the direction of movement). In the inspection method, the primary electron beam 19 can be controlled by adjusting the amount of Y deflection and the irradiation interval, and the following four control methods can be considered: (1) a method in which both the amount of Y deflection and the irradiation interval are fixed, (2) a method in which the amount of Y deflection is fixed and the irradiation interval is adjusted, (3) a method in which the amount of Y deflection is adjusted and the irradiation interval is fixed, and (4) a method in which both the amount of Y deflection and the irradiation interval are adjusted.
[0113] The control method (1) will be described using FIG. 4 . A in FIG. 4 is a conceptual diagram illustrating the irradiation position of an electron beam when viewed from a deflecting view field 201 , and A in FIG. 4 shows a state in which the primary electron beam 19 is irradiated with such that it always passes through a center 202 of the deflecting view field 201 . B in FIG. 4 is a relational diagram showing a relationship among the scanning time and wait time of the primary electron beam 19 and the position in the X direction in this method, and it is assumed that the scanning time T 1 is an irradiation interval between scan (1) and scan (2) and the scanning time T 2 is an irradiation interval between scan (2) and scan (3). When the scanning time T 3 is controlled unchangeably, wait times T 4 and T 5 for their respective irradiations are made uniform by making a scan so that T 1 and T 2 become equal.
[0114] By making the irradiation interval constant just like the control method (1), it becomes possible to make the electrification state uniform and suppress an occurrence of contrast unevenness. Moreover, by making the amount of Y deflection constant, correction processing for focus distortion and the like due to deflection in the Y direction, processing of determining whether or not within the deflecting view field, and the like are made unnecessary, contributing to enhancement of reliability and processing speed and improvement of throughput due to simplification of processing.
[0115] The control method (2) will be described using FIG. 5 . Like A in FIG. 4 , A in FIG. 5 is a conceptual diagram illustrating the irradiation position of an electron beam when viewed from the deflecting view field 201 , and A in FIG. 5 shows a state in which the primary electron beam 19 is irradiated with such that it always passes through the center 202 of the deflecting view field 201 . Like B in FIG. 4 , B in FIG. 5 is a relational diagram showing a relationship among the scanning time and wait time of the primary electron beam 19 and the position in the X direction in the method, and it is assumed that the scanning time T 1 is an irradiation interval between scan (1) and scan (2) and the scanning time T 2 is an irradiation interval between scan (2) and scan (3). When the scanning time T 3 is controlled unchangeably, the irradiation intervals T 1 and T 2 are changed when necessary.
[0116] By making the irradiation interval variable just like the control method (2), it becomes possible to absorb unevenness of the stage speed and improve precision of the irradiation position of an electron beam. Moreover, like the control method (1), it is possible to contribute to enhancement of reliability and processing speed and improvement of throughput, by making the amount of Y deflection constant.
[0117] The control method (3) will be described using FIG. 6 . Like A in FIG. 5 , A in FIG. 6 is a conceptual diagram illustrating the irradiation position of an electron beam when viewed from the deflecting view field 201 , and A in FIG. 6 shows a state in which the primary electron beam 19 is irradiated with, being deflected also in the Y direction according to circumstances so that the primary electron beam 19 is irradiated with on the irradiation target position on the cell 103 , which is the inspection target. Like B in FIG. 4 , B in FIG. 6 is a relational diagram showing a relationship among the scanning time and wait time of the primary electron beam 19 and the position in the X direction in this method, and it is assumed that the scanning time T 1 is an irradiation interval between scan (1) and scan (2) and the scanning time T 2 is an irradiation interval between scan (2) and scan (3). B in FIG. 6 shows a state in which a scan is performed so that T 1 and T 2 become equal.
[0118] Like the control method (1), by making the irradiation interval constant just like the control method (3), it becomes possible to make the electrification state uniform and suppress an occurrence of contrast unevenness. Moreover, by adjusting the amount of Y deflection according to circumstances, it becomes possible to absorb unevenness of the stage speed and improve precision of the irradiation position of an electron beam.
[0119] The control method (4) will be described using FIG. 7 . Like A in FIG. 6 , A in FIG. 7 is a conceptual diagram illustrating the irradiation position of an electron beam when viewed from the deflecting view field 201 , and A in FIG. 7 shows a state in which the primary electron beam 19 is irradiated with, being deflected also in the Y direction according to circumstances so that the primary electron beam 19 is irradiated with on the irradiation target position on the cell 103 , which is the inspection target. Like B in FIG. 5 , B in FIG. 7 is a relational diagram showing a relationship among the scanning time and wait time of the primary electron beam 19 and the position in the X direction in the method, and it is assumed that the scanning time T 1 is an irradiation interval between scan (1) and scan (2) and the scanning time T 2 is an irradiation interval between scan (2) and scan (3). When the scanning time T 3 is controlled unchangeably, the irradiation intervals T 1 and T 2 are changed when necessary.
[0120] By adjusting both the irradiation interval and the amount of Y deflection just like the control method (4), it becomes possible to absorb unevenness of the stage speed and improve precision of the irradiation position of an electron beam. Also, by adjusting both, their respective amount of adjustments can be suppressed, and also effects of both preventing deviation of the irradiation position of an electron beam from the deflecting view field and suppressing an occurrence of contrast unevenness by uniformity of the electrification state can be expected.
[0121] FIG. 8 shows a processing flow of an adjustment function of the amount of Y deflection and irradiation interval. Conditions for the adjustment function are set by an operator (step 301 ), first-time irradiation conditions such as the amount of Y deflection and irradiation interval are calculated based on the conditions and other apparatus operation conditions such as the stage speed (step 302 ), and when the irradiation target position of the initial scan reaches the vicinity of the position indicated by the amount of Y deflection (step 303 ), an inspection by the initial scan is started (step 304 ). When irradiation conditions such as the passage of irradiation interval and arrival at the irradiation target position are met and a scan is performed (step 305 ), the irradiation interval and amount of Y deflection fluctuate depending on both various factors such as stage speed fluctuations and adjustments of the irradiation interval and amount of Y deflection. Irradiation conditions such as the next amount of Y deflection and irradiation interval are calculated with input values such as the new irradiation interval and amount of Y deflection and the irradiation target position with respect to the deflecting view field (step 306 ). The scanning step 305 and calculation of irradiation conditions are repeated until a scan of any number of lines is completed to end the inspection (step 307 ).
[0122] In addition to monitoring of the amount of Y deflection and irradiation interval, parameters for adjusting the amount of Y deflection and irradiation interval need to be optimized for each scan condition and thus, an adjustment interface is needed. The stage speed, amount of Y deflection, and irradiation interval are displayed in a processing condition setting instruction part 59 on the interface 6 or another screen for monitoring the amount of Y deflection and irradiation interval. FIG. 9 is an example of a monitoring screen 203 for monitoring the amount of Y deflection and irradiation interval in which the stage speed is displayed in a stage speed change display part 204 , the amount of Y deflection in a Y deflection amount change display part 205 , and the time interval between irradiations in an irradiation interval change display part 206 as graphs of transitions of their respective states. Furthermore, their respective numerical values can be displayed in a speed numeric information display part 207 , a distance numeric information display part 208 and an interval numeric information display part 209 .
[0123] FIG. 10 is an example of a condition instruction screen 210 of the amount of Y deflection and irradiation interval or adjustments of control thereof, and a tracking mode selection part 211 enables or disables the adjustment function of the amount of Y deflection and irradiation interval or makes algorithms, such as a feedback algorithm, for realizing the function, selectable. A setting value input part 212 makes input of parameters corresponding to the tracking mode possible. An automatic setting function start button 213 starts an auxiliary setting function.
[0124] For example, when both the amount of Y deflection and irradiation interval, which are in a trade-off relationship, are adjusted and controlled, it is sometimes difficult to make adjustments for optimizing control of the amount of Y deflection and irradiation interval, and work efficiency of optimization of control parameters can be improved by displaying transitions of both the amount of Y deflection and irradiation interval. The auxiliary start function can be considered, which has optimal parameters automatically determined from the amount of Y deflection and irradiation interval by repeatedly performing a scan with different parameters without actually irradiating with a primary electron beam.
[0125] Thus, it becomes possible to reduce both fluctuations in contrast of detected images and distortion of images and to improve detection throughput by applying the deflection control method properly in accordance with apparatus conditions, inspection targets, and purposes. | The present invention has a subject to provide an apparatus that optimizes scanning in accordance with circumstances or purposes, reduces distortion of images, and improves throughput, image quality, and defect detection rate by controlling deflection of a charged particle beam in a stage tracking system. To solve this subject, an apparatus according to the present invention is an inspection apparatus for detecting abnormal conditions of an inspection target by irradiating the inspection target with the charged particle beam and detecting generated secondary electrons, including both a stage that moves continuously with the inspection target placed thereon and a deflection control circuit for providing a deflector with a scanning signal that causes the charged particle beam to scan repeatedly in a direction substantially perpendicular to a stage movement axis direction while the charged particle beam being deflected in the stage movement axis direction in accordance with a change in movement speed of the stage during movement of the stage. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates, in general, to a sit-up exerciser facilitating the bowel movement of a user and exercising the waist. More particularly, the present invention relates to a sit-up exerciser having a secondary purpose of promoting a bowel movement, in which two pivot plates correspondingly pivot, a waist support plate is disposed between the pivot plates to prevent the waist from slipping, and the pivoting angle of the pivot plates can be easily adjusted, so that a person who needs to exercise his or her waist can easily exercise it while having his/her bowel movement facilitated in order to promote the health. In addition, the pivoting angle of the pivot plates can be easily adjusted to control the intensity of the exercise, the pivoting speed of the pivot plates can be adjusted to be fast or slow, the temperature of the pivot plates can be adjusted from room temperature up to 70° C. so that the temperature of the surface of the pivot plates can be controlled, and the operating time can be adjusted so that the user can do the exercise that he or she has a preference for.
2. Description of the Related Art
In general, modern people who are leading complicated and busy lives suffer from stress of a variety of different sources. There is a tendency for an increasing number of office workers to exercise in health clubs in order to alleviate such stress. In the case of alleviating the stress by exercising, it is known that quiet exercise is more effective than energetic exercise at doing this. Also in the case of the quiet exercise, it is preferable that the user perform the exercise, for example, while he/she is reading a book on his/her back.
In addition, all forces of the human body come from the waist and it has been reported that about 95% of diseases originate in the waist, which is closely related to the five viscera and the six entrails. Therefore, the waist may be regarded as the most important part of the human body.
However, sporting goods that are currently used in most health clubs are mainly designed to exercise muscles, and thus the health club is not a place that is preferable for a person who needs to exercise his/her waist.
In addition, even if a waist exerciser is provided, such a waist exerciser is configured such that a pivot plate pivots only to the right and left. The waist exerciser is not equipped with any functions for heating the pivot plate or for adjusting the pivoting angle or the pivoting speed of the plate. Consequently, the effect of the exercise is not significant.
SUMMARY OF THE INVENTION
Accordingly, the present invention has been made keeping in mind the above problems occurring in the related art, and the present invention is intended to propose a sit-up exerciser having a secondary purpose of promoting a bowel movement, in which a user can effectively exercise the waist while saving time, since he/she can exercise the waist while he/she is conveniently taking a nap or reading a book while lying on the back or stomach. The user can exercise while performing a warm fomentation by selecting the temperature that is most suitable to increasing the efficiency of the exercise and alleviating stress, since the temperature of the pivot plates can be set to in several different stages. In addition, the user can efficiently perform exercise by setting a speed suitable to him/her, since the pivoting speed of the pivot plates can be set to several stages. Furthermore, the exerciser enables the user to set the pivoting angle of the pivot plates to any one of three stages so that the user can more efficiently exercise, thereby providing the optimal waist exercising effect to the user.
In order to achieve the above object, according to one aspect of the present invention, there is provided a sit-up exerciser having a secondary purpose of promoting a bowel movement, including an exerciser body inside which first and second pivot shafts are pivotally fixed; a first drive motor disposed adjacent to the second pivot shaft inside the exerciser body, the first drive motor having a rotary plate attached thereto; a first pivot lever, in which one end of the first pivot lever is fixed to the rotary plate of the first drive motor, and the other end of the first pivot lever is fixed to a first pivot arm, in which the first pivot arm is fixed to the first pivot shaft and extends horizontally therefrom; a first pivot arm fixed to the first pivot shaft, in which one end of the first pivot lever is fixed to one end of the first pivot arm, and a second drive motor is disposed on the other end of the first pivot arm; a second pivot arm, in which the second pivot arm is disposed on an upper portion of the first pivot arm of the first pivot shaft and extends horizontally therefrom; a second pivot lever, in which one end of the second pivot lever is fixed to the second pivot arm and the other end of the second pivot lever is fixed on the second pivot shaft by being hinged to a third pivot arm, the third pivot arm horizontally extending from the second pivot shaft; pivot plates disposed on the first and second pivot shafts, respectively, in which each of the pivot plates has a heating mattress therein; a waist support disposed between the pivot plates, in which the waist support is vertically movable by a third drive motor; and a control unit, in which the control unit controls a temperature of the heating mattress and a pivoting speed, a pivoting time and a pivoting angle of the pivot plates.
According to the sit-up exerciser having a secondary purpose of promoting a bowel movement of the present invention, the first and second pivot shafts are pivotally fixed inside the exerciser body. The first drive motor is disposed adjacent to the second pivot shaft inside the exerciser body, the first drive motor having the rotary plate attached thereto. One end of the first pivot lever is fixed to the rotary plate of the first drive motor, and the other end of the first pivot lever is fixed to the first pivot arm. The first pivot arm is fixed to the first pivot shaft and extends horizontally therefrom. The first pivot arm is fixed to the first pivot shaft. One end of the first pivot lever is fixed to one end of the first pivot arm, and the second drive motor is disposed on the other end of the first pivot arm. The second pivot arm is disposed on the upper portion of the first pivot arm of the first pivot shaft and extends horizontally therefrom. One end of the second pivot lever is fixed to the second pivot arm and the other end of the second pivot lever is fixed on the second pivot shaft by being hinged to the third pivot arm. The third pivot arm extends horizontally from the second pivot shaft. The pivot plates are disposed on the first and second pivot shafts, respectively. Each of the pivot plates has the heating mattress therein. The waist support is disposed between the pivot plates, and is vertically movable by the third drive motor. The control unit controls the temperature of the heating mattress and the pivoting speed, the pivoting time and the pivoting angle of the pivot plates. Accordingly, the user can effectively exercise the waist while saving time, since he/she can exercise the waist while he/she is conveniently taking a nap or reading a book while lying on the back or stomach. The user can do exercise while performing a warm fomentation by selecting the temperature that is most suitable to increasing the efficiency of the exercise and alleviating stress, since the temperature of the pivot plates can be set to several different stages. In addition, the user can efficiently perform exercise by selecting the speed suitable to him/her, since the pivoting speed of the pivot plates can be set to several stages. Furthermore, the exerciser enables the user to set the pivoting angle of the pivot plates to any one of three stages so that the user can more efficiently exercise, thereby providing the user with the optimal waist exercise effect.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and further advantages of the present invention will be more clearly understood from the following detailed description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 a perspective view showing a sit-up exerciser having a secondary purpose of promoting a bowel movement according to a first embodiment of the present invention;
FIG. 2A and FIG. 2B are front elevation and top-plan views schematically showing the drive unit disposed inside the sit-up exerciser having a secondary purpose of promoting a bowel movement according to the first embodiment of the present invention;
FIG. 3 is a top-plan view showing the first pivot arm for adjusting the angle to which the pivot plates pivot; and
FIG. 4 is a block diagram showing the control unit of the sit-up exerciser having a secondary purpose of promoting a bowel movement according to the first embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in greater detail to a preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings. Wherever possible, the same reference numerals will be used throughout the drawings and the description to refer to the same or like parts.
As shown in FIG. 1 to FIG. 3 , a sit-up exerciser having a secondary purpose of promoting a bowel movement according to a first embodiment of the present invention includes an exerciser body 1 inside which first and second pivot shafts 11 and 12 are pivotally fixed. A first drive motor 2 is disposed adjacent to the second pivot shaft 12 inside the exerciser body 1 , and has a rotary plate 21 attached thereto. One end of a first pivot lever 3 is fixed to the rotary plate 21 of the first drive motor 2 via a pivot bearing, and the other end of the first pivot level 3 is fixed to a first pivot arm 4 that is fixed to the first pivot shaft 11 and extends horizontally. The first pivot arm 4 is fixed to the first pivot shaft 11 , in which one end of the first pivot lever 3 is fixed to one end of the first pivot arm 4 , and a second drive motor 40 is disposed on the other end of the first pivot arm 4 . A second pivot arm 5 is disposed on the upper portion of the first pivot arm 4 of the first pivot shaft 11 , and extends horizontally. One end of a second pivot lever 7 is fixed to the second pivot arm 5 , and the other end of the second pivot lever 7 is fixed on the second pivot shaft 12 by being hinged to a third pivot arm 6 , which extends horizontally from the second pivot shaft 12 . Pivot plates 8 are disposed on the first and second pivot shafts 11 and 12 , respectively, and each of the pivot plates 8 has a heating mattress therein. A control unit 9 is configured to control the temperature of the heating mattresses of the pivot plates 8 , as well as the pivoting speed, pivoting time, and pivoting angle of the pivot plates 8 . The first pivot arm 4 and the first pivot lever 3 are connected and hingeably fixed to each other such that they pivot with respect to each other. The same connection is provided between the second pivot arm 5 and the second pivot lever 7 and between the third pivot arm 6 and the second pivot lever 7 .
A waist support 10 is disposed between the pivot plates 8 such that it supports the lumbar of the waist of the user. The waist support 10 serves to support the waist while the body is being exercised in upward and downward directions, and has a third drive motor 101 in the lower end thereof such that the waist can be moved up and down as the waist is being exercised in the vertical direction.
The drive unit of this waist support has a third drive motor 101 disposed in the upper portion of the inside of the body of the exerciser, the third drive motor 101 being vertically mounted on the central portion of the underside of the waist support to provide power so that the waist support 10 can move up and down. In order to prevent the load on the waist due to excessive rise of the waist, a limit switch (not shown) is provided. The limit switch can control the operation of the waist support 10 when it rises to a predetermined height or higher.
A sensor plate 22 , which can detect the number of rotations of the rotary plate 21 , is fixed to a periphery of the rotary plate 21 of the first drive motor 2 . An encoder 23 , which is disposed adjacent to the rotary plate 21 , detects the number of rotations of the rotary plate 21 while it is rotating.
One end of the first pivot lever 3 is joined and fixed to the rotary plate 21 via the pivot bearing, and the other end of the first pivot lever 3 is coupled and fixed to a fixing plate 43 of the first pivot arm 4 .
The second drive motor 40 is disposed on one end of the first pivot arm 4 , and one end of the first pivot lever 3 is fixedly hinged to the other end of the first pivot arm 4 . The first pivot arm 4 has a fixing recess 42 inside the body 41 of the first pivot arm 4 , and the fixing plate 43 is slidably disposed inside the fixing recess 42 such that it operates to slide inside the fixing recess 42 . One end of the first pivot lever 3 is fixed on the fixing plate 43 , and can slide inside the fixing recess 42 to adjust the pivoting angle of the first pivot shaft 11 . That is, a carrier screw 44 , which is rotated by the second drive motor 40 , is disposed inside the fixing plate 43 such that the fixing plate 43 can be carried inside the fixing recess 42 .
One end of the second pivot arm 5 is fixed to the upper portion of the first pivot shaft 11 , and the second pivot lever 7 is mounted on the other end of the second pivot arm 5 .
One end of the third pivot arm 6 is fixed to the second pivot shaft 12 , and the other end of the third pivot arm 6 is fixed to the second pivot lever 7 .
The pivot plates 8 include fixed plates 81 , which are fixed to the first and second pivot shafts 11 and 12 , respectively. Cushions 82 and heating mattresses 83 are disposed on the fixing plates 81 . Two handles 84 are provided on one of the pivot plates 8 , extending in the direction parallel to the exerciser body 1 , and one handle 85 is provided on the same pivot plate 8 , extending in the direction perpendicular to the exerciser body 1 , such that the user can perform exercise in various postures. A head support 86 is provided on the handle 85 that extends in the perpendicular direction. The head support 86 has a cushion member so that the user can exercise in a comfortable posture.
The control section 9 includes a control Integrated Circuit (IC) 91 , a first drive motor control section 92 , a second drive motor control section 93 , a third drive motor control section 94 , a heating mattress control section 95 and a wired-wireless control section 96 .
A description will be given below of the operation and effects of the sit-up exerciser having a secondary purpose of promoting a bowel movement according to the present invention having the above-described configuration.
When the user intends to use the sit-up exerciser having a secondary purpose of promoting a bowel movement A according to the first embodiment of the present invention, he/she lies first on the pivot plates 8 on the upper portion of the exerciser. In this state, the switch is turned on, and the pivoting speed of the pivot plates 8 is set to three-stage mode. When the pivot plates 8 are set to the three-stage mode, they pivot about 8 times, with the number of rotations of the first drive motor 2 being about 1000 rpm. For reference, the pivot plates 8 pivot 6 times (about 800 rpm) in the first stage, and 12 times (about 14000 rpm) in the seventh stage.
The operating time of the pivot plate 8 is selected from 20, 30, 40, 50 and 60 minutes. In this embodiment, the pivot plate 8 is operated by selecting 20 minutes.
When the temperature of the pivot plate 8 is set to a temperature of about 40° C., the heating mattresses 83 are heated to a temperature of about 40° C. In the state of the heating mattress 83 having been heated to a temperature of about 40° C., the user can enjoy being cozy while he/she is exercising. The heating temperature of the pivot plate 8 can be set from one of 20° C., 30° C., 40° C., 50° C., 60° C. and 70° C.
Regarding the adjustment of the pivoting angle of the pivot plate 8 , the carriage screw 44 rotates following the rotation of the second drive motor 4 . This consequently operates the fixing plate 43 coupled thereto to move away from or closer to the first pivot shaft 11 , thereby determining the pivoting angle of the pivot plates 8 . In this embodiment, when the pivot plate 8 is set to the middle stage mode, it pivots to about 30°. The pivoting angles to which the pivot plate 8 is set include three stages, i.e., weak, middle and strong. In the weak mode, the pivot plate 8 pivots to 13° about the center line, i.e. over the range of 26°. In the middle mode, the pivot plate 8 pivots to 15° about the center line, i.e. over the range of 30°. In the strong mode, the pivot plate 8 pivots to 18° about the center line, i.e. over the range of 36°. The pivoting angle of the pivot plate 8 increases as the pivot plate 8 moves away from the first pivot shaft 11 , but decreases as the pivot plate 8 moves closer to the first pivot shaft 11 .
In the sit-up exerciser having a secondary purpose of promoting a bowel movement A according to an embodiment of the present invention, the user may exercise in the posture in which he/she is facing up, with both hands folded on shoulders. In this state, when the pivot plate 8 pivots, the ligament and the cartilage of the user are aligned so that fat is removed from the sides. This posture can be regarded as assuming a posture that is amenable to removing the fat in the sides. The waist and its surrounding parts are exercised, thereby having the effects of preventing or alleviating a herniated intervertebral disc and removing the fat from the external oblique muscles of the hip joints.
In addition, when the user performs exercise to pivot the pivot plates 8 while lying on the side, the arms are raised up and down to stimulate the function of the bowels and the thoracic vertebrae, thereby removing stress and promoting digestive functions. In this case, the abdomen and the back are exercised, thereby strengthening the bowels and the heart. The physiological angle of the spine can be adjusted to retain the healthy shape of the spine.
In addition, an exercise that the user performs on his/her stomach by pivoting the pivot plates 8 is an exercise that is suitable to overcoming fatigue. This exercise can also adjust the function of the bowels by alleviating the stress of the abdomen, and effectively influences the kidneys, genitalia, liver and stomach. When exercising to the right and left, if it is inconvenient to bend to the right, it can be easily diagnosed that the spleen or male genitalia are malfunctioning. If it is inconvenient to bend to the left, it is easy to make the diagnosis that the kidney or ureter is malfunctioning or that there is bleeding. Such a posture provides effects in that the abnormal lateral curvature of the spine is corrected and that the bowels and the heart are strengthened.
When the user uses the exerciser having the foregoing functions, he/she can start to exercise after selecting the speed, angle, temperature and operating time according to his/her preference by using the wired/wireless control section. A memory function is provided such that it enables a movement to be repeated based on a specification selected by a user, provides a basic three-pattern menu by determining the level of an exercise, which matches the standard specifications of an average person according to respective motion variables (speed, angle, temperature and time), and strong and weak levels based on the level of the exercise, and allows the levels to be adjusted according to the items of the menu.
The sit-up exerciser having a secondary purpose of promoting a bowel movement of the present invention is an article that can be repeatedly fabricated by a common fabrication plant, and therefore the present invention has industrial applicability.
Although the exemplary embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | A sit-up exerciser having a secondary purpose of promoting a bowel movement. Two pivot plates correspondingly pivot, a waist support plate is disposed between the pivot plates to prevent the waist from slipping, and the pivoting angle of the pivot plates can be easily adjusted, so that a person who needs to exercise his or her waist can easily exercise it while having his/her bowel movement facilitated in order to promote the health. The pivoting angle of the pivot plates can be easily adjusted to control the intensity of the exercise, the pivoting speed of the pivot plates can be adjusted to be fast or slow, the temperature of the pivot plates can be adjusted from room temperature up to 70° C. so that the temperature of the surface of the pivot plates can be controlled, and the operating time can be adjusted depending on user's preference. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a hand-held power tool, in particular electrical power tool, including a housing and an identification element which, e.g., can be formed separately from the housing, is provided with an appropriate identification mark, and is mountable on the housing so that it becomes visible on the outer side of the housing from outside. The present invention also relates to a method of manufacturing such a tool, in particular, the identification element.
[0003] 2. Description of the Prior Art
[0004] In the hand-held power tools of the type discussed above, certain data such as, e.g., mark, indication of the type of the power tool, or serial number of the power tool are clearly visible on the apparatus housing. In particular, with a separate manufacturing of the indication element from the remaining of the housing and a subsequent at least partial handling of the indication element, a particularly elegant execution of the indication is possible.
[0005] German Utility model DE 20 2004 020 518 U1 discloses a hand-held power tool with lettering being provided on a separate part of the power tool housing. During the manufacturing of the power tool housing, this separate part is placed in the housing mold and becomes surrounded with the plastic material the housing is made of when the remaining portion of the housing is injection-molded. The lettering is formed of another material than the housing of the power tool.
[0006] With the known approach, the lettering can be produced from a particularly scratch-resistant material in order to retain a clear impression over the service life of the power tool.
[0007] The drawback of the known power tool consists in that the power tool housing already includes the lettering upon being produced and, therefore, is suitable only for a corresponding type of power tools. However, in particular, during manufacturing of a series of power tools with different types of power tools which, however, have the same housing, it makes sense when the housing is suitable, after its production, for all of the power tool types of the series. In this case, the housings can be produced and stored for all of the power tool types and only later be distributed between separate types of the power too, as needed.
[0008] Accordingly, an object of the present invention is to provide a power tool in which the drawbacks of the known power tool are eliminated, and a simple lettering or label is provided that can be used firstly, after the housing has been produced.
SUMMARY OF THE INVENTION
[0009] This and other objects of the present invention, which will become apparent hereinafter, are achieved by forming the identification element as a tag that is pushed into a correspondingly dimensioned receptacle formed in the housing.
[0010] According to the present invention, the housing has, after being produced, a predetermined position for the indication element. The proper indication mark of the housing and its mounting can be effected later, e.g., during the end assembly of the power tool. In addition, the subsequently insertable, in the receptacle, indication element provides for its separate handling and an easy affixing of the indication mark.
[0011] According to a particularly advantageous embodiment of the present invention, the indication element can be secured in the receptacle by a third element of the power tool. This enables a simple, cost-effective and long-lasting fixation of the indication element in the power tool housing.
[0012] Advantageously, the securing element has a locking region, and the identification element has a formlocking element that abuttingly engages the locking region of the securing element in a direction opposite the direction in which the identification element is pushed into the receptacle, when the indication element is positioned in the receptacle. Thereby, in a simple way, a stable and precisely positioned fixation of the indication element relative to the power tool housing is insured.
[0013] Advantageously, the third tool element is formed by an air guide which is produced separately from the housing and then inserted in the housing. At that, e.g., an elastic locking region can be formed on the air guide in a particularly simple manner and which the formlocking element of the identification element can engage. Alternatively, it can be provided that the air guide is inserted into the housing only after the positioning of the indication element therein, with the locking region being so formed that upon insertion of the air guide, it engages the formlocking element from behind, blocking the displacement of the indication element relative to the receptacle.
[0014] Advantageously, the indication mark is arranged in a recess formed in the indication element. Thereby, the indication mark is protected from scratches, in particular when the power tool is laid down.
[0015] Advantageously, the receptacle is provided in a recess formed in the housing. Thereby, double-walling, which requires additional constructional space and a greater material consumption is prevented.
[0016] It is particularly advantageous when both the identification element and the receptacle taper in the direction in which the identification element is pushed into the receptacle. This insures an exact positioning of the indication element when it is pushed in the receptacle.
[0017] Advantageously, the hand-held power tool includes two identification elements of the type discussed above which are provided on two sides of the power tool housing.
[0018] The method of manufacturing such a hand-held power tool includes forming a power tool housing provided on two of its sides thereof with two receptacles, respectively, forming two identification elements dimensioned in accordance with respective dimensions of the two receptacles, as parts of a single cast element, providing the two identification elements with respective identification marks in a single printing process, separating the two identification elements and inserting the two identification elements in the respective receptacles. The foregoing method provides for a particular cost-effective manufacturing of the indication elements and of applying indication marking thereon.
[0019] The novel features of the present invention, which are considered as characteristic for the invention, are set forth in the appended claims. The invention itself, however, both as to its construction and its mode of operation, together with additional advantages and objects thereof, will be best understood from the following detailed description of preferred embodiment, when read with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The drawings show:
[0021] FIG. 1 a side view of a hand-held power tool according to the present invention;
[0022] FIG. 2 a side view of motor housing part of the hand-held power tool shown in FIG. 1 , with the identification element being pulled out;
[0023] FIG. 3 a cross-sectional view along line III-III in FIG. 2 ; and
[0024] FIG. 4 a side view of a cast element with two identification elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] An electrical hand-held power tool 2 according to the present invention, which is shown in FIG. 1 and is formed as a hammer drill, includes a multi-part housing 4 and a motor 6 for driving the power tool 2 and located in a motor housing part 8 . The motor 6 is cooled by an aeration device 10 which is located at the upper end of the motor housing part 8 .
[0026] As shown in FIG. 1 , a tag-shaped first identification element 14 . 1 is secured on a first side S 1 of the motor housing part 8 . On the first identification element 14 . 1 , a first identification mark 16 . 1 is provided. The first identification mark 16 . 1 can contain letters or figures, marking, a pictogram, here, e.g., indicated with XXX, or a mixed form. The first identification mark 16 . 1 is formed on the first identification element as a print or embossing, or by other means bonded to the first identification element 14 . 1 .
[0027] FIGS. 2-3 show the motor housing part 8 separately and before installation of the first identification element 14 . 1 . As can be seen in FIG. 3 , a second, likewise tag-shaped, identification element 14 . 2 is provided on a second side S 2 of the housing 4 opposite the first side S 1 . The second identification element carries a second identification 16 . 2 that corresponds to the first identification mark 16 . 1 . Both identifications 16 . 1 , 16 . 2 are located in respective recesses 18 . 1 , 18 . 2 formed in the corresponding identifications 14 . 1 , 14 . 2 , and are visible from outside of the housing 4 .
[0028] As further shown in FIGS. 2-3 , a receptacle 20 . 1 , 20 . 2 is provided on each side S 1 , S 2 . The receptacle 20 . 1 , 20 . 2 is formed by a respective recess 22 . 1 , 22 . 2 in the housing 4 , which is limited by opposite guides 24 . The guides 24 serve for receiving complementary counter-guides 26 provided on the identification elements 14 . 1 , 14 . 2 . The guides 24 and counter-guides 26 can form, as shown, groove and spring connections.
[0029] As particularly shown in FIG. 3 , a rib-shaped formlocking element 28 is provided on each of the identification elements 14 . 1 , 14 . 2 . When the identification elements 14 . 1 , 14 . 2 are pushed in a displacement direction E, the formlocking elements 28 are pressed against respective locking regions 30 of respective third housing elements 32 ( FIG. 2 ). In the embodiment shown in the drawings, the locking regions are formed by an elastic bar lock 34 , and the housing element 32 is formed by an air guide that is inserted in the motor housing 8 at its upper end 12 , with the bar lock 34 extending therefrom (see FIG. 2 ).
[0030] As soon as the end position of the first identification element 14 . 1 , which is shown in FIG. 1 , or, correspondingly, the end position of the second identification element 14 . 2 is reached, the bar lock 34 snaps behind the formlocking element 28 which, thus, abuts the bar lock 34 in a direction opposite the displacement direction E. Thereby, the identification elements 14 . 1 , 14 . 2 are secured in the housing 4 in their inserted position.
[0031] Alternatively, it is possible to form the locking region 30 by a rigid region of the third housing element 32 . For securing the identification elements 14 . 1 , 14 . 2 in the housing 4 , they are pushed into the receptacles 20 . 1 , 20 . 2 , and only then the third housing element is placed in the housing 4 in order to provide a formlocking connection between the locking region 30 and the formlocking element 28 and which would act in a direction opposite the displacement direction E of the identification elements 14 . 1 and 14 . 2 .
[0032] In each case, both the identification elements 14 . 1 , 14 . 2 and the receptacle 20 . 1 , 20 . 2 taper in the displacement direction in order to achieve a precise positioning during insertion of the identification elements 14 . 1 , 14 . 2 .
[0033] As shown in FIG. 4 , both identification elements 14 . 1 , 14 . 2 , which are received in the receptacle 20 . 1 , 20 . 2 of the power tool 2 , are formed by parts of a single cast element 36 that is produced separately from a conventional housing 4 . After the identification elements 14 . 1 , 14 . 2 have been formed, the identification marks 16 . 1 , 16 . 2 are placed on the single-piece cast piece 36 . Only a single common printing process is necessary for placing the identification marks on the identification elements 14 . 1 , 14 . 2 . Only then, the two identification elements 14 . 1 , 14 . 2 are separated from each other for securing them in the housing 4 during the final assembly in accordance with the above-described procedure.
[0034] Though the present invention was shown and described with references to the preferred embodiment, such is merely illustrative of the present invention and is not to be construed as a limitation thereof and various modifications of the present invention will be apparent to those skilled in the art. It is, therefore, not intended that the present invention be limited to the disclosed embodiment or details thereof, and the present invention includes all variations and/or alternative embodiments within the spirit and scope of the present invention as defined by the appended claims. | A hand-held power tool includes a housing ( 4 ), and a tag-shaped identification element ( 14.1; 14.2 ) mountable on the housing ( 4 ) so that it becomes visible on an outer side of the housing ( 4 ), provided with an identification mark ( 16.1; 16.2 ), insertable in a receptacle ( 20.1; 20.2 ) provided on the housing. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to security schemes used in communication system and more particularly to an improvement to a security scheme for the authentication of a portion of a mobile known as User Subscription Identity Modules.
2. Description of the Related Art
The security of information conveyed over communication systems is a main source of concern for service providers. Subscribers of communication systems many times transmit and receive very sensitive and private information intended for specific parties. Service providers want to give their subscribers a certain degree of confidence in the security capabilities of the communication system. Consequently, different security schemes have been developed and are being used in current communication systems. One security scheme, used particularly in third generation wireless communication systems, is referred to as the Authentication and Key Agreement (AKA) procedure. The AKA procedure is a security scheme that not only authenticates a subscriber and generates security keys, but it also validates received subscriber information to ensure that such information was not improperly modified at some point in the communication system prior to the reception of such information. Third generation wireless communication systems digital voice and relatively high speed data; these communication systems typically convey information in accordance with standards established by standards organizations such as the American National Standards Institute (ANSI) or the European Telecommunications Standards Institute (ETSI).
Referring now to FIG. 1 , there is shown a portion of a wireless communication system. Communication link 102 couples Home Location Register (HLR) 100 to a base station 104 that is part of a Serving Network (SN). The SN is a communication system or part of a communication system that is providing services to subscribers. Base station 104 communicates with subscribers (e.g., mobile 108 ) via wireless communication link 106 . For ease of illustration, only one base station of the SN is shown and also only one mobile is shown. HLR 100 is part of system equipment (owned and operated by the service provider) that performs mobility management for the communication system. Mobility management is the proper handling of subscriber traffic and the calculation of various parameters associated with the AKA procedure. For example, a mobility manager detects the initiation of call by a subscriber and also knows the subscriber's location and which base station is serving such a subscriber. The mobility manager can then inform the base station serving the subscriber making the call as to which base station the call is to be delivered.
HLR 100 contains subscriber specific data records including identification and authentication information for mobiles of all subscribers of the communication system. Base station 104 contains, inter alia, typical radio equipment for transmitting and receiving communication signals and other equipment for processing subscriber and system information. For example, base station 104 contains a Visitors Location Register (VLR) (not shown) which receives security related information from the HLR and derives additional security related information which is then transmitted to the proper mobile. The VLR also receives security related information from mobiles which it processes to authenticate communication between mobiles and the base station. The process of authentication is described herein in the discussion of the AKA procedure. Mobile 108 represents typical subscriber communication equipment (e.g., cell phone, wireless laptop pc) that transmits and receives system information and subscriber information to and from the base station. The system information is information that is generated system equipment to operate the communication system.
Mobile 108 has a User Subscription Identity Module (USIM) portion that is interfaced to the rest of the mobile equipment. The interface between the USIM and the mobile is standardized so that any USIM built in accordance with an interface standard can be used with any mobile equipment which is also configured in accordance with the same interface standard. Typically, the USIM is attached to the mobile as a storage device containing an ID number and other mobile identification data unique to a particular subscriber. Thus, part of the information stored in the HLR is also stored in the USIM. The USIM is capable of communicating with the rest of the mobile equipment commonly referred to as the shell or the mobile shell. Many publicly accessible mobiles (e.g., taxi cell phones) can be used by a subscriber inserting a USIM (also known as a “smart card”) into the mobile. The information stored in the USIM is transferred to the mobile shell allowing the mobile to gain access to the communication system. Another type of arrangement between a USIM and a mobile shell is to integrate the USIM into the circuitry of the mobile shell. A mobile with an integrated USIM is typically owned by an individual subscriber and the communication system uses the information stored in a mobile's USIM to identify and confirm that the mobile has properly obtained access to the SN.
When a mobile wishes to gain access to a communication system, it must first be recognized as an authorized user of the communication system and then it executes an AKA procedure with the system equipment. As a result of the AKA procedure, the mobile's USIM generates two keys: (1) an Integrity Key (IK) used to compute digital signatures of information exchanged between the mobile and the base station. The digital signature computed with the IK is used to validate information integrity. The digital signature is a certain pattern which results when the proper IK is applied to any received information. The IK allows the authentication of information exchanged between the base station and the mobile; that is, the IK is applied to received information resulting in the generation of a digital signature indicating that the received information was not modified (intentionally or unintentionally) in any manner; (2) a ciphering key (CK) is used to encrypt information being transmitted over communication link 106 between base station 104 and mobile 108 . Encryption of information with the ciphering key ensures privacy.
Both the IK and the CK are secret keys established between the base station and the mobile to establish a valid security association. A valid security association refers to a set of identical data patterns (e.g., IK, CK) independently generated by a USIM (coupled to a mobile) and a serving network indicating that the USIM is authorized to have access to the SN and the information received by the mobile from the SN is from an authorized and legitimate SN. A valid security association indicates that a mobile (i.e., the mobile's USIM) has authenticated itself to the SN and the SN has been authenticated by the mobile (i.e., the mobile's USIM). When the IK and CK—independently generated by the serving network and the mobile's USIM—are not identical, the security association is not valid. The determination of whether IK and CK computed at the SN are identical to the IK and CK computed at a USIM of a mobile is discussed infra. The USIM transfers the IK and CK to the mobile shell which uses them as described above. The IK and CK at the network are actually computed by the HLR. The HLR sends various information to the VLR and the mobile during an AKA procedure and generates, inter alia, the IK and CK, which it forwards to the VLR.
In a current standard (3GPP TSG 33.102) for third generation wireless communication systems, an authentication security scheme that uses an AKA procedure has been established. The information needed to execute the AKA procedure is contained in a block of information (stored in the HLR) called the Authentication Vector (AV). The AV is a block of information containing several parameters, namely: RAND, XRES, IK, CK and AUTN. Except for the AUTN and RAND parameters, each of the parameters is generated by the application of an algorithmic non-reversible function ƒ n to RAND and a secret key, K i . An algorithmic non-reversible function is a specific set of steps that mathematically manipulates and processes information such that the original information cannot be regenerated with the resulting processed information. There is actually a group of non-reversible algorithmic functions which are used to generate various parameters used in the AKA procedure; the various parameters and their associated functions are discussed infra. K i is a secret key associated with subscriber i (where i is an integer equal to 1 or greater) and which is stored in the HLR and in subscriber i's USIM. RAND is a random number uniquely specific to each AV and is selected by the HLR. XRES is the Expected Mobile Station Response computed by the USIM of a mobile by applying a non-reversible algorithmic function to RAND and K i . IK is computed by the USIM and the HLR also by the application of a non-reversible algorithmic function to RAND and K i . CK is also computed by both the USIM and the HLR by applying a non-reversible algorithmic function to RAND and K i .
AUTN is an authentication token which is a block of information sent to the VLR by the HLR for authenticating the SN to the mobile. In other words, the AUTN contains various parameters some of which are processed by the USIM of the mobile to confirm that the AUTN was indeed transmitted by a legitimate base station of the SN. AUTN contains the following parameters: AK⊕SQN, AMF and MAC. AK is an Anonymity Key used for concealing the value of SQN which is a unique sequence vector that identifies the AV. AK is computed by applying a non-reversible algorithmic function to RAND and K i . SQN, i.e., the Sequence Number, is independently generated by the USIM and the HLR in synchronized fashion. AMF is the Authentication Management Field whose specific values identify different commands sent from the HLR to the USIM. The AMF can be thought of as an in-band control channel. MAC, i.e., the Message Authentication Code, represents the signature of a message sent between the base station and the mobile which indicates that the message contains correct information; that is, the MAC serves to verify the content of messages exchanged between a mobile and the SN. For example, MAC=ƒ n (RAND, AMF, SQN, K i ) which is a signature of correct values of SQN and AMF computed with the use of non-reversible algorithmic function using a secret key K i and randomized by RAND.
For ease of explanation only, the AKA procedure will now be described in the context of a communication system part of which is shown in FIG. 1 . The communication system shown in FIG. 1 complies with the 3GPP TSG33.102 standard. Initially, the AV is transferred from HLR 100 to the VLR at base station 104 (or to a VLR coupled to base station 104 ). In accordance with the standard, the VLR derives XRES from the received AV. The VLR also derives AUTN and RAND from the received AV and transfers them to mobile 108 via communication link 106 . Mobile 108 receives AUTN and RAND and transfers the RAND and AUTN to its USIM. The USIM validates the received AUTN as follows: The USIM uses the stored secret key (K i ) and RAND to compute the AK, and then uncovers the SQN. The USIM uncovers the SQN by exclusive OR-ing the received AK⊕ SQN with the computed value of AK j ; the result is the uncovered or deciphered SQN. Then the USIM computes the MAC and compares it to the MAC received as a part of the AUTN. If MAC checks, (ie. received MAC=computed MAC) the USIM verifies that the SQN is in a valid acceptable range (as defined by the standard), in which case the USIM considers this attempt at authentication to be a valid one. The USIM uses the stored secret key (K i ) and RAND to compute RES, CK and IK. The RES is a Mobile Station Response. The USIM then transfers IK, CK and RES to the mobile shell and causes the mobile to transmit (via communication link 106 ) RES to base station 104 . RES is received by base station 104 which transfers it to the VLR. The VLR compares RES to XRES and if they are equal to each other, the VLR also derives the CK and IK keys from the Authentication Vector. Because of the equality of XRES to REST the keys computed by the mobile are equal to the keys computed by the HLR and delivered to the VLR.
At this point, a security association exists between base station 104 and mobile 108 . Mobile 108 and base station 104 encrypt information conveyed over link 106 with key CK. Mobile 108 and base station 104 use key IK to authenticate information exchanged between them over communication link 106 . Further, mobile 108 and base station 104 use IK to authenticate the subscriber/SN link established for mobile 108 . The communication system uses the IK for authentication; that is, a proper value of IK from the mobile during communications implies that the mobile has properly gained access to the communication system and has been authorized by the communication system to use the resources (i.e., system equipment including communication links, available channels and also services provided by the SN) of the communication system (i.e., the SN). Thus, IK is used to authenticate the mobile to the SN. The use of IK to authenticate the mobile to the SN is called local authentication. Since base station 104 and mobile 108 already have a valid IK, it is simpler to use this valid IK instead of having to generate a new one requiring exchange of information between base station 104 and HLR 100 (i.e., intersystem traffic) that usually occurs when establishing a security association. In other words, once a subscriber gains access to a system and the subscriber's mobile has been authenticated, the IK and CK generated from the authentication process are used for information exchanged between the user's mobile and the base station and for authenticating the subscriber/SN link without having to re-compute an IK for each subsequent new session. Mobile shells, which comply with the standard established for the AKA procedure, will delete the IK and CK established from the authentication process once their USIM are detached. However, there are many rogue mobiles (unauthorized mobiles that manage to obtain access to a communication system) that do not comply with the requirements of the standard established for the AKA procedure. These rogue mobiles maintain the use of the IK and CK keys even when the USIM has been detached from them. Because of the use of the local authentication technique used in the currently established AKA procedure, the rogue mobiles are able to fraudulently use the resources of a communication system.
The following scenario describes one possible way in which a rogue mobile (e.g., a Taxi phone) can make fraudulent use of a communication system that uses the currently established AKA procedure. A subscriber inserts his or her USIM card into a Taxi phone to make a call. Once the mobile is authenticated as described above, the subscriber can make one or more calls. When all the calls are completed, the subscriber removes the USIM card from the Taxi phone. If the Taxi phone is in compliance with the standard, the phone will delete the CK and IK of the subscriber. However, if the Taxi phone is a rogue phone, it will not delete the CK and IK keys of the subscriber. Unbeknownst to the subscriber, the rogue phone is still authenticated (using local authentication based on IK) even when the subscriber has removed the USIM card. Thus, fraudulent calls can then be made on the rogue phone until the security association is renewed. Depending on the service provider, the security association can last for as long as 24 hours.
What is therefore needed is an improvement to the currently established AKA procedure that will eliminate the fraudulent use of a subscriber's authentication keys by a rogue mobile.
SUMMARY OF THE INVENTION
The present invention provides a method for an improved AKA procedure that prevents rogue mobiles from improperly and fraudulently use the resources of a communication system. Upon the establishment of a security association between a mobile and its base station, the method of the present invention allows the communication system to periodically challenge the authenticity of a mobile. The challenge may be a global challenge to all mobiles being served by the base station or the challenge can be a unique challenge to a specific mobile being served by the base station.
Regardless of the type of challenge presented by the base station, the mobile's USIM is able to compute an authentication response based on information available only to the mobile's USIM and the base station's VLR. The authentication response computed by the mobile's USIM is passed on to the mobile shell which transmits the authentication response to the base station. The received authentication response is then transferred to the base station's VLR which compares it to an authentication response independently computed by the VLR. The mobile is deemed authenticated when the VLR's authentication response is equal to the authentication response received from the mobile shell. In this manner, a security association resulting from the execution of an AKA procedure can be periodically validated with negligible impact on an already established AKA procedure. More importantly, the periodic authentication of a security association prevents rogue mobiles from fraudulently making use of the system resources. The method of the present invention also comprises the aperiodic or continuous or continual challenge of the authenticity of a mobile.
The method of the present invention performs the following steps:
An Authentication Vector (AV) is transmitted by the HLR to the VLR of the base station. The AV contains several parameters used in the execution of the AKA procedure including AK, and SQN. Whereas heretofore, AK was exclusive ORed (i.e., the operation denoted by “⊕”) with SQN to protect SQN when it is transmitted over a publicly accessible communication link between the base station and the mobile, AK and SQN are now received by the VLR without being exclusive ORed to each other. Alternatively, the AK can be included in the Authentication Vector in addition to the value represented by an exclusive OR of the AK and the SQN. Thus, the VLR knows the value of AK. As in the prior art, the VLR transmits to the mobile the concealed SQN exclusive ORed with the AK as a portion of the AV called the AUTN to initiate the AKA procedure. A random number (RAND) generated by the VLR which is needed to initiate the AKA procedure is also transmitted by the VLR to the mobile. The AUTN is transferred from the mobile shell to the mobile's USIM. The USIM computes AK but does not transfer it to the mobile shell. The AKA procedure is executed resulting in a security association established between the mobile and the base station.
Upon the next access request, or any request by a mobile or the base station to make use of the communication system resources, a local authentication challenge is performed between the base station and the mobile. The local authentication challenge can also be performed during a session wherein the mobile is making use of the resources of the communication system. Specifically, the base station transmits a challenge interrogation message to the mobile requesting that the mobile authenticate itself to the base station. The challenge interrogation message can be a unique message intended for a particular mobile or it can be a global message requesting all mobiles being served by the base station to authenticate themselves to the base station. In response, the mobile's USIM computes a local authentication response (AUTH L ). AUTH L is computed by applying a non-reversible algorithmic function ƒ n to AK, IK and a RANDU or RAND G parameter. The RANDU parameter (i.e., RANDom Unique number) is used when the challenge interrogation message is intended for a specific mobile. The RAND G parameter is used when the challenge is transmitted globally to all mobiles being served by the base station. The RANDU or the RAND G parameter is transmitted by the VLR as part of the challenge interrogation message. Upon transmission of the challenge interrogation message to a mobile, the VLR of the base station independently computes AUTH L also using IK, AK and RANDU or RAND G .
The mobile transmits AUTH L to the base station in response to the challenge interrogation message. The AUTH L from the mobile is received by the base station and is transferred to the base station's VLR which compares the received AUTH L to the AUTH L it has computed independently. If the two AUTH L 's are equal, the mobile's USIM is said to be authenticated rendering the security association valid. If the two AUTH L 's are not equal, the security association is deemed invalid and the method of the present invention prevents the mobile from having access to the resources of the communication system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a portion of a wireless communication system;
FIG. 2 shows the steps of the method of the present invention.
DETAILED DESCRIPTION
Referring to FIG. 2 , there is shown the steps of the method of the present invention which will now be described in the context of FIG. 1 . The method of the present invention applies to the AKA scheme defined by the 3GPP TSG 3.102 standard and to other standards that use an AKA scheme. For example, the method applies to various communication systems whose architectures are defined by the ANSI-41 standard. Such communication systems include but are not limited to Wide band CDMA systems (W-CDMA), TDMA (Time Division Multiple Access) systems, UMTS (Universal Mobile Telecommunications System) and third generation GSM (Global System for Mobile communications) systems defined by ETSI. In step 200 , the AKA procedure is initiated; this procedure is initiated either when a mobile (e.g., 108 ) wants access to the service network or the service network has received a call for mobile 108 and wants to set up a call between the mobile and another party. In any event, in step 200 , HLR 100 transmits an AV signal over system link 102 to Base Station 104 . A VLR (not shown) at base station 104 receives the AV over communication link 102 which is not accessible to any subscribers of the communication system. The AV, which normally contains several parameters including AK⊕ SQN, is now sent with a clear value for AK. Unlike in the prior art where the base station receives the AV containing a ciphered combination of SQN and AK (i.e., AK⊕ SQN), the method of the present invention allows the VLR to know the individual value of AK by allowing the HLR to transfer AK to the base station (i.e., the VLR) in the clear. In other words, AK is no longer exclusive ORed with SQN as required by the current AKA procedure. Alternatively, AK⊕ SQN and AK can both be sent to the VLR from the HLR. Thus, once the VLR at base station 104 receives the AV from HLR 100 , the VLR stores the value of AK.
The AV, which in addition to other parameters contains SQN, AK, MAC and AMF, is received by the base station's VLR which masks the SQN with the AK thus assembling the ciphered value of the SQN. This ciphered SQN is transmitted by the base station as part of the AUTN signal along with a RAND signal to mobile 108 . In particular, the VLR ciphers the SQN (i.e., performs AK⊕ SQN) thus disguising the AK, completes assembly of the AUTN, and transmits the authentication request as an AUTN signal along with a RAND signal to mobile 108 . Mobile 108 transfers the received AUTN along with the RAND signal to its USIM for validation and generation of security parameters which define the establishment of a security association.
In step 202 , the parameters IK and CK are generated by the USIM as in the prior art. In particular, the USIM generates RES from f 2 (RAND, K i ); note that f 2 is also used in generating XRES. The USIM generates IK from the computation f 3 (RAND, K i ), generates CK from the computation f 4 (RAND, K i ) and AK from the computation f 5 (RAND, K i ). It will be readily understood that the set of non-reversible algorithmic functions used to compute the parameters is chosen as per the communication standard being followed by the communication system. The particular non-reversible algorithmic functions used to describe the computation of certain parameters, however, may or may not be consistent with the dictates of the standard. Further, the USIM computes the expected value of the MAC (using the f 1 function) and compares it to the value received in the AUTN. If the MAC is valid, the USIM deciphers individual values of AK and SQN and verifies that the SQN value is in an acceptable range. Also, in step 202 , the VLR receives the IK, CK and XRES from the HLR where these parameters were computed in the same manner as the USIM. The USIM transfers RES, CK, and IK to the shell of mobile 108 . Mobile 108 transmits RES to the base station 104 which transfers it to its VLR.
In step 204 , the VLR compares the received RES to the calculated XRES and if RES=XRES then the CK and IK at the VLR are the same as the CK and IK at the mobile and USIM. A valid security association has now been established and confirmed for the Subscriber/SN link (i.e., link 106 ) for a certain duration of a session. The authenticity of the mobile is thus established meaning that the mobile has properly gained access to the SN by obtaining the proper authorization from the SN to user the resources of the SN. The session refers to the length of time elapsed during the authentication process, access given to the subscriber, and the subscriber making use of the resources. For example, a session can be the time elapsed during a telephone call encompassing the time it takes to set up the call as per the standard being followed by the communication system, the time it takes for the system to give the subscriber access to the communication system and the amount of time used by the subscriber in making use of the resources of the communication system by engaging in communications (e.g., voice call) with another party.
In step 206 , at some time during the session, the VLR at base station 104 will challenge the authenticity of the established security association by broadcasting a challenge interrogation message. In particular, whether mobile 108 has obtained authorization from the system to transmit and receive information to and from base station 104 via communication link 106 is being challenged; that is, the authorization for the subscriber/serving network link (i.e., information exchanged over communication link 106 ) is being challenged. The challenge interrogation message can be a global challenge in which case the message is broadcast to all the mobiles being served by the base station. Alternatively, the challenge interrogation message can be a unique message intended for a specific mobile being served by the base station. The challenge interrogation message is transmitted by the VLR periodically, aperiodically, continually or continuously during a session. The challenge interrogation messaged can also be transmitted at the beginning of each session after a security association has been established. The challenge interrogation message is the initiation of a local authentication between mobile 108 and the SN. The challenge interrogation message contains a random number (i.e., RANDG for a global challenge or RANDU for a unique challenge) which is generated by the VLR at base station 104 . The particular format of the challenge interrogation message depends on the format defined the standard with which the communication system complies. Mobile 108 receives the random number and transfers said number to its USIM. The USIM applies a non-reversible algorithmic function to the IK, AK parameters and the random number (i.e., RAND G or RANDU) to compute a local authentication response called AUTH L . In particular, for a global challenge AUTH L =ƒ n (RAND G , AK) IK and for a unique challenge AUTH L =ƒ n (RANDU, AK) IK . The non-reversible algorithmic function used to compute AUTH L can be any one from the group of function (f, where n is an integer equal to 1 or greater) defined by the standard being followed by the communication system. The VLR at base station 104 independently computes AUTH L in the same manner. Because AK is known only to the VLR and the USIM, the AUTH L cannot be computed by a rogue phone since such a phone does not have access to AK; thus the local authentication is performed on information (i.e., AK) known only to the SN and the mobile's USIM. The authentication response (AUTH L ) computed by the USIM is transferred to the mobile shell which transmits it (e.g., by attaching it to messages transmitted to the base station) to base station 104 . Base station 104 transfers the received AUTH L to the VLR which compares it to its independently computed AUTH L .
In an alternative embodiment of the method of the present invention, the USIM of mobile 108 transfers AUTH L to the shell of mobile 108 . The mobile shell computes a parameter called a MAC-I using IK and AUTH L . The mobile shell then transmits MAC-I to the base station which transfers MAC-I to the VLR. The VLR, which independently computes its own MAC-I (also using IK and AUTH L ), and compares it to the received MAC-I. Thus, MAC-I is used for the dual purposes of local authentication and to validate content of information exchanged between the mobile and the SN. By using MAC-I, there is no need to attach AUTH L to messages.
In step 208 , the session and the mobile (i.e., the mobile's USIM) are authenticated if the two AUTH L 's (or MAC-I's) are equal; that is, when the AUTH L (or MAC-I) computed by the VLR is equal to the AUTH L (or MAC-I) received from mobile 108 and computed by the mobile's USIM. The VLR thus confirms the authenticity of an already established link (i.e., SN/Subscriber link established) between mobile 108 and base station 104 or allows a link to be established; that is, the method of the present invention has now moved back to step 204 . The mobile is given access to the resources of the communication system, or in the case of an already established link, the mobile continues to have access to the resources of the communication system. If the VLR cannot authenticate the SN/Subscriber link (i.e., received AUTH L or MAC-I is not equal to AUTH L or MAC-I calculated by VLR), the method of the present invention moves to step 210 wherein the mobile is prevented from having access to the SN; that is, the link is dropped and the CK and IK associated with the link are no longer accepted by the SN (i.e., base station 104 ). The security association is no longer valid and the mobile is not given access to the resources of the communication system. Therefore, a rogue mobile, which has no USIM is not able to authenticate itself to the communication system and thus is not able to fraudulently make use of the resources of the communication system. | A method for improving an established Authentication and Key Agreement procedure which prevents rogue mobiles from fraudulently gaining access to a communication system. The communication system periodically broadcasts a challenge interrogation message requesting that a mobile, which is currently validated to use the system, to authenticate itself to the system. The mobile computes an authentication response based on information known only to the communication system and the USIM of the mobile and transmits said response to the communication system. The communication system also computes an authentication response and compares said response with that received from the mobile. A mobile is authenticated by the communication system when the two authentication responses are equal. Otherwise, the mobile is not given access to the communication system. | 7 |
CROSS REFERENCES TO THE RELATED APPLICATION
[0001] The present application is a Continuation of U.S. application Ser. No. 12/177,866 filed Jul. 22, 2008, which is a Continuation of U.S. Ser. No. 11/944,633 filed on Nov. 25, 2007, now issued as U.S. Pat. No. 7,467,861, which is a Continuation of U.S. Ser. No. 11/014,751 filed on Dec. 20, 2004, now issued as U.S. Pat. No. 7,303,268 which is a Continuation-In-Part application of U.S. Ser. No. 10/760,254 filed on Jan. 21, 2004, now issued as U.S. Pat. No. 7,448,734, all of which are herein incorporated by reference. In the interests of brevity, the disclosure of the parent application is incorporated in its entirety into the present specification by cross reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a high speed print engine for an inkjet printer unit, and more particularly to an ink refill unit suitable for refilling the print engine with ink.
CO-PENDING APPLICATIONS
[0003] The following applications have been filed by the Applicant with the parent application:
[0000]
7,152,972
7,543,808
7,621,620
7,669,961
7,331,663
7,360,861
7,328,973
7,427,121
7,407,262
7,303,252
7,249,822
7,537,309
7,311,382
7,360,860
7,364,257
7,390,075
7,350,896
7,429,096
7,384,135
7,331,660
7,416,287
7,488,052
7,322,684
7,322,685
7,311,381
7,270,405
7,470,007
7,399,072
7,393,076
7,681,967
7,588,301
7,249,833
7,524,016
7,490,927
7,331,661
7,524,043
7,300,140
7,357,492
7,357,493
7,566,106
7,380,902
7,284,816
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7,328,984
7,350,913
7,322,671
7,380,910
7,431,424
7,470,006
7,585,054
7,347,534
7,306,320
7,377,635
7,686,446
11/014,730
[0004] The disclosures of these co-pending applications are incorporated herein by reference.
CROSS REFERENCES
[0005] The following patents or patent applications filed by the applicant or assignee of the present invention are hereby incorporated by cross-reference.
[0000]
7,364,256
7,258,417
7,293,853
7,328,968
7,270,395
7,461,916
7,510,264
7,334,864
7,255,419
7,284,819
7,229,148
7,258,416
7,273,263
7,270,393
6,984,017
7,347,526
7,465,015
7,364,255
7,357,476
11/003,614
7,284,820
7,341,328
7,246,875
7,322,669
6,623,101
6,406,129
6,505,916
6,457,809
6,550,895
6,457,812
7,152,962
6,428,133
7,204,941
7,282,164
7,465,342
7,278,727
7,417,141
7,452,989
7,367,665
7,138,391
7,153,956
7,423,145
7,456,277
7,550,585
7,122,076
7,148,345
7,416,280
7,252,366
7,488,051
7,360,865
7,275,811
7,591,539
7,628,468
7,334,874
7,393,083
7,475,965
7,578,582
7,328,975
10/922,887
7,472,984
10/922,874
7,234,795
7,401,884
7,360,871
7,293,855
7,410,250
7,401,900
7,527,357
7,410,243
7,165,834
10/922,877
6,746,105
7,156,508
7,159,972
7,083,271
7,438,385
7,080,894
7,201,469
7,090,336
7,156,489
7,413,283
7,416,274
7,083,257
7,258,422
7,255,423
7,219,980
7,591,533
7,198,354
7,367,649
7,118,192
7,618,121
7,322,672
7,077,505
7,152,959
7,077,504
7,614,724
7,198,355
7,401,894
7,322,676
7,246,886
7,213,906
7,178,901
7,222,938
7,108,353
7,104,629
7,575,298
7,128,400
7,108,355
6,991,322
7,287,836
7,118,197
7,524,034
7,364,269
7,077,493
6,962,402
7,686,429
7,147,308
7,195,342
7,118,198
7,168,790
7,172,270
7,229,155
6,830,318
7,134,744
7,175,261
7,465,035
7,108,356
7,118,202
7,510,269
7,134,745
7,510,270
7,134,743
7,182,439
7,210,768
7,465,036
7,079,712
7,156,484
7,118,201
7,111,926
7,431,433
09/575,197
6,980,318
6,825,945
7,330,974
6,813,039
6,987,506
7,038,797
7,173,722
6,816,274
7,102,772
7,350,236
6,681,045
6,728,000
6,789,191
7,088,459
7,707,082
7,068,382
7,062,651
6,789,194
6,987,573
6,644,642
6,502,614
6,622,999
6,669,385
6,549,935
7,064,851
6,727,996
6,591,884
6,439,706
6,760,119
7,295,332
6,741,871
6,826,547
6,290,349
6,428,155
6,785,016
6,831,682
6,977,746
6,927,871
6,980,306
6,965,439
6,840,606
7,036,918
7,663,780
6,970,264
7,068,389
7,093,991
7,190,491
7,511,847
10/974,742
10/962,412
7,177,054
7,364,282
10/965,733
10/965,933
7,055,739
7,538,793
6,982,798
6,870,966
6,822,639
6,737,591
7,106,888
7,233,320
6,830,196
6,832,717
6,957,768
7,170,499
7,121,639
7,123,239
7,152,942
10/727,162
7,377,608
7,399,043
7,302,592
7,165,824
7,188,282
10/727,157
7,181,572
7,096,137
10/727,192
7,278,034
7,707,621
7,592,829
10/727,180
10/727,179
10/754,536
10/727,274
7,154,638
7,523,111
7,573,301
7,660,998
6,795,215
10/754,938
6,622,923
10/727,160
6,859,289
7,369,270
6,398,332
7,070,098
7,374,266
6,805,419
6,921,144
6,977,751
7,092,112
6,394,573
10/854,509
6,747,760
7,448,707
10/884,881
10/854,503
7,192,106
10/854,511
7,427,117
7,093,989
7,281,330
7,600,843
7,328,956
7,252,353
7,188,928
10/854,525
7,377,609
7,549,715
10/854,498
7,314,261
7,390,071
7,267,417
10/854,526
7,517,036
7,275,805
10/854,527
7,607,757
7,281,777
10/854,505
7,484,831
10/854,523
10/854,499
7,549,718
10/854,520
7,290,852
7,557,941
7,243,193
10/934,628
10/854,501
7,266,661
7,631,190
10/854,518
BACKGROUND OF THE INVENTION
[0006] Traditionally, most commercially available inkjet printers have a print engine which forms part of the overall structure and design of the printer. In this regard, the body of the printer unit is typically constructed to accommodate the print head and associated media delivery mechanisms, and these features are integral with the printer unit.
[0007] This is especially the case with inkjet printers that employ a printhead that traverses back and forth across the media as the media is progressed through the printer unit in small iterations. In such cases the reciprocating printhead is typically mounted to the body of the printer unit such that it can traverse the width of the printer unit between a media input roller and a media output roller, with the media input and output rollers forming part of the structure of the printer unit. With such a printer unit it may be possible to remove the printhead for replacement, however the other parts of the print engine, such as the media transport rollers, control circuitry and maintenance stations, are typically fixed within the printer unit and replacement of these parts is not possible without replacement of the entire printer unit.
[0008] As well as being rather fixed in their design construction, printer units employing reciprocating type printheads are considerably slow, particularly when performing print jobs of full colour and/or photo quality. This is due to the fact that the printhead must continually traverse the stationary media to deposit the ink on the surface of the media and it may take a number of swathes of the printhead to deposit one line of the image.
[0009] Recently, it has been possible to provide a printhead that extends the entire width of the print media so that the printhead can remain stationary as the media is transported past the printhead. Such systems greatly increase the speed at which printing can occur as the printhead no longer needs to perform a number of swathes to deposit a line of an image, but rather the printhead can deposit the ink on the media as it moves past at high speeds. Such printheads have made it possible to perform full colour 1600 dpi printing at speeds in the vicinity of 60 pages per minute, speeds previously unattainable with conventional inkjet printers.
[0010] Such a pagewidth printhead typically requires high precision and high speed paper movement and as such the entire print engine (printhead, paper handling mechanisms and control circuitry etc) must be configured accordingly to ensure high quality output.
[0011] Accordingly, there is a need to provide a print engine having a pagewidth printhead that can be readily employed within a standard body of a printer unit and is constructed in a manner that ensures that all the necessary parts of the print engine are configured in a manner that enables consistent, high speed printing.
SUMMARY OF THE INVENTION
[0012] In a first aspect the present invention provides a printing fluid dispenser for a printing fluid refill cartridge comprising:
a body storing printing fluid having an outlet through which the printing fluid is dispensed; and a selector arranged to select the amount of the printing fluid to be dispensed from the body.
[0015] Optionally the amount of the printing fluid selected by the selector is an amount selected from a set of discrete amounts of the printing fluid.
[0016] Optionally the set of discrete amounts comprises amounts at about 6 ml intervals in a range of from 6 ml to 50 ml.
[0017] Optionally the selector is arranged to selectively change the storage capacity of the body so as to dispense the selected amount of the stored printing fluid.
[0018] Optionally there is provided a dispenser, wherein:
the selector comprises a series of grooves and a retaining member selectively engageable with each of the grooves; and each selectively engageable position of the retaining member with the grooves provides a different amount of change of the storage capacity of the body.
[0021] Optionally the series of grooves are arranged in a row along a surface of the selector and the retaining member is pivotable with respect to the grooves, said relative pivoting providing the selective engagement of the retaining member with the grooves.
[0022] Optionally the series of grooves are arranged in a substantially circular loop and are rotatable with respect to the retaining member and the body, said relative rotation providing the selective engagement of the retaining member with the grooves.
[0023] Optionally the retaining member is pivotable with respect to the grooves so as to engage and disengage therefrom, the grooves being able to rotate when the retaining member is disengaged and being prevented from rotating when the retaining member is engaged.
[0024] Optionally the selector comprises:
a plunger arranged to seal with an open end of the body opposite the outlet and to plunge into the interior of the body; an urging member arranged about the plunger so as to urge the plunger into the body; a rotatable shaft having the substantially circular loop of grooves about one end and a grooved thread about the other end; and a linking member attached to the grooved thread at one end and to the plunger at the other end so as to be windable into the grooved thread and about the shaft, the urging member causing the rotation of the shaft and thereby the grooves via the linking member when the retaining member is disengaged with the grooves.
[0029] In a further aspect there is provided a dispenser further comprising a plunger having a toothed helical thread which engages with a screw thread provided in an internal wall of the body, wherein:
the selector comprises a drive gear associated with a driving device; and rotation of the drive gear is imparted to the toothed thread so as to rotate the plunger within the screw thread of the body thereby changing the storage capacity of the body.
[0032] Optionally the body incorporates a collapsible reservoir storing the printing fluid and having the outlet at one end thereof.
[0033] In a further aspect there is provided a dispenser, further comprising an aperture removably engageable with an inlet of a printing fluid storage chamber of a printing unit.
[0034] In a further aspect there is provided a dispenser, further comprising means to determine an amount of printing fluid needed to substantially refill the printing fluid storage chamber, wherein the amount of printing fluid to be dispensed is selected by the selector to correspond to the determined amount.
[0035] Optionally the aperture comprises a syringe needle arranged to penetrate a valve seal of the chamber inlet so as to dispense the stored printing fluid therethrough.
[0036] In a further aspect there is provided a dispenser, further comprising a securing arrangement for removably securing the aperture with the chamber inlet.
[0037] Optionally the securing arrangement incorporates at least one first engagement member arranged to be removably engageable with at least one second engagement member of the printing unit.
[0038] Optionally the second engagement member is a slot and the first engagement member is a movable protrusion engageable with the slot.
[0039] Optionally the securing arrangement further incorporates a movable region of a wall of the body which is arranged with the first engagement member, whereby movement of the movable region provides engagement and disengagement of the first and second engagement members.
[0040] Optionally the movable region incorporates a depressible region of the body wall.
[0041] Optionally the printing unit is a printer cartridge which is mountable to a printer and incorporates a printhead.
[0042] Optionally a controller of the printer cartridge is arranged to control the selector so as to select the amount of the printing fluid to be dispensed, the selected amount being sufficient for refilling the printing fluid storage chamber.
[0043] Optionally the printing fluid is ink or ink fixative.
[0044] Optionally the printhead incorporates a pagewidth printhead arranged to print printing fluid across the width of sheets of print media.
[0045] Optionally the printhead incorporates a pagewidth printhead arranged as a two-dimensional array of at least 50,000 printing nozzles for printing across the width of sheets of print media.
[0046] Optionally the printhead incorporates an array of printing fluid ejecting nozzles configured as a pagewidth printhead arranged to print on sheets of print media by ejecting at least 1200 drops of printing fluid per inch across the width of the sheets.
[0047] Optionally the printhead incorporates an array of printing fluid ejecting nozzles configured as a pagewidth printhead arranged to print on sheets of print media by ejecting drops of printing fluid across the width of the sheets with a drop ejection energy of less than about 250 nanojoules per drop.
[0048] Optionally the printhead incorporates a pagewidth printhead arranged to print printing fluid across the width of sheets of print media at a rate of at least 60 sheets per minute.
[0049] Optionally the printhead incorporates an array of printing fluid ejecting nozzles configured as a pagewidth printhead arranged to print on sheets of print media by ejecting drops of printing fluid across the width of the sheets at a rate of at least 500 million drops per second.
[0050] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use in an inkjet printer comprising:
a media input tray for supplying print media for printing; a print engine for printing an image on said print media; and a media output tray for collecting the printed media; wherein the print engine comprises a removable inkjet cartridge of a type having a pagewidth printhead and an ink supply and a cradle having a body adapted to receive the removable inkjet cartridge and to control the operation of the printhead for printing.
[0055] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with a print engine comprising:
a removable inkjet cartridge of a type having a pagewidth printhead and an ink supply; and a cradle having a body adapted to receive the removable inkjet cartridge and to control the operation of the printhead for printing; wherein the cradle is configured to be secured to the inkjet printer to receive print media from a media input tray and to deliver printed media to a media output tray.
[0059] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge unit comprising:
a body portion having one or more ink storage compartments; and a pagewidth printhead assembly mountable to said body and configured to receive ink from the one or more compartments and to distribute the ink along the length of the printhead assembly.
[0062] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge unit comprising:
a body portion having one or more ink storage compartments; a pagewidth printhead assembly mountable to said body portion and configured to receive ink from the one or more compartments for printing; and a capper unit mountable to said body portion so as to extend along the length of the printhead assembly, the capper unit housing a capping element which is movable with respect to the capper unit to contact a surface of the printhead assembly.
[0066] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge unit comprising:
a body portion housing one or more ink storage compartments; a pagewidth printhead assembly configured to receive ink from the one or more ink storage compartments and having a plurality of nozzles arranged in use to deliver the ink onto passing print media; and an electrical connector in electrical communication with the nozzles of the printhead assembly and disposed along the length of the printhead assembly for mating with a corresponding connectors of the inkjet printer to control operation of the nozzles.
[0070] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge unit comprising:
a body portion having a plurality of ink storage compartments; and a pagewidth printhead assembly configured to receive ink from ink storage compartments and distribute said ink to a plurality of nozzles arranged in use to deliver the ink onto passing print media; wherein the ink storage compartments comprise an absorption material which stores the ink therein under capillary action for supply to the nozzles of the printhead assembly.
[0074] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge having a pagewidth printhead assembly comprising:
a body portion for receiving ink from one or more ink sources and distributing the ink along the length of the printhead assembly; a plurality of integrated circuits extending the length of the printhead assembly, each integrated circuit having a plurality of nozzles formed in rows thereon, each of the nozzles being arranged in use to deliver the ink onto passing print media; and an ink distribution member upon which the integrated circuits are fixed and which distributes the ink from the body portion to the nozzles of the integrated circuits; wherein the integrated circuits are aligned in an abutting arrangement across the length of the ink distribution member.
[0079] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge having a pagewidth printhead assembly comprising:
a body portion for receiving ink from one or more ink sources and distributing the ink along the length of the printhead assembly; one or more integrated circuits extending substantially the length of the printhead assembly, the or each integrated circuit having a plurality of nozzles formed thereon, each of the nozzles being arranged in use to deliver the ink onto passing print media; an ink distribution member upon which the or each integrated circuit are fixed and which distributes the ink from the body portion to the nozzles of the or each integrated circuit; wherein the body portion has one or more connectors formed thereon for securing the printhead assembly to the one or more ink sources to facilitate ink flow therebetween.
[0084] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge having a pagewidth printhead assembly comprising:
a body portion for receiving ink from one or more ink sources and distributing the ink along the length of the printhead assembly; one or more integrated circuits extending substantially the length of the printhead assembly, the or each integrated circuit having a plurality of nozzles formed thereon, each of the nozzles being arranged in use to deliver the ink onto passing print media; and an ink distribution member upon which the or each integrated circuit is fixed and which distributes the ink from the body portion to the nozzles of the or each integrated circuit; wherein an electrical connector in electrical communication with the or each integrated circuit extends along the length of the printhead assembly for mating with a corresponding electrical connector of the inkjet printer.
[0089] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge having a pagewidth printhead assembly comprising:
a body portion for receiving ink from one or more ink sources and having one or more channels formed therein for distributing the ink substantially along the length of the printhead assembly; one or more integrated circuits extending substantially the length of the printhead assembly, the or each integrated circuit having a plurality of nozzles, each of the nozzles being arranged in use to deliver the ink onto passing print media; and an ink distribution member upon which the or each integrated circuit is fixed and which distributes the ink from the body portion to each of the integrated circuits; wherein the ink distribution member is a unitary element having a plurality of conduits formed therethrough, each of the conduits having an inlet which receives ink from one of the channels of the body portion and an outlet which delivers the ink to a predetermined number of nozzles of the one or more integrated circuits.
[0094] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge having a pagewidth printhead assembly comprising:
a body portion for receiving ink from one or more ink sources and having one or more channels formed therein for distributing the ink substantially along the length of the printhead assembly; one or more integrated circuits extending substantially the length of the printhead assembly, each integrated circuit having a plurality of nozzles, each of the nozzles being arranged in use to deliver the ink onto passing print media; and an ink distribution member upon which each integrated circuit is fixed and which distributes the ink from the body portion to each of the integrated circuits; wherein the ink distribution member comprises a first layer which directs the ink from the one or more channels of the body portion for delivery to each integrated circuit, and a second layer attached to said first layer for receiving and securing each integrated circuit in a position to receive the ink from the first layer.
[0099] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge having a pagewidth printhead adapted for capping by a capping assembly comprising:
a body configured to extend the length of the printhead; and a capping element housed within said body and movable with respect to the body to cap at least a portion of said printhead; wherein, the body includes a mounting element for removably mounting said capping assembly to said printhead.
[0103] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge having a pagewidth printhead adapted for capping by a capping assembly comprising:
a body configured to extend the length of the printhead; and a capping element housed within said body, said capping element having a rim portion adapted to cap at least a portion of said printhead; wherein, the capping element is movable with respect to said body between a first and a second position, said first position being where said rim portion extends from said body, and said second position being where said rim portion is contained within said body.
[0107] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge having a pagewidth printhead adapted for capping by a capping assembly comprising:
a body configured to extend the length of the printhead; and a capping element housed within said body and movable with respect to said body between a first and a second position, said first position being where a portion of the capping element extends from said body, and said second position being where said capping element is contained within said body; wherein, the capping element is biased into said first position.
[0111] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge having a pagewidth printhead adapted for capping by a capping assembly comprising:
a body configured to extend the length of the printhead; a capping element housed within said body and having a rim portion adapted to cap at least a portion of the printhead; a displacement assembly housed within the body for moving the capping element between a first position where the rim portion of the capping element extends from said body, and a second position where the rim portion of the capping element is contained within the body; wherein, the displacement assembly is controlled by an electromagnet which determines the position.
[0116] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge adapted for use with a cradle unit comprising:
a body complementary to a removable inkjet cartridge of a type having a pagewidth printhead and an ink supply; and a controller for controlling the operation of the printhead to facilitate printing; wherein, a plurality of terminals are located along the length of the body to contact corresponding terminals located along the length of the removable inkjet cartridge to enable electrical communication between the controller and the cartridge.
[0120] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge adapted for use with a cradle unit comprising:
a body complementary to a removable inkjet cartridge of a type having a pagewidth printhead and an ink supply; a controller for controlling the operation of the printhead to facilitate printing; and a plurality of terminals in electrical communication with said controller for transmitting control signals from said controller to corresponding terminals provided on said cartridge; wherein said plurality of terminals are arranged to pivotally engage with said corresponding terminals provided on said cartridge when said cartridge is received by said body.
[0125] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge adapted for use with a cradle unit comprising:
a body complementary to a removable inkjet cartridge of a type having a pagewidth printhead and a refillable ink supply; and a controller for controlling the operation of the printhead to facilitate printing; wherein, said body includes a cover assembly for enclosing the removable inkjet cartridge within the body, said cover assembly having at least one port formed therein through which a refill unit is received for refilling the ink supply of the cartridge.
[0129] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge adapted for use with a cradle unit comprising:
a body complementary to a removable inkjet cartridge of a type having a pagewidth printhead and a refillable ink supply; and a controller for controlling the operation of the printhead to facilitate printing; wherein, said body is configured to receive a refill unit for supplying refill ink to the cartridge and includes a refill actuator for dispensing ink from said refill unit into said refillable ink supply.
[0133] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with an inkjet cartridge adapted for use with a cradle unit comprising:
a body complementary to a removable inkjet cartridge of a type having a pagewidth printhead, an ink supply and a capper assembly; and a controller for controlling the operation of the printhead to facilitate printing; wherein, said body includes an electromagnet assembly mounted thereto which is controlled by said controller for operating said capper assembly of the removable inkjet cartridge.
[0137] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with a removable inkjet cartridge of a type having a pagewidth printhead and an ink supply, the removable cartridge being arranged for use with a cradle unit having a body complementary to the removable cartridge and a controller for controlling the operation of the printhead to facilitate printing, the cradle unit being adapted for covering by a cover assembly comprising at least one port formed therein through which a refill unit is received for refilling the ink supply of the cartridge.
[0138] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with a removable inkjet cartridge of a type having a pagewidth printhead and an ink supply, the removable cartridge being arranged for use with a cradle unit having a body complementary to the removable cartridge and a controller for controlling the operation of the printhead to facilitate printing, the cradle unit being adapted for covering by a cover assembly comprising a refill actuator for dispensing ink from an ink refill unit into said refillable ink supply.
[0139] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with a removable inkjet cartridge unit of a type having a pagewidth printhead assembly in fluid communication with one or more ink storage compartments, the removable cartridge unit being arranged for priming by an ink priming system comprising:
a priming inlet provided on said printhead assembly for receiving a supply of ink for priming the cartridge unit; and an ink flow passage providing fluid connection between said printhead assembly and one of the ink storage compartments; wherein the ink supplied to the priming inlet of the printhead assembly flows from the printhead assembly to the ink storage compartment via the ink flow passage to prime both the printhead assembly and the ink storage compartment with ink simultaneously.
[0143] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for use with a removable inkjet cartridge unit of a type having a pagewidth printhead assembly in fluid communication with one or more ink storage compartments, the removable cartridge unit being arranged for priming by an ink priming system comprising:
a priming inlet provided on said printhead assembly for receiving a supply of ink for priming the cartridge unit; an ink flow passage providing fluid connection between said printhead assembly and one of the ink storage compartments; and a bypass flow passage providing additional fluid connection between the ink flow passage and the ink storage compartment; wherein the ink supplied to the priming inlet of the printhead assembly flows from the printhead assembly to the ink storage compartment via the ink flow passage and the bypass flow passage to prime both the printhead assembly and the ink storage compartment with ink simultaneously.
[0148] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for refilling a printing unit with supply of printing fluid, the method of refilling comprising the steps of:
removably mounting a dispenser of printing fluid to the printing unit so as to align an outlet of the dispenser with an inlet of a printing fluid storage chamber of the printing unit; determining an amount of printing fluid needed to substantially refill the printing fluid storage chamber; and selectively dispensing an amount of printing fluid from the dispenser corresponding to the determined amount.
[0152] In a further aspect there is provided a printing fluid dispenser, the printing fluid refill cartridge having a dispensing assembly comprising:
a body for storing printing fluid having an outlet through which the printing fluid is dispensed; and a plunger arranged to selectively change the storage capacity of the body and expel the printing fluid through said outlet by selective engagement of a movable retaining member with a series of grooves arranged along a surface of the plunger, thereby dispensing a selected amount of printing fluid from the outlet.
[0155] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is a refill unit arranged for use with a print engine and the refilling is controlled by a system comprising:
an information storage element incorporated in the refill unit for storing information on the amount of printing fluid contained in the refill unit; and an information reader incorporated in the print engine for reading the information stored by the storage element when the refill unit is mounted to the print engine and for controlling the refilling of the print engine with the printing fluid contained in the refill unit based on the information read.
[0158] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is a printing fluid refill unit comprising an information storage element for storing information on the amount of printing fluid contained in the refill unit and for connecting with an information reader incorporated in the print engine for reading the information stored by the storage element when the refill unit is mounted to the print engine,
wherein the information stored by the storage element enables the reader to control the refilling of the print engine with the printing fluid contained in the refill unit.
[0160] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for refilling a printing unit, wherein the refilling is controlled by a method comprising the steps of:
storing information on an amount of printing fluid contained in the refill cartridge in an information storage element incorporated therein; mounting the refill cartridge to the printing unit; reading the information on the amount of printing fluid with an information reader incorporated in the printing unit; and controlling the refilling of the printing unit with printing fluid contained in the refill cartridge based on the information read.
[0165] In a further aspect there is provided a printing fluid dispenser, wherein the printing fluid refill cartridge is arranged for refilling an inkjet cartridge associated with a printing fluid storage device comprising a porous body having a plurality of individual channels arranged in an array to store printing fluid and supply the stored printing fluid to at least one printing fluid ejecting nozzle of a printhead of a printer unit,
wherein a first end of each of the channels is in fluid communication with a printing fluid supply to extract printing fluid from the fluid supply for storage therein under capillary action and the stored printing fluid is supplied to the at least one nozzle under capillary action.
[0167] In a further aspect the present invention provides an inkjet printer unit comprising:
a media input tray for supplying print media for printing; a print engine for printing an image on said print media; and a media output tray for collecting the printed media; wherein the print engine comprises a removable inkjet cartridge of a type having a pagewidth printhead and an ink supply and a cradle having a body adapted to receive the removable inkjet cartridge and to control the operation of the printhead for printing.
[0172] In a further aspect the present invention provides a print engine for an inkjet printer comprising:
a removable inkjet cartridge of a type having a pagewidth printhead and an ink supply; and a cradle having a body adapted to receive the removable inkjet cartridge and to control the operation of the printhead for printing; wherein the cradle is configured to be secured to the inkjet printer to receive print media from a media input tray and to deliver printed media to a media output tray.
[0176] In a further aspect the present invention provides a cartridge unit for an inkjet printer comprising:
[0000] a body portion having one or more ink storage compartments; and
a pagewidth printhead assembly mountable to said body and configured to receive ink from the one or more compartments and to distribute the ink along the length of the printhead assembly.
[0177] In a further aspect the present invention provides a cartridge unit for an inkjet printer comprising:
a body portion having one or more ink storage compartments; a pagewidth printhead assembly mountable to said body portion and configured to receive ink from the one or more compartments for printing; and a capper unit mountable to said body portion so as to extend along the length of the printhead assembly, the capper unit housing a capping element which is movable with respect to the capper unit to contact a surface of the printhead assembly.
[0181] In a further aspect the present invention provides a cartridge unit for an inkjet printer comprising:
a body portion housing one or more ink storage compartments; a pagewidth printhead assembly configured to receive ink from the one or more ink storage compartments and having a plurality of nozzles arranged in use to deliver the ink onto passing print media; and an electrical connector in electrical communication with the nozzles of the printhead assembly and disposed along the length of the printhead assembly for mating with a corresponding connectors of the inkjet printer to control operation of the nozzles.
[0185] In a further aspect the present invention provides cartridge unit for an inkjet printer comprising:
a body portion having a plurality of ink storage compartments; and a pagewidth printhead assembly configured to receive ink from ink storage compartments and distribute said ink to a plurality of nozzles arranged in use to deliver the ink onto passing print media; wherein the ink storage compartments comprise an absorption material which stores the ink therein under capillary action for supply to the nozzles of the printhead assembly.
[0189] In a further aspect the present invention provided a pagewidth printhead assembly for an inkjet printer comprising:
a body portion for receiving ink from one or more ink sources and distributing the ink along the length of the printhead assembly; a plurality of integrated circuits extending the length of the printhead assembly, each integrated circuit having a plurality of nozzles formed in rows thereon, each of the nozzles being arranged in use to deliver the ink onto passing print media; and an ink distribution member upon which the integrated circuits are fixed and which distributes the ink from the body portion to the nozzles of the integrated circuits; wherein the integrated circuits are aligned in an abutting arrangement across the length of the ink distribution member.
[0194] In an further aspect the present invention provides a pagewidth printhead assembly for an inkjet printer comprising:
[0000] a body portion for receiving ink from one or more ink sources and distributing the ink along the length of the printhead assembly;
one or more integrated circuits extending substantially the length of the printhead assembly, the or each integrated circuit having a plurality of nozzles formed thereon, each of the nozzles being arranged in use to deliver the ink onto passing print media; and
an ink distribution member upon which the or each integrated circuit are fixed and which distributes the ink from the body portion to the nozzles of the or each integrated circuit;
wherein the body portion has one or more connectors formed thereon for securing the printhead assembly to the one or more ink sources to facilitate ink flow therebetween.
[0195] In a further aspect the present invention provides a pagewidth printhead assembly for an inkjet printer comprising:
[0000] a body portion for receiving ink from one or more ink sources and distributing the ink along the length of the printhead assembly;
one or more integrated circuits extending substantially the length of the printhead assembly, the or each integrated circuit having a plurality of nozzles formed thereon, each of the nozzles being arranged in use to deliver the ink onto passing print media; and
an ink distribution member upon which the or each integrated circuit is fixed and which distributes the ink from the body portion to the nozzles of the or each integrated circuit;
wherein an electrical connector in electrical communication with the or each integrated circuit extends along the length of the printhead assembly for mating with a corresponding electrical connector of the inkjet printer.
[0196] In a further aspect the present invention provides a pagewidth printhead assembly for an inkjet printer comprising:
[0000] a body portion for receiving ink from one or more ink sources and having one or more channels formed therein for distributing the ink substantially along the length of the printhead assembly; one or more integrated circuits extending substantially the length of the printhead assembly, the or each integrated circuit having a plurality of nozzles, each of the nozzles being arranged in use to deliver the ink onto passing print media; and
an ink distribution member upon which the or each integrated circuit is fixed and which distributes the ink from the body portion to each of the integrated circuits;
wherein the ink distribution member is a unitary element having a plurality of conduits formed therethrough, each of the conduits having an inlet which receives ink from one of the channels of the body portion and an outlet which delivers the ink to a predetermined number of nozzles of the one or more integrated circuits.
[0197] In a further aspect the present invention provides a pagewidth printhead assembly for an inkjet printer comprising:
[0000] a body portion for receiving ink from one or more ink sources and having one or more channels formed therein for distributing the ink substantially along the length of the printhead assembly;
one or more integrated circuits extending substantially the length of the printhead assembly, each integrated circuit having a plurality of nozzles, each of the nozzles being arranged in use to deliver the ink onto passing print media; and
an ink distribution member upon which each integrated circuit is fixed and which distributes the ink from the body portion to each of the integrated circuits;
wherein the ink distribution member comprises a first layer which directs the ink from the one or more channels of the body portion for delivery to each integrated circuit, and a second layer attached to said first layer for receiving and securing each integrated circuit in a position to receive the ink from the first layer.
[0198] In a further aspect the present invention provides a capping assembly for capping a pagewidth printhead of an inkjet printer comprising:
[0000] a body configured to extend the length of the printhead; and
a capping element housed within said body and movable with respect to the body to cap at least a portion of said printhead;
wherein, the body includes a mounting element for removably mounting said capping assembly to said printhead.
[0199] In a further aspect the present invention provides a capping assembly for capping a pagewidth printhead of an inkjet printer comprising:
[0000] a body configured to extend the length of the printhead; and
a capping element housed within said body, said capping element having a rim portion adapted to cap at least a portion of said printhead;
wherein, the capping element is movable with respect to said body between a first and a second position, said first position being where said rim portion extends from said body, and said second position being where said rim portion is contained within said body.
[0200] In a further aspect the present invention provides a capping assembly for capping a pagewidth printhead of an inkjet printer comprising:
[0000] a body configured to extend the length of the printhead; and
a capping element housed within said body and movable with respect to said body between a first and a second position, said first position being where a portion of the capping element extends from said body, and said second position being where said capping element is contained within said body;
wherein, the capping element is biased into said first position.
[0201] In a further aspect the present invention provides a capping assembly for capping a pagewidth printhead of an inkjet printer comprising:
[0000] a body configured to extend the length of the printhead;
a capping element housed within said body and having a rim portion adapted to cap at least a portion of the printhead;
a displacement assembly housed within the body for moving the capping element between a first position where the rim portion of the capping element extends from said body, and a second position where the rim portion of the capping element is contained within the body;
wherein, the displacement assembly is controlled by an electromagnet which determines the position.
[0202] In a further aspect the present invention provides a cradle unit for an inkjet printer comprising:
[0000] a body complementary to a removable inkjet cartridge of a type having a pagewidth printhead and an ink supply; and
a controller for controlling the operation of the printhead to facilitate printing;
wherein, a plurality of terminals are located along the length of the body to contact corresponding terminals located along the length of the removable inkjet cartridge to enable electrical communication between the controller and the cartridge.
[0203] In a further aspect the present invention provides a cradle unit for an inkjet printer comprising:
[0000] a body complementary to a removable inkjet cartridge of a type having a pagewidth printhead and an ink supply;
a controller for controlling the operation of the printhead to facilitate printing; and
a plurality of terminals in electrical communication with said controller for transmitting control signals from said controller to corresponding terminals provided on said cartridge;
wherein said plurality of terminals are arranged to pivotally engage with said corresponding terminals provided on said cartridge when said cartridge is received by said body.
[0204] In a further aspect the present invention provides a cradle unit for an inkjet printer comprising:
[0000] a body complementary to a removable inkjet cartridge of a type having a pagewidth printhead and a refillable ink supply; and
a controller for controlling the operation of the printhead to facilitate printing;
wherein, said body includes a cover assembly for enclosing the removable inkjet cartridge within the body, said cover assembly having at least one port formed therein through which a refill unit is received for refilling the ink supply of the cartridge.
[0205] In a further aspect the present invention provides a cradle unit for an inkjet printer comprising:
[0000] a body complementary to a removable inkjet cartridge of a type having a pagewidth printhead and a refillable ink supply; and
a controller for controlling the operation of the printhead to facilitate printing;
wherein, said body is configured to receive a refill unit for supplying refill ink to the cartridge and includes a refill actuator for dispensing ink from said refill unit into said refillable ink supply.
[0206] In a further aspect the present invention provides a cradle unit for an inkjet printer comprising:
a body complementary to a removable inkjet cartridge of a type having a pagewidth printhead, an ink supply and a capper assembly; and a controller for controlling the operation of the printhead to facilitate printing; wherein, said body includes an electromagnet assembly mounted thereto which is controlled by said controller for operating said capper assembly of the removable inkjet cartridge.
[0210] In a further aspect the present invention provides a cover assembly for a cradle unit of an inkjet printer having a body complementary to a removable inkjet cartridge of a type having a pagewidth printhead and an ink supply and a controller for controlling the operation of the printhead to facilitate printing; the cover assembly comprising:
at least one port formed therein through which a refill unit is received for refilling the ink supply of the cartridge.
[0212] In a further aspect the present invention provides a cover assembly for a cradle unit of an inkjet printer having a body complementary to a removable inkjet cartridge of a type having a pagewidth printhead and an ink supply and a controller for controlling the operation of the printhead to facilitate printing; the cover assembly comprising:
a refill actuator for dispensing ink from an ink refill unit into said refillable ink supply.
[0214] In a further aspect the present invention provides an ink priming system for a cartridge unit of the type having a pagewidth printhead assembly in fluid communication with one or more ink storage compartments, the system comprising:
a priming inlet provided on said printhead assembly for receiving a supply of ink for priming the cartridge unit; and an ink flow passage providing fluid connection between said printhead assembly and one of the ink storage compartments; wherein the ink supplied to the priming inlet of the printhead assembly flows from the printhead assembly to the ink storage compartment via the ink flow passage to prime both the printhead assembly and the ink storage compartment with ink simultaneously.
[0218] In a further aspect the present invention provides an ink priming system for a cartridge unit of the type having a pagewidth printhead assembly in fluid communication with one or more ink storage compartments, the system comprising:
a priming inlet provided on said printhead assembly for receiving a supply of ink for priming the cartridge unit; an ink flow passage providing fluid connection between said printhead assembly and one of the ink storage compartments; and a bypass flow passage providing additional fluid connection between the ink flow passage and the ink storage compartment; wherein the ink supplied to the priming inlet of the printhead assembly flows from the printhead assembly to the ink storage compartment via the ink flow passage and the bypass flow passage to prime both the printhead assembly and the ink storage compartment with ink simultaneously.
[0223] In a further aspect the present invention provides a printing fluid dispenser for a printing fluid refill cartridge comprising:
a body storing printing fluid having an outlet through which the printing fluid is dispensed; and a selector arranged to select the amount of the printing fluid to be dispensed from the body.
[0226] In a further aspect the present invention provides a method of refilling a supply of printing fluid in a printing unit, comprising the steps of:
removably mounting a dispenser of printing fluid to the printing unit so as to align an outlet of the dispenser with an inlet of a printing fluid storage chamber of the printing unit; determining an amount of printing fluid needed to substantially refill the printing fluid storage chamber; and selectively dispensing an amount of printing fluid from the dispenser corresponding to the determined amount.
[0230] In a further aspect the present invention provides a dispensing assembly for a printing fluid refill cartridge, the dispensing assembly comprising:
a body for storing printing fluid having an outlet through which the printing fluid is dispensed; and a plunger arranged to selectively change the storage capacity of the body and expel the printing fluid through said outlet by selective engagement of a movable retaining member with a series of grooves arranged along a surface of the plunger, thereby dispensing a selected amount of printing fluid from the outlet.
[0233] In a further aspect the present invention provides a system for controlling refilling of a print engine by a printing fluid refill unit, comprising:
an information storage element incorporated in the refill unit for storing information on the amount of printing fluid contained in the refill unit; and an information reader incorporated in the print engine for reading the information stored by the storage element when the refill unit is mounted to the print engine and for controlling the refilling of the print engine with the printing fluid contained in the refill unit based on the information read.
[0236] In a further aspect the present invention provides a printing fluid refill unit for a print engine, comprising an information storage element for storing information on the amount of printing fluid contained in the refill unit and for connecting with an information reader incorporated in the print engine for reading the information stored by the storage element when the refill unit is mounted to the print engine,
wherein the information stored by the storage element enables the reader to control the refilling of the print engine with the printing fluid contained in the refill unit.
[0238] In a further aspect the present invention provides a method of controlling refilling of a printing unit by a printing fluid refill cartridge, comprising the steps of:
storing information on an amount of printing fluid contained in the refill cartridge in an information storage element incorporated therein; mounting the refill cartridge to the printing unit; reading the information on the amount of printing fluid with an information reader incorporated in the printing unit; and controlling the refilling of the printing unit with printing fluid contained in the refill cartridge based on the information read.
[0243] In a further aspect the present invention provides a printing fluid storage device comprising a porous body having a plurality of individual channels arranged in an array to store printing fluid and supply the stored printing fluid to at least one printing fluid ejecting nozzle of a printhead of a printer unit,
wherein a first end of each of the channels is in fluid communication with a printing fluid supply to extract printing fluid from the fluid supply for storage therein under capillary action and the stored printing fluid is supplied to the at least one nozzle under capillary action.
BRIEF DESCRIPTION OF THE DRAWINGS
[0245] In the drawings:
[0246] FIG. 1 shows a front perspective view of a printer unit employing a print engine according to an embodiment of the present invention;
[0247] FIG. 2 shows the printer unit of FIG. 1 with the lid open exposing the print engine;
[0248] FIG. 3 shows a schematic of document data flow in a printing system according to one embodiment of the present invention;
[0249] FIG. 4 shows a more detailed schematic showing an architecture used in the printing system of FIG. 3 ;
[0250] FIG. 5 shows a block diagram of an embodiment of the control electronics as used in the printing system of FIG. 3 ;
[0251] FIG. 6 shows an exploded perspective view of a print engine according to an embodiment of the present invention;
[0252] FIG. 7 shows the print engine of FIG. 6 with cartridge unit inserted in the cradle unit;
[0253] FIG. 8 shows the cradle unit of FIG. 7 with the cover assembly in the closed position;
[0254] FIG. 9 shows a front perspective view of the cartridge unit of FIG. 7 ;
[0255] FIG. 10 shows a front perspective view of the underside of the cartridge unit of FIG. 9 ;
[0256] FIG. 11 shows an exploded perspective view of the cartridge unit of FIG. 7 ;
[0257] FIG. 12 shows an alternative exploded view of the cartridge unit of FIG. 7 ;
[0258] FIG. 13 shows a front perspective view of the main body of the cartridge unit of FIG. 7 with the lid assembly removed;
[0259] FIG. 14 shows an exploded front perspective view of the main body of FIG. 13 ;
[0260] FIG. 15 shows a sectional side view of the main body of FIG. 13 ;
[0261] FIG. 16 shows an example of an ink storage arrangement for use in the cartridge unit of FIG. 9 according to one embodiment;
[0262] FIG. 17 shows a cross-sectional view of an ink storage compartment employing the ink storage arrangement of FIG. 16
[0263] FIG. 18 shows a front perspective view of a printhead assembly suitable for use with the cartridge unit of FIG. 9 ;
[0264] FIG. 19 shows a front perspective view of the underside of the printhead assembly of FIG. 18 ;
[0265] FIG. 20 shows an exploded view of the printhead assembly of FIG. 18 ;
[0266] FIG. 21 shows a cross-sectional end view of the printhead assembly of FIG. 18 ;
[0267] FIG. 22 shows a simplified schematic depiction of linked integrated circuits according to one embodiment of the present invention;
[0268] FIG. 23 shows a simplified schematic depiction of two linked integrated circuits employing a right angled join;
[0269] FIGS. 24A and 24B show a schematic depiction of two linked integrated circuits employing an angled join;
[0270] FIG. 25 shows a simplified schematic depiction of two linked integrated circuits employing a vertical offset join;
[0271] FIG. 26 shows a simplified schematic depiction of two linked integrated circuits employing a sloped placement join;
[0272] FIGS. 27A and 27B show a simplified schematic drawing of two linked integrated circuits employing a dropped triangle nozzle join;
[0273] FIG. 28A shows a magnified perspective view of an integrated circuit as shown in FIGS. 27A and 27B employing a dropped triangle nozzle arrangement;
[0274] FIG. 28B shows a magnified perspective view of the join between two integrated circuits employing the nozzle arrangement of FIG. 28A ;
[0275] FIG. 28C shows an underside view of the integrated circuit of FIG. 28A ;
[0276] FIG. 29 shows an exploded perspective view of an alternative printhead assembly according to another embodiment of the present invention;
[0277] FIG. 30 shows a partly assembled perspective view of the printhead assembly of FIG. 29 ;
[0278] FIG. 31 shows a plurality of holes being laser drilled into the adhesive layer of the printhead assembly of FIG. 29 ;
[0279] FIG. 32 shows a plurality of integrated circuits being arranged along the surface of the adhesive layer of FIG. 31 ;
[0280] FIGS. 33A-33C show various views of a portion of an ink distribution member according to a further embodiment of the present invention;
[0281] FIG. 34A shows a transparent top view of a printhead assembly employing the ink distribution member of FIGS. 33A-33C showing in particular, the ink passages for supplying ink to the integrated circuits;
[0282] FIG. 34B shows an enlarged view of FIG. 34A ;
[0283] FIG. 35 shows a schematic view of a priming arrangement for priming an ink storage compartment of the present invention;
[0284] FIG. 36 shows a schematic view of an alternative priming arrangement for priming an ink storage compartment of the present invention;
[0285] FIG. 37 shows a schematic view of the priming arrangement of FIG. 36 with the bypass valve in the closed position;
[0286] FIG. 38 shows a schematic view of yet another alternative priming arrangement for priming an ink storage compartment of the present invention;
[0287] FIG. 39 shows a schematic view of the alternative priming arrangement of FIG. 38 with the bypass valve in a closed position.
[0288] FIG. 40 shows yet another alternative arrangement for priming the ink storage compartment of the present invention, employing a needle which passes through the side wall of the compartment;
[0289] FIG. 41 shows a vertical sectional view of a single nozzle for ejecting ink, for use with the invention, in a quiescent state;
[0290] FIG. 42 shows a vertical sectional view of the nozzle of FIG. 41 during an initial actuation phase;
[0291] FIG. 43 shows a vertical sectional view of the nozzle of FIG. 42 later in the actuation phase;
[0292] FIG. 44 shows a perspective partial vertical sectional view of the nozzle of FIG. 41 , at the actuation state shown in FIG. 43 ;
[0293] FIG. 45 shows a perspective vertical section of the nozzle of FIG. 41 , with ink omitted;
[0294] FIG. 46 shows a vertical sectional view of the of the nozzle of FIG. 45 ;
[0295] FIG. 47 shows a perspective partial vertical sectional view of the nozzle of FIG. 41 , at the actuation state shown in FIG. 42 ;
[0296] FIG. 48 shows a plan view of the nozzle of FIG. 41 ;
[0297] FIG. 49 shows a plan view of the nozzle of FIG. 41 with the lever arm and movable nozzle removed for clarity;
[0298] FIG. 50 shows a perspective vertical sectional view of a part of a printhead chip incorporating a plurality of the nozzle arrangements of the type shown in FIG. 41 ;
[0299] FIG. 51 shows a schematic cross-sectional view through an ink chamber of a single nozzle for injecting ink of a bubble forming heater element actuator type.
[0300] FIGS. 52(A) to 52(C) show the basic operational principles of a thermal bend actuator;
[0301] FIG. 53 shows a three dimensional view of a single ink jet nozzle arrangement constructed in accordance with FIG. 22 ;
[0302] FIG. 54 shows an array of the nozzle arrangements shown in FIG. 53 ;
[0303] FIG. 55 shows a schematic showing CMOS drive and control blocks for use with the printer of the present invention;
[0304] FIG. 56 shows a schematic showing the relationship between nozzle columns and dot shift registers in the CMOS blocks of FIG. 55 ;
[0305] FIG. 57 shows a more detailed schematic showing a unit cell and its relationship to the nozzle columns and dot shift registers of FIG. 56 ;
[0306] FIG. 58 shows a circuit diagram showing logic for a single printer nozzle in the printer of the present invention;
[0307] FIG. 59 shows a front perspective view of a lid assembly of a cartridge unit according to an embodiment of the present invention;
[0308] FIG. 60 shows a front perspective view of the underside of the lid assembly of FIG. 59 ;
[0309] FIG. 61 shows an exploded front perspective view of the lid assembly of FIG. 59 ;
[0310] FIG. 62 shows a front perspective view of a capper assembly of a cartridge unit according to an embodiment of the present invention;
[0311] FIG. 63 shows an exploded front perspective view of the capper assembly of FIG. 62 ;
[0312] FIG. 64 shows an exploded front perspective view of the underside of the capper assembly of FIG. 62 ;
[0313] FIG. 65 shows a sectional end view of the capper assembly of FIG. 62 ;
[0314] FIG. 66 shows a sectional perspective view of the capper assembly operationally mounted to the cartridge unit of the present invention in a capped state;
[0315] FIG. 67 shows a sectional perspective view of the capper assembly operationally mounted to the cartridge unit of the present invention in an uncapped state;
[0316] FIGS. 68A-68D show various perspective views of the frame structure of the cradle unit according to an embodiment of the present invention;
[0317] FIG. 69 shows a perspective front view of a cartridge unit support member of the cradle unit according to an embodiment of the present invention;
[0318] FIG. 70 shows a perspective side view of the frame structure of FIGS. 68A-68D with the cartridge unit support member of FIG. 69 attached thereto;
[0319] FIGS. 71A-71B show various views of the idle roller assembly of the cradle unit according to one embodiment of the present invention;
[0320] FIG. 72 shows a sectional side view of the idle roller assembly of FIGS. 71A-71B mounted to the cartridge support member of FIG. 69 ;
[0321] FIGS. 73A and 73B show front and back perspective views of the PCB assembly of the present invention having the control circuitry mounted thereto for controlling the print engine of the present invention;
[0322] FIGS. 74A-74C show various views of the PCB assembly of FIGS. 73A and 73B mounted between arm supports;
[0323] FIGS. 75A and 75B show a support bar assembly for the PCB assembly of FIGS. 73A and 73B in accordance with one embodiment of the present invention;
[0324] FIG. 76 shows a perspective view of the support bar assembly of FIGS. 75A and 75B assembled to the PCB assembly of FIGS. 74A-74C ;
[0325] FIGS. 77A and 77B shows perspective views of the assembly of FIG. 76 attached to the cradle unit of the present invention;
[0326] FIG. 78A-78C show various views of the cover assembly of the cradle unit according to an embodiment of the present invention;
[0327] FIG. 79 shows a perspective view of the cover assembly as attached to the cradle unit;
[0328] FIG. 80 shows the print engine of the present invention with the cover assembly in an open position;
[0329] FIG. 81 shows the print engine of the present invention with the cover assembly in a closed position;
[0330] FIG. 82 shows a front perspective view of the push rod assembly in isolation from the cover assembly;
[0331] FIG. 83 shows a perspective view of the foot portion of the push rod assembly of FIG. 82 ;
[0332] FIG. 84 shows an ink refill unit according to one embodiment of the present invention;
[0333] FIG. 85 shows the ink refill unit of FIG. 84 in relation to the print engine of the present invention;
[0334] FIG. 86 shows the ink refill unit positioned for refilling ink within the print engine as shown in FIG. 85 ;
[0335] FIG. 87 shows the cartridge unit as removed from the cradle unit of FIGS. 85 and 86 ;
[0336] FIG. 88 shows an underside view of the ink refill unit of FIG. 84 ;
[0337] FIG. 89 illustrates the ink refill unit of FIG. 84 with its lid assembly removed;
[0338] FIG. 90 shows an exploded view of the various components of the ink refill unit of FIG. 84 ;
[0339] FIG. 91 illustrates a syringe assembly isolated from the ink refill unit as shown in FIGS. 89 and 90 ;
[0340] FIG. 92 shows an end perspective view of the syringe assembly as shown in FIG. 91 ;
[0341] FIG. 93 illustrates a base assembly isolated from the other components of the ink refill unit as shown in FIGS. 89 and 90 ;
[0342] FIGS. 94A-94C show an ink distribution system provided by the ink refill unit positioned on the print engine as shown in FIG. 85 ;
[0343] FIG. 95 shows the ink refill unit with its lid assembly removed in accordance with an alternative embodiment of a syringe assembly;
[0344] FIG. 96 shows an exploded view of the various components of the ink refill unit as shown in FIG. 95 ;
[0345] FIG. 97 shows a syringe assembly isolated from the ink refill unit as shown in FIG. 95 ;
[0346] FIG. 98 shows an end sectional view of the syringe assembly as shown in FIG. 95 ;
[0347] FIG. 99 shows a base assembly isolated from the other components of the ink refill unit as shown in FIGS. 95 and 96 ;
[0348] FIG. 100 shows yet another embodiment of an ink refill unit suitable for use with the present invention;
[0349] FIG. 101 shows an opposite perspective view of the ink refill unit of FIG. 100 ;
[0350] FIG. 102 shows an underside view of the ink refill unit of FIG. 100 ;
[0351] FIG. 103 shows the ink refill unit of FIG. 100 with its end cap removed;
[0352] FIG. 104 shows an exploded view of the various components of the ink refill unit of FIG. 100 ;
[0353] FIG. 105 shows the working relationship between the internal components of the ink refill unit as shown in FIGS. 100 and 104 ; and
[0354] FIG. 106 shows a side sectional view of the ink refill unit of FIG. 100 .
DETAILED DESCRIPTION OF EMBODIMENTS
[0355] As discussed previously, the present invention resides in a print engine 1 that can be readily incorporated into a body of a printer unit 2 to perform the printing functions of the printer unit.
[0356] As shown in FIGS. 1 and 2 , the printer unit 2 , which incorporates the print engine 1 , may be in any form but typically has a media supply region 3 for supporting and supplying media 8 to be printed by the print engine, and a media output or collection region 4 for collecting the printed sheets of media. The printer unit 2 may also have a user interface 5 for enabling a user to control the operation of the printer unit, and this user interface 5 may be in the form of an LCD touch screen as shown.
[0357] The printer unit 2 typically has an internal cavity 6 for receiving the print engine 1 , and access to the internal cavity may be provided by a lid 7 which is hingedly attached to the body of the printer unit 2 .
[0358] The print engine 1 is configured to be positioned and secured within the printer unit 2 such that media 8 located in media supply region 3 can be fed to the print engine 1 for printing and delivered to the collection region 4 for collection following printing. In this regard, the print engine 1 includes media transport means which take the sheets of media 8 from the media supply region 3 and deliver the media past the printhead assembly, where it is printed, into the media output tray 4 . A picker mechanism 9 is provided with the printer unit 2 to assist in feeding individual streets of media 8 from the media supply 3 to the print engine 1 .
[0359] As shown schematically in FIG. 3 , in use, the printer unit 2 is arranged to print documents received from an external source, such as a computer system 702 , onto a print media, such as a sheet of paper. In this regard, the printer unit 100 printer unit 2 includes means which allow electrical connection between the printer unit 2 and the computer system 702 to receive data which has been pre-processed by the computer system 702 . In one form, the external computer system 702 is programmed to perform various steps involved in printing a document, including receiving the document (step 703 ), buffering it (step 704 ) and rasterizing it (step 706 ), and then compressing it (step 708 ) for transmission to the printer unit 2 .
[0360] The printer unit 2 according to one embodiment of the present invention, receives the document from the external computer system 702 in the form of a compressed, multi-layer page image, wherein control electronics provided within the print engine 1 buffers the image (step 710 ), and then expands the image (step 712 ) for further processing. The expanded contone layer is dithered (step 714 ) and then the black layer from the expansion step is composited over the dithered contone layer (step 716 ). Coded data may also be rendered (step 718 ) to form an additional layer, to be printed (if desired) using an infrared ink that is substantially invisible to the human eye. The black, dithered contone and infrared layers are combined (step 720 ) to form a page that is supplied to a printhead for printing (step 722 ).
[0361] In this particular arrangement, the data associated with the document to be printed is divided into a high-resolution bi-level mask layer for text and line art and a medium-resolution contone color image layer for images or background colors. Optionally, colored text can be supported by the addition of a medium-to-high-resolution contone texture layer for texturing text and line art with color data taken from an image or from flat colors. The printing architecture generalises these contone layers by representing them in abstract “image” and “texture” layers which can refer to either image data or flat color data. This division of data into layers based on content follows the base mode Mixed Raster Content (MRC) mode as would be understood by a person skilled in the art. Like the MRC base mode, the printing architecture makes compromises in some cases when data to be printed overlap. In particular, in one form all overlaps are reduced to a 3-layer representation in a process (collision resolution) embodying the compromises explicitly.
[0362] As mentioned previously, data is delivered to the printer unit 2 in the form of a compressed, multi-layer page image with the pre-processing of the image performed by a mainly software-based computer system 702 . In turn, the print engine 1 processes this data using a mainly hardware-based system as is shown in more detail in FIG. 4 .
[0363] Upon receiving the data, a distributor 730 converts the data from a proprietary representation into a hardware-specific representation and ensures that the data is sent to the correct hardware device whilst observing any constraints or requirements on data transmission to these devices. The distributor 730 distributes the converted data to an appropriate one of a plurality of pipelines 732 . The pipelines are identical to each other, and in essence provide decompression, scaling and dot compositing functions to generate a set of printable dot outputs.
[0364] Each pipeline 732 includes a buffer 734 for receiving the data. A contone decompressor 736 decompresses the color contone planes, and a mask decompressor decompresses the monotone (text) layer. Contone and mask scalers 740 and 742 scale the decompressed contone and mask planes respectively, to take into account the size of the medium onto which the page is to be printed.
[0365] The scaled contone planes are then dithered by ditherer 744 . In one form, a stochastic dispersed-dot dither is used. Unlike a clustered-dot (or amplitude-modulated) dither, a dispersed-dot (or frequency-modulated) dither reproduces high spatial frequencies (i.e. image detail) almost to the limits of the dot resolution, while simultaneously reproducing lower spatial frequencies to their full color depth, when spatially integrated by the eye. A stochastic dither matrix is carefully designed to be relatively free of objectionable low-frequency patterns when tiled across the image. As such, its size typically exceeds the minimum size required to support a particular number of intensity levels (e.g. 16×16×8 bits for 257 intensity levels).
[0366] The dithered planes are then composited in a dot compositor 746 on a dot-by-dot basis to provide dot data suitable for printing. This data is forwarded to data distribution and drive electronics 748 , which in turn distributes the data to the correct nozzle actuators 750 , which in turn cause ink to be ejected from the correct nozzles 752 at the correct time in a manner which will be described in more detail later in the description.
[0367] As will be appreciated, the components employed within the print engine 1 to process the image for printing depend greatly upon the manner in which data is presented. In this regard it may be possible for the print engine 1 to employ additional software and/or hardware components to perform more processing within the printer unit 2 thus reducing the reliance upon the computer system 702 . Alternatively, the print engine 1 may employ fewer software and/or hardware components to perform less processing thus relying upon the computer system 702 to process the image to a higher degree before transmitting the data to the printer unit 2 .
[0368] In all situations, the components necessary to perform the above mentioned tasks are provided within the control electronics of the print engine 1 , and FIG. 5 provides a block representation of an embodiment of the electronics.
[0369] In this arrangement, the hardware pipelines 732 are embodied in a Small Office Home Office Printer Engine Chip (SoPEC). As shown, a SoPEC device consists of 3 distinct subsystems: a Central Processing Unit (CPU) subsystem 771 , a Dynamic Random Access Memory (DRAM) subsystem 772 and a Print Engine Pipeline (PEP) subsystem 773 .
[0370] The CPU subsystem 771 includes a CPU 775 that controls and configures all aspects of the other subsystems. It provides general support for interfacing and synchronizing all elements of the print engine 1 . It also controls the low-speed communication to QA chips (which are described delow). The CPU subsystem 771 also contains various peripherals to aid the CPU, such as General Purpose Input Output (GPIO, which includes motor control), an Interrupt Controller Unit (ICU), LSS Master and general timers. The Serial Communications Block (SCB) on the CPU subsystem provides a full speed USB1.1 interface to the host as well as an Inter SoPEC Interface (ISI) to other SoPEC devices (not shown).
[0371] The DRAM subsystem 772 accepts requests from the CPU, Serial Communications Block (SCB) and blocks within the PEP subsystem. The DRAM subsystem 772 , and in particular the DRAM Interface Unit (DIU), arbitrates the various requests and determines which request should win access to the DRAM. The DIU arbitrates based on configured parameters, to allow sufficient access to DRAM for all requestors. The DIU also hides the implementation specifics of the DRAM such as page size, number of banks and refresh rates.
[0372] The Print Engine Pipeline (PEP) subsystem 773 accepts compressed pages from DRAM and renders them to bi-level dots for a given print line destined for a printhead interface (PHI) that communicates directly with the printhead. The first stage of the page expansion pipeline is the Contone Decoder Unit (CDU), Lossless Bi-level Decoder (LBD) and, where required, Tag Encoder (TE). The CDU expands the JPEG-compressed contone (typically CMYK) layers, the LBD expands the compressed bi-level layer (typically K), and the TE encodes any Netpage tags for later rendering (typically in IR or K ink), in the event that the printer unit 2 has Netpage capabilities. The output from the first stage is a set of buffers: the Contone FIFO unit (CFU), the Spot FIFO Unit (SFU), and the Tag FIFO Unit (TFU). The CFU and SFU buffers are implemented in DRAM.
[0373] The second stage is the Halftone Compositor Unit (HCU), which dithers the contone layer and composites position tags and the bi-level spot layer over the resulting bi-level dithered layer.
[0374] A number of compositing options can be implemented, depending upon the printhead with which the SoPEC device is used. Up to 6 channels of bi-level data are produced from this stage, although not all channels may be present on the printhead. For example, the printhead may be CMY only, with K pushed into the CMY channels and IR ignored. Alternatively, any encoded tags may be printed in K if IR ink is not available (or for testing purposes).
[0375] In the third stage, a Dead Nozzle Compensator (DNC) compensates for dead nozzles in the printhead by color redundancy and error diffusing of dead nozzle data into surrounding dots.
[0376] The resultant bi-level 5 channel dot-data (typically CMYK, Infrared) is buffered and written to a set of line buffers stored in DRAM via a Dotline Writer Unit (DWU).
[0377] Finally, the dot-data is loaded back from DRAM, and passed to the printhead interface via a dot FIFO. The dot FIFO accepts data from a Line Loader Unit (LLU) at the system clock rate (pclk), while the PrintHead Interface (PHI) removes data from the FIFO and sends it to the printhead at a rate of ⅔ times the system clock rate.
[0378] In the preferred form, the DRAM is 2.5 Mbytes in size, of which about 2 Mbytes are available for compressed page store data. A compressed page is received in two or more bands, with a number of bands stored in memory. As a band of the page is consumed by the PEP subsystem 773 for printing, a new band can be downloaded. The new band may be for the current page or the next page.
[0379] Using banding it is possible to begin printing a page before the complete compressed page is downloaded, but care must be taken to ensure that data is always available for printing or a buffer under-run may occur.
[0380] The embedded USB 1.1 device accepts compressed page data and control commands from the host PC, and facilitates the data transfer to either the DRAM (or to another SoPEC device in multi-SoPEC systems, as described below).
[0381] Multiple SoPEC devices can be used in alternative embodiments, and can perform different functions depending upon the particular implementation. For example, in some cases a SoPEC device can be used simply for its onboard DRAM, while another SoPEC device attends to the various decompression and formatting functions described above. This can reduce the chance of buffer under-run, which can happen in the event that the printer commences printing a page prior to all the data for that page being received and the rest of the data is not received in time. Adding an extra SoPEC device for its memory buffering capabilities doubles the amount of data that can be buffered, even if none of the other capabilities of the additional chip are utilized.
[0382] Each SoPEC system can have several quality assurance (QA) devices designed to cooperate with each other to ensure the quality of the printer mechanics, the quality of the ink supply so the printhead nozzles will not be damaged during prints, and the quality of the software to ensure printheads and mechanics are not damaged.
[0383] Normally, each printing SoPEC will have an associated printer unit QA, which stores information relating to the printer unit attributes such as maximum print speed. The cartridge unit may also contain a QA chip, which stores cartridge information such as the amount of ink remaining, and may also be configured to act as a ROM (effectively as an EEPROM) that stores printhead-specific information such as dead nozzle mapping and printhead characteristics. The refill unit may also contain a QA chip, which stores refill ink information such as the type/colour of the ink and the amount of ink present for refilling. The CPU in the SoPEC device can optionally load and run program code from a QA Chip that effectively acts as a serial EEPROM. Finally, the CPU in the SoPEC device runs a logical QA chip (ie, a software QA chip).
[0384] Usually, all QA chips in the system are physically identical, with only the contents of flash memory differentiating one from the other.
[0385] Each SoPEC device has two LSS system buses that can communicate with QA devices for system authentication and ink usage accounting. A large number of QA devices can be used per bus and their position in the system is unrestricted with the exception that printer QA and ink QA devices should be on separate LSS busses.
[0386] In use, the logical QA communicates with the ink QA to determine remaining ink. The reply from the ink QA is authenticated with reference to the printer QA. The verification from the printer QA is itself authenticated by the logical QA, thereby indirectly adding an additional authentication level to the reply from the ink QA.
[0387] Data passed between the QA chips is authenticated by way of digital signatures. In the preferred embodiment, HMAC-SHA1 authentication is used for data, and RSA is used for program code, although other schemes could be used instead.
[0388] As will be appreciated, the SoPEC device therefore controls the overall operation of the print engine 1 and performs essential data processing tasks as well as synchronising and controlling the operation of the individual components of the print engine 1 to facilitate print media handling, as will be discussed below.
Print Engine
[0389] The print engine 1 is shown in detail in FIGS. 6-8 and consists of two parts: a cartridge unit 10 and a cradle unit 12 .
[0390] As shown, the cartridge unit 10 is shaped and sized to be received within the cradle unit 12 and secured in position by a cover assembly 11 mounted to the cradle unit.
[0391] The cradle unit 12 is provided with an external body 13 having anchor portions 14 which allow it to be fixed to the printer unit 2 in a desired position and orientation, as discussed above, to facilitate printing.
[0392] In its assembled form as shown in FIG. 8 , with cartridge unit 10 secured within the cradle unit 12 and cover assembly 11 closed, the print engine 1 is able to control various aspects associated with printing, including transporting the media past the printhead in a controlled manner as well as the controlled ejection of ink onto the surface of the passing media. In this regard, the print engine 1 may also include electrical contacts which facilitate electrical connection with the user interface 5 of the printer unit 2 to enable control of the print engine 1 .
Cartridge Unit
[0393] The cartridge unit 10 is shown in detail in FIGS. 9-12 . With reference to the exploded views of FIGS. 11 and 12 , the cartridge unit 10 generally consists of a main body 20 , a lid assembly 21 , a printhead assembly 22 and a capper assembly 23 .
[0394] Each of these parts are assembled together to form an integral unit which combines ink storage together with the ink ejection means in a complete manner. Such an arrangement ensures that the ink is directly supplied to the printhead assembly 22 for printing, as required, and should there be a need to replace either or both of the ink storage or the printhead assembly, this can be readily done by replacing the entire cartridge unit 10 .
[0395] As is evident in FIGS. 9 and 10 , the cartridge unit 10 has facilities for receiving a refill supply of ink to replenish the ink storage when necessary and the cartridge unit itself carries an integral capping assembly 23 for capping the printhead when not in use.
Main Body
[0396] The main body 20 of the cartridge unit 10 is shown in more detail in FIGS. 13-15 and comprises a moulded plastics body which defines a plurality of ink storage compartments 24 in which the various colours and/or types of ink are stored. Each of the ink storage compartments 24 are separated from one another to prevent mixing of the different inks, as is shown more clearly in FIG. 14 , and extend along the length of the main body 20 .
[0397] There are five ink storage compartments 24 shown, having a square or rectangular shape, with the end compartments being larger than the other compartments. The larger end compartments are intended to store the ink more readily consumed during the printing process, such as black ink or (infrared ink in Netpage applications) whilst the smaller compartments are intended to store the cyan, magenta and yellow inks traditionally used in colour printing. The base 25 of each of the ink storage compartments 24 is provided with a raised portion 26 which surrounds an ink outlet 27 , through which the ink flows for supply to the printhead assembly 22 .
[0398] The raised portions 26 are typically moulded into the main body 20 and act to separate the outlet 27 from the base 25 of the ink storage compartment 24 to ensure a sufficient flow rate of ink from the compartment 24 .
[0399] In this regard, an air barrier/ink filter 28 made from a fine mesh material is placed over the ink outlet 27 , atop of the raised portions 26 , thereby leaving a space between the filter and the outlet for receiving ink. The air barrier/ink filter 28 is formed such that ink can readily pass through the mesh to the printhead assembly 22 but any air bubbles present in the ink are prevented from passing through.
[0400] As shown in FIG. 14 , the ink storage compartments 24 are provided with an absorbent material 29 such as a foam for storing the ink. The absorbent material 29 is shaped to conform to the shape of the ink storage compartment 24 and is fitted within the corresponding compartment to be supported on top of the air barrier/ink filter 28 . In this arrangement, the lower surface of the absorbent material 29 is separated from the base 25 of the ink storage compartments via the raised portions 26 . The absorbent material 29 acts to absorb ink supplied to the compartment 24 such that the ink is suspended internally within. The manner in which ink is supplied to the compartment 24 will be discussed in more detail later, however it should be appreciated that the structure of the absorbent material is such that it contains a number of open pores which receive and draw in the ink under capillary action.
[0401] The ink fills the space between the ink filter/air barrier 28 and the outlet 27 thereby forming an ink dam, which is in fluid communication with the ink in the printhead assembly 22 and the ink suspended within the absorbent material 29 . Due to the nature of the absorbent material 29 and the fact that the ink is retained therein under capillary action, a back pressure is created which prevents the ink from freely flowing from the compartment 24 and out the nozzles of the printhead assembly 22 .
[0402] Whilst the use of a foam or sponge material as an absorbent material 29 which stores the ink therein under capillary attraction forces is well established in the art, due to the nature of such materials, their use may cause contaminants to be introduced into the stored ink. These contaminants can then make their way to the ink delivery nozzles of the printhead assembly 22 , causing blockages and therefore (possible irreparable) malfunction of the ink delivery nozzles. Whilst conventional arrangements have typically employed filters and the like in an attempt to protect the nozzles, such filters may themselves become blocked due to the presence of particulate material present in the foam or sponge material.
[0403] In this regard, in an alternative embodiment, the absorbent material 29 may be provided as a block or stack of layers made from a polymer material, such as polycarbonate, acrylic, polysulfone, polystyrene, fluoropolymer, cyclic olefin polymer, cyclic olefin copolymer, etc, having the channels 16 formed therein in the form of a micro-capillary array, as shown in FIG. 16 , with each channel having an average diameter of about 10 microns or less.
[0404] In this arrangement, the body of the absorbent material 29 , in which the micro-capillary array of the channels 16 is formed, remains stable and rigid at all times. That is, the rigid walls of the channels remain intact during exposure to the ink whereby particulate matter is not introduced into the ink, unlike the cellular or interlaced arrangement of compressible pores within the conventional foam and sponge materials which contribute to contaminant production.
[0405] The absorbent material 29 having the channels 16 formed as a micro-capillary array therein can be arranged within the individual ink storage compartments 24 as shown in FIG. 17 . An ink trapping layer 17 is provided between the ink filter/air barrier 28 and the absorbent material 29 . The trapping layer 17 absorbs the supplied ink in multiple-directions, thus allowing for the ingress of the ink into the longitudinally orientated channels 16 , and in this regard merely acts as a means for presenting the ink to the channels 16 . The trapping layer 17 may be provided as a foam or sponge material with a thickness substantially less than that of the absorbent material 29 , since the function of the trapping layer is merely to supply ink to the channels 16 of the absorbent material 29 and not to store the ink.
[0406] The ink drawn into and stored within the channels 16 is able to pass to the nozzles of the printhead assembly 22 via the ink trapping layer 17 . The use of foam or sponge material in the ink trapping layer 17 may result in some particulate contamination occurring in the ink. However, this may be minimized by providing the layer with a thickness and density which is just sufficient for absorbing the necessary amount of ink for effective absorption into the channels 16 . In any event, since the ink is effectively stored only in the absorbent material 29 , the contaminant level that may be produced in the ink trapping layer is significantly reduced from the levels produced by the conventional structures.
[0407] A pressed metal chassis 30 is fitted to the underside of the main body via clips 31 formed in the chassis 30 which mate with corresponding clips formed in the main body 20 . The pressed metal chassis 30 is shaped to conform to the underside of the main body 20 and includes a plurality of holes 32 that extend therethrough which are positioned to correspond with the ink outlets 27 of the ink storage compartments 24 such that there is a passage for ink to pass through the chassis 30 . The chassis 30 provides additional stability to the cartridge unit 10 and includes an edge 33 that extends downwardly from the main body 20 which defines a contact region where the flex printed circuit board 52 of the printhead assembly 22 contacts with corresponding electrical contacts 128 in the cradle unit 12 , in a manner which will be described in more detail later in the description. The chassis 30 also has a plurality of elongate recesses 34 formed along its length, through which connecting clips provided on the printhead assembly 22 pass, for connection to the main body 20 , as will be described in more detail below.
[0408] A seal moulding 35 is attached to the chassis 30 to complete and seal the ink flow path from the ink storage compartments 24 through the chassis 30 . The seal moulding 35 is made from an elastomeric material and has a plurality of hollow cylindrical inserts 36 formed along its surface which extend through the holes 32 formed in the chassis 30 and into the ink outlets 27 of each of the ink storage compartments 24 , as shown in FIG. 15 . The distal ends of the hollow cylindrical inserts 36 abut with the main body 20 to seal the ink outlets 27 and ensure ink flow through the seal moulding 35 . The seal moulding 35 is fixed to the surface of the metal chassis 30 by a lock-fit or a suitable adhesive and acts to provide a substantially planar surface upon which the printhead assembly 22 is attached. The planar surface having a plurality of outlet holes 39 provided therein through which ink can flow to the printhead assembly.
[0409] As is shown in FIGS. 14 and 15 a flex printed circuit board (PCB) backer 37 is attached to the side of the main body 20 via locating studs 38 and extends over the downwardly projecting edge 33 of the chassis 30 . The flex PCB backer 37 is made from a suitable elastomeric material and provides a backing onto which the flex PCB 52 of the printhead assembly 22 is supported following attachment of the printhead assembly 22 to the main body 20 . As will be discussed in more detail later in the description, the flex PCB 52 from the printhead assembly 22 is provided with a suitable recess which fits over the locating studs 38 such that the electrical dimpled contacts 53 formed on the flex PCB 52 are positioned over the flex PCB backer 37 and extend outwardly therefrom to contact suitable electrical contacts 128 provided in the cradle unit 12 . This arrangement provides some degree of flexibility in this contact region such that appropriate electrical contact can be established between the cradle unit 12 and the cartridge unit 10 to allow the transmission of data and power therebetween to control the ink ejecting nozzles of the printhead assembly 22 . This arrangement also ensures that the forces associated with the contact between the cartridge unit 12 and the cradle unit 10 in this region are carried by the chassis 30 and not transferred to the printhead assembly 22 which could cause damage to the delicate printhead integrated circuits.
[0410] As shown in FIGS. 13 and 14 , the main body 20 also includes a pair of end supports 40 which extend from the main body 20 in a downward direction with respect to the cartridge unit 10 . The end supports 40 are arranged such that the seal moulding 35 and the flex PCB backer 37 extend along the main body 20 between the two end supports 40 . The purpose of the end supports 40 will be described later in the description.
Printhead Assembly
[0411] The printhead assembly 22 is shown in more detail in FIGS. 18 to 21 , and is adapted to be attached to the underside of the main body 20 to receive ink from the outlet holes 39 formed in the planar surface of the seal moulding 35 .
[0412] As shown more clearly in FIG. 20 , the printhead assembly 22 comprises an upper moulding 42 , having features which facilitate connection of the printhead assembly to the main body 20 of the cartridge unit 10 . These features are in the form of u-shaped clips 43 that project from the surface of the upper moulding 42 . The clips 43 pass through the elongate recesses 34 provided in the chassis 30 and become captured by lugs (not shown) formed in the main body 20 , thereby securing the printhead assembly 22 to the main body 20 .
[0413] In order to receive ink from the ink storage compartments 24 , the surface of the upper moulding 42 has a plurality of ink inlets 44 which project therefrom. The ink inlets 44 are received within the outlet holes 39 of the seal moulding 35 , when the printhead assembly 22 is secured to the main body 20 , and provide a path for the ink to flow to the printhead integrated circuits for printing. To ensure a sealed connection, the ink inlets 44 are shaped to fit within the outlet holes 39 of the seal moulding 35 and may also be provided with an outer coating that facilitates sealing.
[0414] The upper moulding 42 is made from a liquid crystal polymer (LCP) and is bonded to a lower moulding 45 via an adhesive film 46 . The lower moulding 45 is also made from an LCP and has a plurality of channels 47 formed along its length. Each of the channels 47 are provided to receive ink from one of the ink storage compartments 24 , via an ink inlet 44 , and distribute the ink along the length of the printhead assembly 22 for feeding to the ink delivery nozzles 51 of the printhead assembly 22 . The channels preferably have a width of 1 mm and are separated by walls having a width of 0.75 mm. In the embodiment shown, the lower moulding 45 has five channels 47 extending along its length with each of the ink channels 47 receiving ink from one of the corresponding ink inlets 44 . Such an arrangement ensures that the different inks remain separated throughout the journey from the individual ink storage compartments 24 to the corresponding ink delivery nozzles of the printhead integrated circuit. In this regard, the adhesive film 46 also acts to seal the individual ink channels 47 and prevent cross channel mixing of the ink when the lower moulding 45 is assembled to the upper moulding 42 .
[0415] In order to further distribute the ink from the ink channels 47 of the lower moulding 45 to the printhead integrated circuits (ICs) 50 , an ink distribution member 48 is attached to the lower moulding 45 and acts as an interface between the printhead ICs 50 and the ink channels 47 of the lower moulding 45 . The purpose of the ink distribution member 48 is to provide a flow path for ink to flow from the relatively wide channels 47 to the relatively small and narrow channels 98 formed on the underside of the printhead ICs 50 which feed the ink to the individual ink delivery nozzles 51 .
[0416] In order to appreciate the manner in which the ink distribution member 48 functions to perform millimetric-to-micrometric fluid distribution to the nozzles of the printhead ICs 50 , reference is firstly made to the manner in which the printhead ICs 50 are arranged to form the printing zone of the printhead assembly 22 .
[0417] As alluded to above, the present invention is related to page-width printing and as such the printhead ICs 50 are arranged to extend horizontally across the width of the passing media to deposit ink droplets thereon to create an image. To achieve this, individual printhead ICs 50 are linked together in abutting arrangement across the surface of the ink distribution member 48 of the printhead assembly 22 , as shown simply in FIG. 22 . The length of an individual printhead IC 50 is around 20-22 mm and as such in order to print an A4/US letter sized page, 11 - 12 individual printhead ICs 50 may be linked together in abutting fashion. Other printing sizes may also be possible and as such the number of individual printhead ICs 50 required may vary depending upon the application.
[0418] Each printhead IC 50 has a plurality of individual ink delivery nozzles 51 formed therein, the structure and control of which will be described in more detail later. The nozzles 51 within an individual printhead IC 50 are grouped physically to reduce ink supply complexity and wiring complexity, and are also grouped logically to minimize power consumption and to allow a variety of printing speeds.
[0419] As mentioned previously, each printhead IC 50 is able to print five different colours (C, M, Y, K and IR) and contains 1280 ink delivery nozzles 51 per colour, with these nozzles being divided into even and odd nozzles (640 each). Even and odd nozzles for each colour are provided on different rows on the printhead IC 50 and are aligned vertically to perform true 1600 dpi printing, meaning that the nozzles 51 are arranged in 10 rows. The horizontal distance between two adjacent nozzles 51 on a single row is 31.75 microns, whilst the vertical distance between rows of nozzles is based on the firing order of the nozzles, but rows are typically separated by an exact number of dot lines, plus a fraction of a dot line corresponding to the distance the paper will move between row firing times Also, the spacing of even and odd rows of nozzles for a given colour must be such that they can share an ink channel, as will be described below.
[0420] The manner in which individual printhead ICs 50 are linked together in abutting fashion may be performed in a variety of ways. As shown in FIG. 23 , the simplest way to achieve this linkage of the printhead ICs 50 is to form a rectangular join between adjacent ICs 50 . However, due to the nature of this rectangular join, it may result in a gap between adjacent nozzles at the join interface which could produce a vertical stripe down the printed page of media where no ink is deposited, which may be unacceptable in some printing applications.
[0421] This may be overcome by providing a sloping join as shown in FIG. 24 a which provides nozzle overlap at the join interface. As shown by the enlarged view of nozzle rows of a single colour at the interface in FIG. 24 b , such an arrangement does not produce a visible join along the printing page as discussed above. In this arrangement, the ICs 50 must be perfectly aligned vertically to link in this fashion and as such this may not be always possible.
[0422] To overcome this problem, the ICs 50 may be provided with a vertical offset, as shown in FIG. 25 . This offset can be seen by the vertical offset between the longitudinal edges of adjacent ICs 50 , and this offset increases with each join along the length of the printhead assembly 22 . For example, if the offset was equivalent to 7 lines of nozzles per join, then for 11 ICs joined in this manner, there would be a total of 10 joins and 70 additional nozzle lines. This then results in an increase in the lines of data storage required for the printhead assembly. To overcome this, each IC 50 may be placed on a mild slope to achieve a constant number of print lines regardless of the number of joins, as shown in FIG. 26 . It will be appreciated that in this arrangement the rows of nozzles on the ICs 50 are aligned, but the IC is placed in a sloped orientation, such that if all the nozzles were fired at once, the effect would be lots of sloped lines provided on the page of media, however with the nozzles being fired in the correct order relative to the paper movement, a straight line for n dots would be printed, followed by another straight line for another n dots separated by I line.
[0423] Yet another system for linking the ICs 50 in abutting fashion is shown in FIGS. 27 a and 27 b . In this arrangement, the ICs 50 are shaped at their ends to link together to form a horizontal line of ICs, with no vertical offset between neighboring ICs. A sloping join is provided between the ICs which has a 45 degree angle to the upper and lower chip edges. Typically, the joining edge is not straight and has a sawtooth profile to facilitate positioning, and the ICs 50 are intended to be spaced about 11 microns apart, measured perpendicular to the joining edge. In this arrangement, the left most ink delivery nozzles on each row are dropped by 10 line pitches and arranged in a triangle configuration as shown in FIG. 27 a and FIGS. 28 a and 28 b . This arrangement provides a degree of overlap of nozzles at the join and maintains the pitch of the nozzles to ensure that the drops of ink are delivered consistently along the printing zone. This arrangement also ensures that more silicon is provided at the edge of the IC 50 to ensure sufficient linkage. Control of the operation of the nozzles is performed by the SoPEC device, however compensation for the nozzles is performed in the printhead, or may also be performed by the SoPEC device, depending on the storage requirements. In this regard it will be appreciated that the dropped triangle arrangement of nozzles disposed at one end of the IC 50 provides the minimum on-printhead storage requirements. However where storage requirements are less critical shapes other than a triangle can be used, for example, the dropped rows may take the form of a trapezoid.
[0424] FIG. 28 a shows more clearly the upper surface of a portion of the individual ICs. As can be seen bond pads 96 are provided along an edge thereof which provide a means for receiving data and or power to control the operation of the nozzles from the SoPEC of the cradle unit 12 . Fiducials 97 are also provided on the surface of the ICs to assist in positioning and aligning the ICs 50 with respect to each other. The fiducials 97 are in the form of markers that are readily identifiable by appropriate positioning equipment to indicate the true position of the IC 50 with respect to a neighbouring IC 50 , and are strategically positioned at the edges of the IC, proximal the join. As shown in FIG. 28 b , the fiducials 97 align with corresponding fiducials 97 provided on the surface of a neighbouring IC 50 to ensure alignment of the ICs to appropriate limits, as discussed above.
[0425] The underside of a printhead IC 50 is shown in relation to FIG. 28 c . As shown, along the underside of the IC 50 there are provided a number of etched channels 98 , with each channel 98 in communication with a pair of rows of nozzles 51 . The channels 98 are about 80 microns wide and extend the length of the IC 50 and include silicon walls 99 formed therein, to divide the channels 98 into portions. The channels are adapted to receive ink from the ink channels 47 of the lower moulding 45 and distribute the ink to the pair of rows of nozzles 51 to eject that ink of a specific colour or type. The partitioning of the channels 98 by the silicon walls 99 ensures that the flow path to the nozzles is not too great thereby reducing the likelihood of ink starvation to the individual nozzles along the length of the IC. In this regard, each portion feeds approximately 128 nozzles and is individually fed a supply of ink.
[0426] Each of the ICs 50 are positioned and secured to the surface of the ink distribution member 48 . As mentioned previously, the ink distribution member delivers the ink from the 1 mm wide channels 47 formed in the lower moulding 45 to the 80 micron wide channels 98 formed in the underside of the printhead ICs 50 .
[0427] The ink distribution member 48 can be configured in a number of forms. In one embodiment the ink distribution member 48 may be in the form of a laminated structure consisting of a number of layers bonded to one another, as described in U.S. Pat. No. 6,409,323 and pending US Application No. 2004/0113997.
[0428] In an alternative embodiment, the ink distribution member 48 may be in a two-part form comprising an intermediate layer 172 and an adhesive layer 173 , as shown in FIG. 29 . In this arrangement, the intermediate layer 172 is arranged to fit over the exposed channels 47 of the lower moulding 45 to seal the channels 47 and to form a sealed unit with the lower moulding 45 . The intermediate layer 172 has a plurality of holes 174 formed therethrough along its length each of which are aligned with the channels 47 and are spaced at regular intervals along the length thereof.
[0429] As shown more clearly in FIG. 30 , the holes 174 formed through the intermediate layer 172 which relate to the most central channel 47 of the lower moulding 45 are in the form of small diameter holes equi-spaced at intervals along the length of the intermediate layer 172 . Larger diameter holes 174 are provided which correspond to the other channels 47 of the lower moulding 45 , which are displaced laterally from the most central channel. These holes 174 are similarly equi-spaced along the length of the intermediate layer and micro conduits 176 are provided which extend from the larger diameter holes to terminate at a central region of the intermediate layer 172 , proximal the smaller diameter holes. These conduits 176 distribute the ink from each of the holes 172 to a central region of the intermediate layer to deliver the different types/colours of ink to the channels 98 formed in the underside of the integrated circuits 50 .
[0430] The intermediate layer 172 is also made from a liquid crystal polymer (LCP) which is injection moulded to the appropriate shape and configuration. The intermediate layer 172 is bonded to the lower moulding 45 via a thermal adhesive, such as 3 M 816 or Abelflex 5206 or 5205, which is applied between the intermediate layer 172 and the lower moulding 45 and placed in a laminator.
[0431] To facilitate placement and to secure the integrated circuits 50 upon the surface of the intermediate layer 172 a bonding film 175 is applied to the surface of the intermediate layer 172 . The bonding film 175 is in the form of a laminate polymer film which may be a thermoplastic film such as a PET or Polysulphone film, or it may be in the form of a thermoset film, such as those manufactured by AL technologies and Rogers Corporation. The bonding film 175 preferably has co-extruded adhesive layers formed on both sides thereof and is laminated onto the upper surface of the intermediate layer 172
[0432] Following lamination of the bonding layer 175 to the intermediate layer 172 , holes are drilled through the bonding layer 175 to coincide with the centrally located small diameter holes 174 , and the ends of the conduits 176 . This is shown in FIG. 31 . These holes provide a separate flow passage through the bonding layer 175 for each of the different types of inks, which feed directly to the appropriate channel portions 98 formed on the underside of the integrated circuits 50 for supply to the ink delivery nozzles 51 associated with each channel portion 98 , as discussed above. Fiducial locating marks 177 are also drilled into the surface of the bonding layer to assist in attaching and positioning the ICs 50 thereon.
[0433] In order to attach the ICs 50 to the surface of the bonding layer 175 , the ICs 50 are placed in a die and heated to 170° C. and then pressed into the bonding layer 175 at 40 psi pressure for about 3 seconds. This results in the ICs 50 being thermally bonded to the intermediate layer 172 , as shown in FIG. 32 . As shown, the fiducial locating marks 177 formed in the surface of the bonding layer 175 aid in positioning the ICs such that the channels 98 formed in the underside of the ICs 50 correctly align with the holes drilled through the bonding layer 175 to provide a flow path for ink to be fed to the nozzles for printing.
[0434] In this embodiment the ink distribution member 48 is in the form of a two part element containing an intermediate layer 172 which fits over the channels 47 formed in the lower moulding 45 , and a bonding layer 175 allowing fluid flow therethrough and which acts to attach the ICs to the surface of the intermediate layer 172 .
[0435] In yet another embodiment, the ink distribution member 48 may be in the form of a one-piece element with the ICs being directly attached to its upper surface. In this regard, rather than providing an intermediate layer 172 having holes 174 that extend therethrough and conduits 176 formed in the upper surface thereof to direct the flow of ink towards the central region of the intermediate layer 172 , the conduits are formed within the body of the ink distribution member 48 such that the upper surface of the ink distribution member only has small diameter holes formed centrally therein for delivering the ink to the undersurface of the ICs.
[0436] The manner in which this is achieved is shown in FIGS. 33 a - 33 c . These Figures merely show the manner in which the ink can be directed from one of the channels 47 of the lower moulding 45 , and it will be appreciated that the same approach can be similarly applied to deliver ink from the remainder of the channels 47 .
[0437] As shown, the underside of the ink distribution member 48 is provided with a plurality of holes or inlets 180 therein, each having a diameter of approximately 1 mm, which corresponds to the width of the channels 47 provided in the lower moulding 45 . The inlets 180 do not extend through the body of the ink distribution member 48 , but rather extend into the member 48 to a depth of about a ¾ the thickness of the member 48 , as shown in the sectioned view of FIG. 33 c.
[0438] For the inlets 180 associated with the centre channel 47 of the lower moulding, an outlet 182 , in the form of a 80 micron wide hole, is provided in the uppermost surface of the ink distribution member 48 which extends into the end wall of the inlet 180 to provide a path for the ink to flow out of the ink distribution member. For the inlets 180 associated with the other channels 47 of the lower moulding 45 , a tunnel 181 is provided from a side wall of the inlet 180 within the ink distribution member 48 which acts to direct the flow of the ink received in the inlet through the body of the ink distribution member 48 to a central position therein. An outlet 182 , as described above, is then formed on an uppermost side of the ink distribution member to provide a path for the ink present in the tunnel 181 to exit the ink distribution member at the desired position along the surface of the ink distribution member. The outlets 182 are essentially 80 microns in width, to correspond with the width of the channels 98 provided on the underside of the integrated circuits 50 .
[0439] The ink distribution member 48 of this embodiment is made from a photo-structurable glass-ceramic material, such as Forturan glass. These materials, when exposed to specific levels of pulsed UV laser energy density (fluence), have a photo-chemical reaction which creates a density of nanocrystals within the volume thereof, the density of which is directly proportional to the fluence of the exposed laser beam. In this regard, in order to form the desired inlets 180 , outlets 182 and tunnels 181 connecting the inlets and outlets, the ink distribution member 48 is mounted upon a precision XYZ stage for exposure to a focussed laser beam. Various tools may be used to control the size and shape of the critically exposed volume of the glass structure to ensure that the desired pattern and shape is created within the ink distribution member. Typical exposure times may vary from 15 minutes to 1 hour.
[0440] Following exposure the ink distribution member is loaded into an oven for thermal treatment to aid in causing crystallisation of exposed regions of the glass. The exposed and thermally treated glass is then loaded into a mild etchant for around 7 minutes to etch the exposed regions, however the etch time may vary dependant upon the thickness of the glass and the depth of the cut. The thermal treatment and etching steps may be repeated in order to form the complete ink distribution member as shown in the figures.
[0441] With this arrangement, ink present in the channels 47 of the lower moulding 45 is drawn into the ink distribution member 48 via inlets 180 which are positioned over the channels 47 at regular intervals therealong. Upon entering the inlets 180 , where required, the ink is directed to a central region of the ink distribution member 48 via the above mentioned tunnels 181 , where the ink can then exit the ink distribution member 48 via the outlets 182 at a predetermined position which is aligned with the corresponding channels 98 formed in the underside of the ICs 50 .
[0442] The ICs 50 are secured to the upper surface of the ink distribution member 48 to receive the ink therefrom, using spun coated adhesive applied to the underside of the IC 50 , or by screen printing epoxy on the upper surface of the ink distribution member 48 . In this regard, the fiducials provided on the ICs 50 and on the surface of the ink distribution member 48 assist in positioning the ICs 50 such that the channels 98 formed in the underside of the ICs 50 are aligned with the appropriate outlet 182 formed in the upper surface of the member 48 to receive the correct type/colour of ink.
[0443] FIGS. 34 a and 34 b show the manner in which this is arranged to control the delivery of ink from the five channels 47 of the lower moulding 45 . These figures provide a top view of the arrangement and for reasons of clarity, the various elements are shown in outline to indicate the manner in which ink flows between the elements. FIG. 34 a is a top view of the arrangement showing the ICs 50 located centrally upon the ink distribution member 48 . The ink distribution member 48 is in turn secured to the lower moulding 45 such that the inlets 180 align with the respective channels 47 at regular intervals along the length thereof to receive ink from the channels 47 for distribution to the ICs 50 . The inlets 180 associated with the central channel 47 are in direct fluid communication with an outlet 182 , which delivers the ink to the underside of the ICs 50 . The inlets 180 associated with the other channels 47 include tunnels 181 formed within the ink distribution member 48 which are in fluid communication with associated outlets 182 disposed remote from the inlets 180 to deliver ink to the underside of the ICs 50 . As is shown, in this arrangement the outlets 182 are centrally arranged on the upper surface of the ink distribution member in a predetermined pattern, with the position of each outlet defining a point at which ink of a specific colour is delivered to the IC 50 .
[0444] FIG. 34 b is a magnified view of FIG. 34 a , showing in detail the manner in which the ink is supplied to the underside of the ICs 50 . The channels 98 formed on the underside of the IC 50 are clearly shown, as are the silicon walls 99 provided along the length of the channels 98 , which divide the channels 98 into portions. As shown, the ICs 50 are positioned on the surface of the ink distribution member such that the outlets 182 align with the channels 98 at the junction of the channel portions, namely at the region where the silicon walls 99 are situated. This then ensures that one outlet 182 supplies ink to two channel portions, allowing a regular spacing of outlets to be achieved along the surface of the ink distribution member 48 .
[0445] In the above described embodiment, the ink distribution member 48 is in the form of a on-piece element thereby overcoming the need to provide separate layers and reducing the complexity of the system, as sealing between layers is no longer required.
[0446] Following attachment and alignment of each of the printhead ICs 50 to the surface of the ink distribution member 48 , a flex PCB 52 is attached along an edge of the ICs 50 so that control signals and power can be supplied to the bond bads 96 of the ICs 50 to effect printing. As shown more clearly in FIG. 20 , the flex PCB 52 folds around the printhead assembly 22 in an upward direction with respect to the cartridge unit 10 , and has a plurality of dimpled contacts 53 provided along its length for receiving power and or data signals from the control circuitry of the cradle unit 12 . A plurality of holes 54 are also formed along the distal edge of the flex PCB 52 which provide a means for attaching the flex PCB 52 to the locating studs 38 formed on the main body 20 , such that the dimpled contacts 53 of the flex PCB 52 extends over the flex PCB backer 37 . The manner in which the dimpled contacts 53 of the flex PCB 52 contact the power and data contacts 128 of the cradle unit 12 is described later.
[0447] A media shield 55 is attached to the printhead assembly 22 along an edge thereof and acts to protect the printhead ICs 50 from damage which may occur due to contact with the passing media. The media shield 55 is attached to the upper moulding 42 upstream of the printhead ICs 50 as shown more clearly in FIG. 21 , via an appropriate clip-lock arrangement or via an adhesive.
[0448] When attached in this manner, the printhead ICs 50 sit below the surface of the media shield 55 , out of the path of the passing media.
[0449] As shown in FIGS. 20 and 21 , a space 56 is provided between the media shield 55 and the upper 42 and lower 45 moulding which can receive pressurized air from an air compressor or the like. As this space 56 extends along the length of the printhead assembly 22 , compressed air can be supplied to the space 56 from either end of the printhead assembly 22 and be evenly distributed along the assembly. The inner surface 57 of the media shield 55 is provided with a series of fins 58 which define a plurality of air outlets evenly distributed along the length of the media shield 55 through which the compressed air travels. This arrangement therefore provides a stream of air across the printhead ICs 50 in the direction of the media delivery which acts to prevent dust and other particulate matter carried with the media from settling on the surface of the printhead ICs, which could cause blockage and damage to the nozzles.
[0450] A cross section of the complete printhead assembly 22 is shown in FIG. 21 . As shown, ink is received from the ink storage compartments 24 via the ink inlets 44 of the upper moulding 42 , which feed the ink directly into one of the ink channels 47 of the lower moulding 45 . The ink is in turn fed from the ink channels 47 to the ink delivery nozzles 51 of the printhead ICs 50 by way of the ink distribution member 48 .
[0451] As shown in FIGS. 20 and 21 , the lower moulding 45 is provided with a plurality of priming inlets 59 at one end thereof. Each of the priming inlets 59 communicate directly with one of the channels 47 and provide a means for priming the printhead assembly 22 and the ink storage compartments 24 with ink prior to shipment and use. Various ways in which the priming is achieved will now be described with reference to FIGS. 35-40 .
[0452] FIG. 35 is a simplified cross-sectional representation of an ink storage compartment 24 as described previously. Ink is primed into the absorbent material 29 through the ink outlet 27 which links the compartment 24 to the channels 47 of the printhead assembly 22 . In this regard, the ink is supplied via the priming inlets 59 along the channels 47 of the lower moulding 45 , with each channel 47 in fluid communication with one ink outlet 27 of an ink storage compartment 24 to deliver ink of a specific type/colour to that ink storage compartment 24 .
[0453] Priming of the ink storage compartments 24 is typically performed prior to shipment of the cartridge unit 10 and as such, an ink source can be temporarily attached to the priming inlets 59 , wherein upon completion of priming, the priming inlets can be capped/sealed.
[0454] As discussed above, priming ink is supplied under pressure to the ink storage compartment 24 via the ink outlets 27 . The priming ink flows into the space between the ink filter/air barrier 28 and the outlet 27 , and is absorbed into the absorbent material 29 through the ink filter/air barrier 28 . As discussed above, due to the porous nature of the absorbent material 29 the ink becomes suspended within the absorbent material due to capillary attraction forces. By keeping the upper surface of the absorbent material 29 dry and exposed to atmospheric pressure through the vent hole 63 , the ink is able to be continually drawn into the pores of the absorbent material 29 via capillary action (as shown by arrows B).
[0455] As discussed above, ink present in the channels 47 of the lower moulding 45 is also supplied to the ink delivery nozzles 51 of the integrated circuits 50 , via the ink distribution member 48 . During the above described priming process, the ink flows to the nozzles 51 to prime the individual nozzles with ink, and due to the capillary action of the absorbent material 29 in the ink storage compartments 24 , a sufficient backpressure is established in the ink supply to prevent leakage of the ink out of the nozzles 51 .
[0456] In this regard, the priming operation is ceased before the absorbent material becomes completely saturated and its upper surface becomes wet with ink, so that the necessary backpressure can be maintained. This may be controlled by limiting the supply of ink or by more sophisticated methods, such as sensing the level of ink within the body. Hydrophobic material may also be used on the surface of the ICs 50 in the vicinity of the nozzles 51 so as to assist in leakage prevention.
[0457] In the above-described arrangement, it may be necessary to maintain the pressure of the supplied ink to be below a level which ensures the ink is not ejected through the nozzle outlets 51 during priming. Practically, this situation may increase the required time necessary to prime the cartridge unit 10 .
[0458] An alternative embodiment for configuring the ink storage compartments 24 which provides a means of substantially obviating the need to limit the ink pressure during priming is illustrated in FIGS. 35 to 39 . In this embodiment, a bypass fluid path 185 is provided in fluid communication with the ink outlet 27 .
[0459] The bypass fluid path 185 allows the priming ink an additional path into the ink storage compartment 24 where it can be absorbed by the absorbent material 29 . In this regard, the priming ink does not only flow through the ink filter air barrier 28 directly into the absorbent material 29 , but can also flow into at least a portion of a well region 24 a of the compartment 24 , as illustrated by arrows C in FIG. 36 . The well region 24 a is the annular region surrounding the raised portions 26 on the base 25 of the compartments where there is a gap between the base 25 of the compartment 24 and the absorbent material 29 . This well region 24 a defines a space where the priming ink can be readily delivered via the bypass fluid path 185 .
[0460] With this arrangement, by providing more than one path for the ink to enter the ink storage compartment 24 , a larger surface area of the absorbent material 29 is exposed to the priming ink and as such the ink is drawn into the absorbent material more quickly and the supply pressure of the priming ink can be reduced.
[0461] The path 185 is provided with a bypass valve 186 which is open during initial priming of the cartridge unit 10 and is closed upon completion of the priming operation, as shown in FIG. 37 . The bypass valve 186 may be provided by way of a variety of arrangements and may be either manually or automatically controlled. For example, the bypass valve 186 may be provided as a manual depression button as illustrated in FIGS. 38 and 39 .
[0462] In this arrangement, the bypass valve 186 is in the form of a button 187 provided as a flexible portion of the bottom wall of the path 185 . The button 187 may be made from a rubber material and may be connected to the wall of the path 185 via an annular weakened portion 187 a . Initially, and during priming, the button 187 is positioned as shown in FIG. 38 to allow the priming ink to flow through the path 185 . Once priming is complete, the path 185 is closed by depressing the button 187 into a circular recessed region 188 of the internal wall of the path 185 . In this regard, the button 187 is captured by the lip 189 and retained therein, thereby blocking the bypass valve 186 , as shown in FIG. 39 .
[0463] It will be appreciated that those skilled in the art will understand that other bypass valve structures are possible and encompassed by the present invention. For example, a simple alternative to the above may be providing the additional fluid path 185 as a compressible silicon tube or the like.
[0464] The bypass valve 186 may be configured to be irreversibly closed once the priming is completed. On the other hand, if refilling of the storage compartments via the priming inlets of the printhead assembly 22 is desired, a bypass valve capable of being opened and closed without limit may be provided.
[0465] Another embodiment of the ink storage compartments 24 which provides an alternative or additional arrangement for priming the compartments 24 with ink is illustrated in FIG. 40 .
[0466] In this arrangement, a port 190 is provided in at least one of the side walls of each compartment 24 in a position below the upper surface of the absorbent material 29 . The ports 190 are provided for the insertion of a needle 191 from an external ink source syringe or the like (not shown) which penetrates into the absorbent material 29 , and through which the priming ink is supplied into the body. The ports 190 are configured so that the needle 191 supplies the priming ink towards the lower portion of the absorbent material 29 , shown with arrows D in FIG. 40 , so as to prevent wetting of the uppermost portion of the absorbent material 29 , for the reasons discussed above.
[0467] Each port 190 is provided with a valve 192 which allows penetration of the needle 191 and is sealed when the needle is extracted and at other times. For example, the valve 192 may incorporate an elastomeric seal.
[0468] In this way, the priming ink is delivered directly to the absorbent material 29 and through capillary force is suspended therein for delivery to the nozzles of the printhead assembly 22 , as shown with arrow E in FIG. 40 .
[0469] The arrangement of this embodiment may be provided independently of those of the above-described embodiments, or may be used in conjunction with those arrangements to provide an additional refilling mechanism for the ink storage compartments 24 .
Ink Delivery Nozzles
[0470] An example of a type of ink delivery nozzle arrangement suitable for the present invention, comprising a nozzle and corresponding actuator, will now be described with reference to FIGS. 41 to 50 . FIG. 50 shows an array of ink delivery nozzle arrangements 801 formed on a silicon substrate 8015 . Each of the nozzle arrangements 801 are identical, however groups of nozzle arrangements 801 are arranged to be fed with different colored inks or fixative. In this regard, the nozzle arrangements are arranged in rows and are staggered with respect to each other, allowing closer spacing of ink dots during printing than would be possible with a single row of nozzles. Such an arrangement makes it possible to provide a high density of nozzles, for example, more than 5000 nozzles arrayed in a plurality of staggered rows each having an interspacing of about 32 microns between the nozzles in each row and about 80 microns between the adjacent rows. The multiple rows also allow for redundancy (if desired), thereby allowing for a predetermined failure rate per nozzle.
[0471] Each nozzle arrangement 801 is the product of an integrated circuit fabrication technique. In particular, the nozzle arrangement 801 defines a micro-electromechanical system (MEMS).
[0472] For clarity and ease of description, the construction and operation of a single nozzle arrangement 801 will be described with reference to FIGS. 41 to 49 .
[0473] The ink jet printhead integrated circuit 50 includes a silicon wafer substrate 8015 having 0.35 Micron 1 P4M 12 volt CMOS microprocessing electronics is positioned thereon.
[0474] A silicon dioxide (or alternatively glass) layer 8017 is positioned on the substrate 8015 . The silicon dioxide layer 8017 defines CMOS dielectric layers. CMOS top-level metal defines a pair of aligned aluminium electrode contact layers 8030 positioned on the silicon dioxide layer 8017 . Both the silicon wafer substrate 8015 and the silicon dioxide layer 8017 are etched to define an ink inlet channel 8014 having a generally circular cross section (in plan). An aluminium diffusion barrier 8028 of CMOS metal 1 , CMOS metal ⅔ and CMOS top level metal is positioned in the silicon dioxide layer 8017 about the ink inlet channel 8014 . The diffusion barrier 8028 serves to inhibit the diffusion of hydroxyl ions through CMOS oxide layers of the drive electronics layer 8017 .
[0475] A passivation layer in the form of a layer of silicon nitride 8031 is positioned over the aluminium contact layers 8030 and the silicon dioxide layer 8017 . Each portion of the passivation layer 8031 positioned over the contact layers 8030 has an opening 8032 defined therein to provide access to the contacts 8030 .
[0476] The nozzle arrangement 801 includes a nozzle chamber 8029 defined by an annular nozzle wall 8033 , which terminates at an upper end in a nozzle roof 8034 and a radially inner nozzle rim 804 that is circular in plan. The ink inlet channel 8014 is in fluid communication with the nozzle chamber 8029 . At a lower end of the nozzle wall, there is disposed a moving rim 8010 , that includes a moving seal lip 8040 . An encircling wall 8038 surrounds the movable nozzle, and includes a stationary seal lip 8039 that, when the nozzle is at rest as shown in FIG. 44 , is adjacent the moving rim 8010 . A fluidic seal 8011 is formed due to the surface tension of ink trapped between the stationary seal lip 8039 and the moving seal lip 8040 . This prevents leakage of ink from the chamber whilst providing a low resistance coupling between the encircling wall 8038 and the nozzle wall 8033 .
[0477] As best shown in FIG. 48 , a plurality of radially extending recesses 8035 is defined in the roof 8034 about the nozzle rim 804 . The recesses 8035 serve to contain radial ink flow as a result of ink escaping past the nozzle rim 804 .
[0478] The nozzle wall 8033 forms part of a lever arrangement that is mounted to a carrier 8036 having a generally U-shaped profile with a base 8037 attached to the layer 8031 of silicon nitride.
[0479] The lever arrangement also includes a lever arm 8018 that extends from the nozzle walls and incorporates a lateral stiffening beam 8022 . The lever arm 8018 is attached to a pair of passive beams 806 , formed from titanium nitride (TiN) and positioned on either side of the nozzle arrangement, as best shown in FIGS. 44 and 49 . The other ends of the passive beams 806 are attached to the carrier 8036 .
[0480] The lever arm 8018 is also attached to an actuator beam 807 , which is formed from TiN. It will be noted that this attachment to the actuator beam is made at a point a small but critical distance higher than the attachments to the passive beam 806 .
[0481] As best shown in FIGS. 41 and 47 , the actuator beam 807 is substantially U-shaped in plan, defining a current path between the electrode 809 and an opposite electrode 8041 . Each of the electrodes 809 and 8041 are electrically connected to respective points in the contact layer 8030 . As well as being electrically coupled via the contacts 809 , the actuator beam is also mechanically anchored to anchor 808 . The anchor 808 is configured to constrain motion of the actuator beam 807 to the left of FIGS. 44 to 46 when the nozzle arrangement is in operation.
[0482] The TiN in the actuator beam 807 is conductive, but has a high enough electrical resistance that it undergoes self-heating when a current is passed between the electrodes 809 and 8041 . No current flows through the passive beams 806 , so they do not expand.
[0483] In use, the device at rest is filled with ink 8013 that defines a meniscus 803 under the influence of surface tension. The ink is retained in the chamber 8029 by the meniscus, and will not generally leak out in the absence of some other physical influence.
[0484] As shown in FIG. 42 , to fire ink from the nozzle, a current is passed between the contacts 809 and 8041 , passing through the actuator beam 807 . The self-heating of the beam 807 due to its resistance causes the beam to expand. The dimensions and design of the actuator beam 807 mean that the majority of the expansion in a horizontal direction with respect to FIGS. 41 to 43 . The expansion is constrained to the left by the anchor 808 , so the end of the actuator beam 807 adjacent the lever arm 8018 is impelled to the right.
[0485] The relative horizontal inflexibility of the passive beams 806 prevents them from allowing much horizontal movement the lever arm 8018 . However, the relative displacement of the attachment points of the passive beams and actuator beam respectively to the lever arm causes a twisting movement that causes the lever arm 8018 to move generally downwards. The movement is effectively a pivoting or hinging motion. However, the absence of a true pivot point means that the rotation is about a pivot region defined by bending of the passive beams 806 .
[0486] The downward movement (and slight rotation) of the lever arm 8018 is amplified by the distance of the nozzle wall 8033 from the passive beams 806 . The downward movement of the nozzle walls and roof causes a pressure increase within the chamber 8029 , causing the meniscus to bulge as shown in FIG. 42 . It will be noted that the surface tension of the ink means the fluid seal 8011 is stretched by this motion without allowing ink to leak out.
[0487] As shown in FIG. 43 , at the appropriate time, the drive current is stopped and the actuator beam 807 quickly cools and contracts. The contraction causes the lever arm to commence its return to the quiescent position, which in turn causes a reduction in pressure in the chamber 8029 . The interplay of the momentum of the bulging ink and its inherent surface tension, and the negative pressure caused by the upward movement of the nozzle chamber 8029 causes thinning, and ultimately snapping, of the bulging meniscus to define an ink drop 802 that continues upwards until it contacts adjacent print media.
[0488] Immediately after the drop 802 detaches, meniscus 803 forms the concave shape shown in FIG. 43 . Surface tension causes the pressure in the chamber 8029 to remain relatively low until ink has been sucked upwards through the inlet 8014 , which returns the nozzle arrangement and the ink to the quiescent situation shown in FIG. 61 .
[0489] Another type of printhead nozzle arrangement suitable for the present invention will now be described with reference to FIG. 51 . Once again, for clarity and ease of description, the construction and operation of a single nozzle arrangement 1001 will be described.
[0490] The nozzle arrangement 1001 is of a bubble forming heater element actuator type which comprises a nozzle plate 1002 with a nozzle 1003 therein, the nozzle having a nozzle rim 1004 , and aperture 1005 extending through the nozzle plate. The nozzle plate 1002 is plasma etched from a silicon nitride structure which is deposited, by way of chemical vapor deposition (CVD), over a sacrificial material which is subsequently etched.
[0491] The nozzle arrangement includes, with respect to each nozzle 1003 , side walls 1006 on which the nozzle plate is supported, a chamber 1007 defined by the walls and the nozzle plate 1002 , a multi-layer substrate 1008 and an inlet passage 1009 extending through the multi-layer substrate to the far side (not shown) of the substrate. A looped, elongate heater element 1010 is suspended within the chamber 1007 , so that the element is in the form of a suspended beam. The nozzle arrangement as shown is a microelectromechanical system (MEMS) structure, which is formed by a lithographic process.
[0492] When the nozzle arrangement is in use, ink 1011 from a reservoir (not shown) enters the chamber 1007 via the inlet passage 1009 , so that the chamber fills. Thereafter, the heater element 1010 is heated for somewhat less than 1 micro second, so that the heating is in the form of a thermal pulse. It will be appreciated that the heater element 1010 is in thermal contact with the ink 1011 in the chamber 1007 so that when the element is heated, this causes the generation of vapor bubbles in the ink. Accordingly, the ink 1011 constitutes a bubble forming liquid.
[0493] The bubble 1012 , once generated, causes an increase in pressure within the chamber 1007 , which in turn causes the ejection of a drop 1016 of the ink 1011 through the nozzle 1003 .
[0494] The rim 1004 assists in directing the drop 1016 as it is ejected, so as to minimize the chance of a drop misdirection.
[0495] The reason that there is only one nozzle 1003 and chamber 1007 per inlet passage 1009 is so that the pressure wave generated within the chamber, on heating of the element 1010 and forming of a bubble 1012 , does not effect adjacent chambers and their corresponding nozzles.
[0496] The increase in pressure within the chamber 1007 not only pushes ink 1011 out through the nozzle 1003 , but also pushes some ink back through the inlet passage 1009 . However, the inlet passage 1009 is approximately 200 to 300 microns in length, and is only approximately 16 microns in diameter. Hence there is a substantial viscous drag. As a result, the predominant effect of the pressure rise in the chamber 1007 is to force ink out through the nozzle 1003 as an ejected drop 1016 , rather than back through the inlet passage 1009 .
[0497] As shown in FIG. 51 , the ink drop 1016 is being ejected is shown during its “necking phase” before the drop breaks off. At this stage, the bubble 1012 has already reached its maximum size and has then begun to collapse towards the point of collapse 1017 .
[0498] The collapsing of the bubble 1012 towards the point of collapse 1017 causes some ink 1011 to be drawn from within the nozzle 1003 (from the sides 1018 of the drop), and some to be drawn from the inlet passage 1009 , towards the point of collapse. Most of the ink 1011 drawn in this manner is drawn from the nozzle 1003 , forming an annular neck 1019 at the base of the drop 16 prior to its breaking off.
[0499] The drop 1016 requires a certain amount of momentum to overcome surface tension forces, in order to break off. As ink 1011 is drawn from the nozzle 1003 by the collapse of the bubble 1012 , the diameter of the neck 1019 reduces thereby reducing the amount of total surface tension holding the drop, so that the momentum of the drop as it is ejected out of the nozzle is sufficient to allow the drop to break off.
[0500] When the drop 1016 breaks off, cavitation forces are caused as reflected by the arrows 1020 , as the bubble 1012 collapses to the point of collapse 1017 . It will be noted that there are no solid surfaces in the vicinity of the point of collapse 1017 on which the cavitation can have an effect.
[0501] Yet another type of printhead nozzle arrangement suitable for the present invention will now be described with reference to FIGS. 52-54 . This type typically provides an ink delivery nozzle arrangement having a nozzle chamber containing ink and a thermal bend actuator connected to a paddle positioned within the chamber. The thermal actuator device is actuated so as to eject ink from the nozzle chamber. The preferred embodiment includes a particular thermal bend actuator which includes a series of tapered portions for providing conductive heating of a conductive trace. The actuator is connected to the paddle via an arm received through a slotted wall of the nozzle chamber. The actuator arm has a mating shape so as to mate substantially with the surfaces of the slot in the nozzle chamber wall.
[0502] Turning initially to FIGS. 52( a )-( c ), there is provided schematic illustrations of the basic operation of a nozzle arrangement of this embodiment. A nozzle chamber 501 is provided filled with ink 502 by means of an ink inlet channel 503 which can be etched through a wafer substrate on which the nozzle chamber 501 rests. The nozzle chamber 501 further includes an ink ejection port 504 around which an ink meniscus forms.
[0503] Inside the nozzle chamber 501 is a paddle type device 507 which is interconnected to an actuator 508 through a slot in the wall of the nozzle chamber 501 . The actuator 508 includes a heater means e.g. 509 located adjacent to an end portion of a post 510 . The post 510 is fixed to a substrate.
[0504] When it is desired to eject a drop from the nozzle chamber 501 , as illustrated in FIG. 52( b ), the heater means 509 is heated so as to undergo thermal expansion. Preferably, the heater means 509 itself or the other portions of the actuator 508 are built from materials having a high bend efficiency where the bend efficiency is defined as:
[0000]
bend
efficiency
=
Young
'
s
Modulus
×
(
Coefficient
of
thermal
Expansion
)
Density
×
Specific
Heat
Capacity
[0505] A suitable material for the heater elements is a copper nickel alloy which can be formed so as to bend a glass material.
[0506] The heater means 509 is ideally located adjacent the end portion of the post 510 such that the effects of activation are magnified at the paddle end 507 such that small thermal expansions near the post 510 result in large movements of the paddle end.
[0507] The heater means 509 and consequential paddle movement causes a general increase in pressure around the ink meniscus 505 which expands, as illustrated in FIG. 52( b ), in a rapid manner. The heater current is pulsed and ink is ejected out of the port 504 in addition to flowing in from the ink channel 503 .
[0508] Subsequently, the paddle 507 is deactivated to again return to its quiescent position. The deactivation causes a general reflow of the ink into the nozzle chamber. The forward momentum of the ink outside the nozzle rim and the corresponding backflow results in a general necking and breaking off of the drop 512 which proceeds to the print media. The collapsed meniscus 505 results in a general sucking of ink into the nozzle chamber 502 via the ink flow channel 503 . In time, the nozzle chamber 501 is refilled such that the position in FIG. 52( a ) is again reached and the nozzle chamber is subsequently ready for the ejection of another drop of ink.
[0509] FIG. 53 illustrates a side perspective view of the nozzle arrangement. FIG. 54 illustrates sectional view through an array of nozzle arrangement of FIG. 53 . In these figures, the numbering of elements previously introduced has been retained.
[0510] Firstly, the actuator 508 includes a series of tapered actuator units e.g. 515 which comprise an upper glass portion (amorphous silicon dioxide) 516 formed on top of a titanium nitride layer 517 . Alternatively a copper nickel alloy layer (hereinafter called cupronickel) can be utilized which will have a higher bend efficiency.
[0511] The titanium nitride layer 517 is in a tapered form and, as such, resistive heating takes place near an end portion of the post 510 . Adjacent titanium nitride/glass portions 515 are interconnected at a block portion 519 which also provides a mechanical structural support for the actuator 508 .
[0512] The heater means 509 ideally includes a plurality of the tapered actuator unit 515 which are elongate and spaced apart such that, upon heating, the bending force exhibited along the axis of the actuator 508 is maximized. Slots are defined between adjacent tapered units 515 and allow for slight differential operation of each actuator 508 with respect to adjacent actuators 508 .
[0513] The block portion 519 is interconnected to an arm 520 . The arm 520 is in turn connected to the paddle 507 inside the nozzle chamber 501 by means of a slot e.g. 522 formed in the side of the nozzle chamber 501 . The slot 522 is designed generally to mate with the surfaces of the arm 520 so as to minimize opportunities for the outflow of ink around the arm 520 . The ink is held generally within the nozzle chamber 501 via surface tension effects around the slot 522 .
[0514] When it is desired to actuate the arm 520 , a conductive current is passed through the titanium nitride layer 517 within the block portion 519 connecting to a lower CMOS layer 506 which provides the necessary power and control circuitry for the nozzle arrangement. The conductive current results in heating of the nitride layer 517 adjacent to the post 510 which results in a general upward bending of the arm 20 and consequential ejection of ink out of the nozzle 504 . The ejected drop is printed on a page in the usual manner for an inkjet printer as previously described.
[0515] An array of nozzle arrangements can be formed so as to create a single printhead. For example, in FIG. 54 there is illustrated a partly sectioned various array view which comprises multiple ink ejection nozzle arrangements of FIG. 53 laid out in interleaved lines so as to form a printhead array. Of course, different types of arrays can be formulated including full color arrays etc.
[0516] The construction of the printhead system described can proceed utilizing standard MEMS techniques through suitable modification of the steps as set out in U.S. Pat. No. 6,243,113 entitled “Image Creation Method and Apparatus (IJ 41 )” to the present applicant, the contents of which are fully incorporated by cross reference.
[0517] The integrated circuits 50 may be arranged to have between 5000 to 100,000 of the above described ink delivery nozzles arranged along its surface, depending upon the length of the integrated circuits and the desired printing properties required. For example, for narrow media it may be possible to only require 5000 nozzles arranged along the surface of the printhead assembly to achieve a desired printing result, whereas for wider media a minimum of 10,000, 20,000 or 50,000 nozzles may need to be provided along the length of the printhead assembly to achieve the desired printing result. For full colour photo quality images on A4 or US letter sized media at or around 1600 dpi, the integrated circuits 50 may have 13824 nozzles per color. Therefore, in the case where the printhead assembly 22 is capable of printing in 4 colours (C, M, Y, K), the integrated circuits 50 may have around 53396 nozzles disposed along the surface thereof. Further, in a case where the printhead assembly 22 is capable of printing 6 printing fluids (C, M, Y, K, IR and a fixative) this may result in 82944 nozzles being provided on the surface of the integrated circuits 50 . In all such arrangements, the electronics supporting each nozzle is the same.
[0518] The manner in which the individual ink delivery nozzle arrangements may be controlled within the printhead assembly 22 will now be described with reference to FIGS. 55-58 .
[0519] FIG. 55 shows an overview of the integrated circuit 50 and its connections to the SoPEC device (discussed above) provided within the control electronics of the print engine 1 . As discussed above, integrated circuit 50 includes a nozzle core array 901 containing the repeated logic to fire each nozzle, and nozzle control logic 902 to generate the timing signals to fire the nozzles. The nozzle control logic 902 receives data from the SoPEC device via a high-speed link.
[0520] The nozzle control logic 902 is configured to send serial data to the nozzle array core for printing, via a link 907 , which may be in the form of an electrical connector. Status and other operational information about the nozzle array core 901 is communicated back to the nozzle control logic 902 via another link 908 , which may be also provided on the electrical connector.
[0521] The nozzle array core 901 is shown in more detail in FIGS. 56 and 57 . In FIG. 56 , it will be seen that the nozzle array core 901 comprises an array of nozzle columns 911 . The array includes a fire/select shift register 912 and up to 6 color channels, each of which is represented by a corresponding dot shift register 913 .
[0522] As shown in FIG. 57 , the fire/select shift register 912 includes forward path fire shift register 930 , a reverse path fire shift register 931 and a select shift register 932 . Each dot shift register 913 includes an odd dot shift register 933 and an even dot shift register 934 . The odd and even dot shift registers 933 and 934 are connected at one end such that data is clocked through the odd shift register 933 in one direction, then through the even shift register 934 in the reverse direction. The output of all but the final even dot shift register is fed to one input of a multiplexer 935 . This input of the multiplexer is selected by a signal (corescan) during post-production testing. In normal operation, the corescan signal selects dot data input Dot[x] supplied to the other input of the multiplexer 935 . This causes Dot[x] for each color to be supplied to the respective dot shift registers 913 .
[0523] A single column N will now be described with reference to FIG. 57 . In the embodiment shown, the column N includes 12 data values, comprising an odd data value 936 and an even data value 937 for each of the six dot shift registers. Column N also includes an odd fire value 938 from the forward fire shift register 930 and an even fire value 939 from the reverse fire shift register 931 , which are supplied as inputs to a multiplexer 940 . The output of the multiplexer 940 is controlled by the select value 941 in the select shift register 932 . When the select value is zero, the odd fire value is output, and when the select value is one, the even fire value is output.
[0524] Each of the odd and even data values 936 and 937 is provided as an input to corresponding odd and even dot latches 942 and 943 respectively.
[0525] Each dot latch and its associated data value form a unit cell, such as unit cell 944 . A unit cell is shown in more detail in FIG. 58 . The dot latch 942 is a D-type flip-flop that accepts the output of the data value 936 , which is held by a D-type flip-flop 944 forming an element of the odd dot shift register 933 . The data input to the flip-flop 944 is provided from the output of a previous element in the odd dot shift register (unless the element under consideration is the first element in the shift register, in which case its input is the Dot[x] value). Data is clocked from the output of flip-flop 944 into latch 942 upon receipt of a negative pulse provided on LsyncL.
[0526] The output of latch 942 is provided as one of the inputs to a three-input AND gate 945 . Other inputs to the AND gate 945 are the Fr signal (from the output of multiplexer 940 ) and a pulse profile signal Pr. The firing time of a nozzle is controlled by the pulse profile signal Pr, and can be, for example, lengthened to take into account a low voltage condition that arises due to low power supply (in a removable power supply embodiment). This is to ensure that a relatively consistent amount of ink is efficiently ejected from each nozzle as it is fired. In the embodiment described, the profile signal Pr is the same for each dot shift register, which provides a balance between complexity, cost and performance. However, in other embodiments, the Pr signal can be applied globally (ie, is the same for all nozzles), or can be individually tailored to each unit cell or even to each nozzle.
[0527] Once the data is loaded into the latch 942 , the fire enable Fr and pulse profile Pr signals are applied to the AND gate 945 , combining to the trigger the nozzle to eject a dot of ink for each latch 942 that contains a logic 1.
[0528] The signals for each nozzle channel are summarized in the following table:
[0000]
Name
Direction
Description
D
Input
Input dot pattern to shift register bit
Q
Output
Output dot pattern from shift register bit
SrClk
Input
Shift register clock in - d is captured on rising
edge of this clock
LsyncL
Input
Fire enable - needs to be asserted for nozzle to fire
Pr
Input
Profile - needs to be asserted for nozzle to fire
[0529] As shown in FIG. 58 , the fire signals Fr are routed on a diagonal, to enable firing of one color in the current column, the next color in the following column, and so on. This averages the current demand by spreading it over 6 columns in time-delayed fashion.
[0530] The dot latches and the latches forming the various shift registers are fully static in this embodiment, and are CMOS-based. The design and construction of latches is well known to those skilled in the art of integrated circuit engineering and design, and so will not be described in detail in this document.
[0531] The nozzle speed may be as much as 20 kHz for the printer unit 2 capable of printing at about 60 ppm, and even more for higher speeds. At this range of nozzle speeds the amount of ink than can be ejected by the entire printhead assembly 22 is at least 50 million drops per second. However, as the number of nozzles is increased to provide for higher-speed and higher-quality printing at least 100 million drops per second, preferably at least 500 million drops per second and more preferably at least 1 billion drops per second may be delivered. At such speeds, the drops of ink are ejected by the nozzles with a maximum drop ejection energy of about 250 nanojoules per drop.
[0532] Consequently, in order to accommodate printing at these speeds, the control electronics must be able to determine whether a nozzle is to eject a drop of ink at an equivalent rate. In this regard, in some instances the control electronics must be able to determine whether a nozzle ejects a drop of ink at a rate of at least 50 million determinations per second. This may increase to at least 100 million determinations per second or at least 500 million determinations per second, and in many cases at least 1 billion determinations per second for the higher-speed, higher-quality printing applications.
[0533] For the printer unit 2 of the present invention, the above-described ranges of the number of nozzles provided on the printhead assembly 22 together with the nozzle firing speeds and print speeds results in an area print speed of at least 50 cm 2 per second, and depending on the printing speed, at least 100 cm 2 per second, preferably at least 200 cm 2 per second, and more preferably at least 500 cm 2 per second at the higher-speeds. Such an arrangement provides a printer unit 2 that is capable of printing an area of media at speeds not previously attainable with conventional printer units.
Lid Assembly
[0534] The lid assembly 21 of the cartridge unit 10 is shown in FIGS. 59-61 . The lid assembly 21 is arranged to fit over the main body 20 , thereby sealing each of the ink storage compartments 24 . As such, the lid assembly 21 is shaped to conform to the shape of main body 20 and is attached to the main body via ultrasonic welding, or any other suitable method which provides a sealed connection.
[0535] The outer surface 60 of the lid assembly 21 is provided with a number of ink refill ports 61 , for receiving ink from a refill unit 200 and for directing the refill ink into one of the ink storage compartments 24 of the main body 20 . In the embodiment shown in FIG. 59 , there are five ink refill ports 61 provided, with each of the refill ports being in fluid communication with one of the five ink storage compartments 24 to facilitate refilling of the associated compartments with ink.
[0536] The ink refills ports 61 are in the form of holes extending through the lid assembly 11 and each hole is provided with a valve fitting 62 made from an elastomeric moulding. The valve fittings 62 act to seal the ports 61 during non refill periods and provide a means for interacting with an outlet of the ink refill unit 200 to ensure controlled transfer of ink between the ink refill unit 200 and the ink storage compartment 24 . In this regard, when an ink refill unit 200 is not in communication with the ink refill ports 61 the valve fittings 62 seal the ink refill ports, and when the ink refill unit 200 is in communication with the ink refill ports, the valve fittings permits transfer of ink from the ink refill unit through the ink refill ports. The manner in which this is achieved is described later in the description.
[0537] The outer surface 60 of the lid assembly 21 also includes a venting arrangement which provides air venting of each ink storage compartment 24 . The venting arrangement consists of individual vent holes 63 which extend into the individual ink storage compartments 24 and channels 64 which extend from the vent holes 63 to the edge of the lid assembly 21 . The channels 64 are preferably etched into the outer surface 60 of the lid assembly and assume a tortuous path in the passage from the vent holes 63 to the edge of the lid assembly.
[0538] As shown in FIG. 61 , a film 65 is placed over the outer surface 60 of the lid assembly and includes holes 66 formed therein which fit around the ink refill ports 61 . The film 65 may be an adhesive film such as a sticker/label or the like which may also have printed thereon instruction information to assist the user in handling the cartridge unit 10 . When applied to the surface of the lid assembly 21 , the film sits atop the etched channels 64 formed in the outer surface 60 , thereby enclosing the venting passage from the vent hole 63 to the edge of the lid assembly 21 which enables the ink storage compartment to breathe via the tortuous path.
[0539] The underside of the lid assembly 21 is shown in more detail in FIG. 60 and includes flow channels 67 extending from the underside of the ink refill ports 61 to direct the refill ink into the appropriate ink storage compartment 24 . As shown in FIG. 61 , a weld membrane 68 is welded to the underside of the ink refill ports 61 and the flow channels 67 to form sealed delivery passages along which the ink passes en route to each of the ink storage compartments 24 .
[0540] The underside of the lid assembly 21 , also includes moulded features or ridges 69 which extend into the ink storage compartments 24 when the lid assembly 21 is sealed to the main body 20 . These moulded features or ridges 69 ensure that an air gap is formed above the absorbent material 29 for venting via the vent hole 63 to assist the absorbent material 29 to function to absorb the ink and retain the ink suspended therein under capillary action.
[0541] As shown in FIGS. 59 and 60 , extending downwardly from the outer surface 60 of the lid assembly 21 are a pair of guide walls 70 . The guide walls 70 assist in locating the lid assembly 21 on the main body 20 during assembly. The guide walls 70 also have a recessed portion 71 formed therein which acts as a hand grip to assist in handling the cartridge unit during use.
[0542] As shown more clearly in FIG. 59 , the guide wall 70 that extends along the face of the main body 20 proximal the printhead assembly 22 also includes a series of holes 72 in a lower edge thereof. These holes 72 are arranged to align with and receive the locating studs 38 provided on the main body 20 onto which the flex PCB backer 37 and the flex PCB 52 of the printhead assembly 22 are attached. In this arrangement, when the lid assembly 21 is fixed to the main body 20 , a portion of the flex PCB 52 of the printhead assembly 22 is sandwiched between the guide wall 70 and the flex PCB backer 37 , thereby acting to help retain the flex PCB 52 in position.
Capper Assembly
[0543] As discussed previously and shown in FIGS. 11 and 12 , the main body 20 of the cartridge unit 10 is provided with downwardly projecting end supports 40 . The end supports 40 are integral with the main body 20 and are arranged such that the printhead assembly 22 is positioned between the end supports. Each of the end supports 40 are configured to receive the capping assembly 23 and as such have retaining projections 73 formed on their surfaces to retain the capping assembly 23 in position.
[0544] The capping assembly 23 is shown in more detail in FIGS. 62 to 67 , and generally consists of a capper chassis 74 which receives the various components of the capping assembly 23 therein. The capper chassis 74 is in the form of an open ended channel having a pair of upwardly extending tongue portions 75 at its ends which are shaped to fit over the end supports 40 of the main body and engage with the retaining projections 73 provided thereon to secure the capper assembly 23 in position. The capper chassis 74 essentially retains the parts of the capper assembly 23 therein, and is made from a suitable metal material, having rigidity and resilience, such as a pressed steel plate.
[0545] The base of the capper chassis 74 is shown more clearly in FIG. 64 and includes a centrally located removed portion 76 and spring arms 77 extending from either side of the removed portion 76 towards the tongue portions 75 . The spring arms 77 are hingedly fixed to the chassis 74 at the region proximal the removed portion, and are biased inwards of the capper chassis. The spring arms 77 may be made from the same material as the chassis and formed by removing material from the chassis pressing the arms from the base of the chassis. Whilst the spring arms 77 are shown as being integral with the chassis 74 , they may be provided as a separate insert which may be inserted into the open channel of the chassis 74 , as would be appreciated by a person skilled in the art.
[0546] A rigid insert 78 is provided to fit within the chassis 74 to provide added rigidity to the capper assembly 23 . In this regard the insert 78 is made from moulded steel and forms an open u-shaped channel. A lower capper moulding 79 is located within the insert 78 and retained within the insert via engagement of a number of lugs 80 formed along the sides of the lower capper moulding 79 with corresponding holes 81 provided in the sides of the insert 78 . The lower capper moulding 79 is made from a suitable plastic material and forms a body having closed ends and an open top. The ends of the lower capper moulding 79 are provided with air vents 82 which provide a means for air to enter the capper assembly and ventilate the capper assembly.
[0547] The base of the lower capper moulding is provided with a pair of centrally located projections 83 which are received within slots 84 formed in the base of the rigid insert 78 . The projections 83 extend through the rigid insert 78 , beyond its outer base surface to define a region for receiving an electromagnetic button 85 , which is spot welded to the outer base surface of the rigid insert 78 between the projections 83 . The purpose of the electromagnetic button 85 will be discussed in more detail later in the description; however it should be appreciated that the electromagnetic button 85 can be made of any material which is capable of experiencing magnetic attraction forces.
[0548] A strip of absorbent media 86 is provided to fit within the lower capping moulding 79 , and may be made from any type of material capable of absorbing and retaining ink therein, such as urethane foam or the like. The absorbent media 86 is shaped to fit within the lower capper moulding 79 and includes a stepped portion 87 which projects above the lower capper moulding 79 and extends centrally along the length of the absorbent media 86 , as is shown more clearly with regard to FIGS. 63 and 65 .
[0549] An upper capper moulding 88 is then provided to fit over the lower capper moulding 79 and the absorbent media 86 . The upper capper moulding 88 has essentially two portions, a lower portion 89 which seals along the edges of the lower capper moulding 79 to retain the absorbent media 86 therein, and an upper portion 90 which essentially conforms to the shape of the stepped portion 87 of the absorbent media 86 . The lower portion 89 is made from a rubber or plastics material and has an edge portion which sits along the upper edge of the lower capping moulding 79 and which is attached thereto by an ultrasonic weld or any other suitable attachment means. The upper portion 90 has an open upper surface and is made from a dual shot elastomeric material. The open upper surface is in the form of a rim portion 91 that extends beyond the absorbent media 86 and defines a perimeter seal for sealing the integrated circuits 50 of the printhead assembly 22 , as is shown in relation to FIG. 65 . The space formed between the upper edge of the rim portion 91 and the absorbent media 86 is the space which seals the integrated circuits 50 of the printhead assembly 22 .
[0550] In this arrangement, the upper capper moulding 88 , absorbent media 86 , lower capper moulding 79 and the rigid insert 78 form a unit which is adapted to fit within the capper chassis 74 . In order to secure the unit in place, a retainer element 92 is provided which fits over the upper capping moulding 88 and is secured to the chassis 74 as shown in FIG. 62 .
[0551] The retainer element 92 is essentially in the form of an open ended channel which fits over the upper capper moulding 88 and encloses the components therein. A slot 93 is formed in the upper surface of the retainer element 92 through which the upper portion 90 of the upper capper moulding 88 can protrude and the slot is shaped to conform to the shape of the upper portion 90 of the upper capper moulding 88 , as is shown in FIG. 65 . The upper surface of the retainer element 92 is curved and acts as a media guide during printing, as will be described in more detail later. The retainer element 92 is fixed to the chassis via a snap-fit arrangement whereby lugs 94 formed in the retainer element 92 are received in recesses 95 provided in the chassis 74 . When assembled in this manner, the components of the capper assembly 23 are contained within the retainer element 92 and the chassis 74 , and the electromagnetic button 85 secured to the rigid insert 78 is aligned with the centrally located removed portion 76 of the chassis.
[0552] Upon assembly and attachment of the capper assembly 23 to the end supports 40 of the main body 20 , due to the presence of the spring arms 77 extending inwardly from the base of the chassis 74 , the rigid insert 78 which contains the lower capper moulding 79 , absorbent media 86 and the upper capper moulding 88 therein, is supported on the spring arms 77 and is raised from the base of the chassis 74 . This state is shown in FIGS. 62 and 65 , and in this state the upper portion 90 of the upper capper moulding 88 protrudes through the slot 93 provided in the retainer element 92 . This state is the capping state, whereby the upper rim portion 91 of the upper capper moulding 88 contacts the printhead assembly 22 and acts as a perimeter seal around the printhead integrated circuits 50 , sealing them within the confined space of the capper assembly 23 . In the capping state, the nozzles 51 of the printhead integrated circuits 50 may fire and spit ink into the absorbent material 86 . The absorbent material 86 , is typically retained in a moist state at all times, such that when the integrated circuits are in the capping state, the nozzles are sealed in a moist environment which prevents ink from drying in the nozzles of the integrated circuits and blocking the nozzles.
[0553] In order to perform printing, the capper assembly 23 must be moved from a capping state to a printing state. This is achieved by causing the rigid insert 78 to act against the spring arms 77 of the chassis 74 and move in a downwards direction, towards the base of the chassis 74 . This movement is caused by applying an electromagnetic force in the vicinity of the base of the capper assembly 23 , proximal the centrally located removed portion 76 . The activation of the electromagnet force attracts the electromagnet button 85 fixed to the underside of the rigid insert 78 , thereby causing the rigid insert, which contains the lower capper moulding 79 , absorbent media 86 and the upper capper moulding 88 therein, to move in a downward direction with respect to the printhead assembly 22 . The centrally located removed portion 76 of the base of the chassis 74 allows the electromagnet button 85 to be fully retracted against the spring arms 77 towards the source of the electromagnetic force. This in turn causes the upper rim portion 91 of the upper capping moulding 88 to retract into the retainer element 92 such that it is flush with the outer surface of the retainer element 92 and does not protrude therefrom. It will be appreciated that the retainer element 92 does not move and is fixed in position. Such a state is referred to as the printing state, and in this state there is a gap formed between the retainer element 92 and the printhead assembly 22 through which the media can pass for printing. In the printing state, the retainer element 92 acts as a media guide and the media contacts the retainer element and is supported on the surface of the retainer element as it passes the printhead assembly for printing.
[0554] FIGS. 66 and 67 show the cartridge unit 10 in the capping state and the printing state respectively. It will be appreciated that due to the action of the spring arms 77 , the capping state is the relaxed state of the capper assembly 23 and whenever printing is not occurring the cartridge unit 10 is in the capping state. In this regard, the cartridge unit 10 is packaged and shipped in the capping state. As such, to move the cartridge unit 10 into a printing state, power must be supplied to an electromagnet, which is located in the cradle unit 12 as described later, to cause the upper capper moulding 88 to retract into the retainer element 92 . In the event of power failure or cessation of power to the printer unit, the electromagnetic force is removed, and the capper assembly 23 returns to the capping state under action of the spring arms 77 , thereby protecting the printhead integrated circuits 50 against prolonged periods of exposure to drying air.
Cradle Unit
[0555] The cradle unit 12 is shown in relation to FIGS. 6-8 and generally consists of a main body 13 which defines an opening for receiving the cartridge unit 10 , and a cover assembly 11 adapted to close the opening to secure the cartridge unit 10 in place within the cradle unit 12 .
[0556] The main body 13 of the cradle unit 12 includes a frame structure 101 as shown in FIGS. 68 a - 68 d . The frame structure 101 generally comprises two end plates 102 and a base plate 103 connecting each of the end plates 102 . As mentioned previously, each of the end plates 102 is provided with anchor portions 14 formed the base thereof to enable the print engine 1 to be secured in position within the printer unit 2 . A drive roller 104 and an exit roller 105 are mounted between the end plates 102 via mounting bearings 106 and are separated a distance to accommodate the cartridge unit 10 when the print engine 1 is fully assembled. The drive roller 104 and the exit roller 105 are each driven by a brushless DC motor 107 which is mounted to one of the end plates 102 and drives each of the drive and exit rollers via a drive mechanism 108 , such as a drive belt. Such a system ensures that both the drive roller 104 and the exit roller 105 are driven at the same speed to ensure a smooth and consistent passage of the media through the print engine 1 .
[0557] An electromagnet assembly 109 is mounted to the underside of the base plate 103 in a central position as shown most clearly in FIGS. 68 c and 68 d . The purpose of the electromagnet assembly 109 is to actuate the capper assembly 23 of the cartridge unit 10 , as previously discussed. A hole 110 is provided in the base plate 103 around the electromagnet assembly 109 to facilitate communication with the electromagnet button 85 on the capper assembly 23 .
[0558] A refill solenoid assembly 111 is mounted to the other end plate 102 , opposite the DC motor 107 , and is provided to operate a refill unit 200 to refill the cartridge unit 10 with refill ink, as will be described later. The refill solenoid assembly 111 is positioned such that an actuator arm 112 extends beyond the upper edge of the end plate 102 , the purpose of which will become apparent later in the description.
[0559] Cartridge unit guides 113 are also mounted to the interior surfaces of each of the end plates 102 . The guides are located at the rear of the cradle unit 12 and assist in positioning the cartridge unit 10 within the cradle unit 12 to ensure that removal and replacement of the cartridge unit 10 is a simple process. To further accommodate the cartridge unit 10 , a cartridge unit support member 114 is mounted between the end plates 102 at the front of the cradle unit 12 . The cartridge unit support member 114 is shown in more detail in FIG. 69 , and is in the form of a shaped plate fixed to the front portion of the cradle unit 12 . The cartridge unit support member 114 has a pair of clips 115 which fit into recesses 116 formed in the end plates 102 and has further anchor points 117 which enable the cartridge unit support member to be fixed to the end plates 102 , via screws or the like, to form a surface upon which the cartridge unit 10 can be received and supported. The cartridge unit support member 114 together with the cartridge unit guides 113 , defines a space 118 for receiving the cartridge unit 10 therein which conforms to the shape of the cartridge unit 10 , as shown in FIG. 70 .
[0560] An idle roller assembly 119 is fixed to the cartridge unit support member 114 and includes a plurality of roller wheels 120 which are positioned to contact the surface of the drive roller 104 and rotate therewith. The idle roller assembly 119 is shown in FIGS. 71 a and 71 b and comprises a curved multi-sectioned plate 121 with each section of the plate having a pair of roller wheels 120 provided at its distal end. Each section of the plate 121 is spring loaded against the surface of the cartridge unit support member 114 via a suitable spring means 122 , to allow the roller wheels 120 to move with respect to the surface of the drive roller 104 to accommodate print media therebetween. The idle roller assembly 119 is attached to the under-surface of the cartridge unit support member 114 via clips 123 which are received in corresponding slots 124 formed in the cartridge unit support member 114 , as is shown in FIG. 72 . Such an arrangement ensures that the media that is presented to the print engine 1 from the picker mechanism 9 of the printer unit 2 , is gripped between the drive roller 104 and the idle roller assembly 119 for transport past the printhead assembly 22 of the cartridge unit 10 for printing.
[0561] The control electronics for the print engine which controls the operation of the integrated circuits 50 of the printhead assembly 22 , as well as the operation of the drive roller 104 and exit roller 105 and other related componentry, is provided on a printed circuit board (PCB) 125 as shown in FIGS. 73 a and 73 b . As can be seen, one face of the PCB 125 contains the SoPEC devices 126 and related componentry 127 for receiving and distributing the data and power received, as will be discussed later, whilst the other face of the PCB includes rows of electrical contacts 128 along an edge thereof which provides a means for transmitting the power and data signals to the printhead assembly 22 in a manner to be described below. The PCB 125 is mounted between two arms 129 , with each of the arms having a claw portion 130 to receive the PCB 125 in position, as shown in FIGS. 74 a - 74 c . Each arm 129 is configured to have a substantially straight edge 131 and an angled edge 132 having a protrusion 133 formed thereon. The PCB 125 is positioned between the arms 129 such that the face of the PCB having the electrical contacts 128 formed along the lower edge thereof extends between the substantially straight edges 131 of the arms 129 .
[0562] The upper region of each of the arms 129 includes an upwardly extending finger portion 134 and a spring element 135 is provided for each of the arms 129 , the purpose of the finger portion 134 and the spring element 135 will be discussed in more detail later.
[0563] In order to provide stability to the PCB 125 as it is mounted between the two arms 129 , a support bar 136 is attached to the assembly which acts along the bottom edge of the PCB 125 , on the face that contains the SoPEC devices 126 and the related componentry 127 . This support bar 136 is shown in FIGS. 75 a - 75 b and consists of a curved plate 137 made from a suitable material such as steel which has appropriate strength and rigidity properties. The support bar 136 has a contact edge 138 which is arranged to contact the surface of the PCB 125 , along its bottom edge opposite the electrical contacts 128 . The contact edge 138 has a pair of attachment points 139 at its ends which allow the support bar 136 to be secured to the PCB 125 via screws or other suitable attachment means. Locating projections 140 , are also provided to mate with appropriate locating holes in the PCB 125 to assist in correctly position the support bar 136 in place. The contact edge 138 includes an electrical insulator coating 141 along its length which performs the contact between the support bar 136 and the PCB 125 . It will be appreciated that the support bar 136 contacts the surface of the PCB 125 along its' lower edge and provides backing support to the electrical contacts 128 when they come into contact with the corresponding dimple contacts 53 provided on the flex PCB 52 of the printhead assembly 22 .
[0564] The support bar 136 also includes a relatively straight portion 142 which extends substantially horizontally from the contact edge 138 . The straight portion 142 includes a pair of tabs 143 that extend longitudinally from its ends to engage with corresponding slots 144 provided in the arms 129 to further secure the support bar 136 in position. A plurality of star wheels 145 is also provided along the length of the straight portion 142 in a staggered arrangement. The star wheels 145 are secured within slots 146 formed in the straight portion 142 and are provide on spring loaded axles 147 which permits relative movement of the star wheels 145 with respect to the straight portion of the support bar 146 . The star wheels 145 are provided to contact the surface of the exit roller 105 to assist in gripping and removing the printed media from the print engine 1 , as will be discussed below. FIG. 76 shows the support bar 136 attached to the PCB 125 and arms 129 .
[0565] The arms 129 are attached to a bottom portion of end plates 102 at the pivot point 148 via a screw arrangement as shown in FIGS. 77 a and 77 b . In this arrangement the arms 129 , and subsequently the PCB 125 and support bar 136 , is able to pivot about the pivot point 148 between an open position wherein the contacts 128 on the PCB 125 are remote from the dimpled contacts 53 on the flex PCB 52 of the cartridge unit 22 , and a closed position where the contacts 128 on the PCB 125 are in pressing contact with the dimpled contacts 53 on the flex PCB 52 of the cartridge unit 22 . As clearly shown, upon attachment of the arms 129 to the end plates 102 , the star wheels 145 are in contact with the surface of the exit roller 105 , to capture the sheet of media therebetween for removal of the sheet from the print engine 1 to a collection area 4 for collection.
[0566] The cover assembly 11 , as shown in FIGS. 78 a - 78 c , is attached to the upper portion of the end plates 102 via pivot pins 150 which are received in holes 151 formed in the upper portion of the end plates 102 . The cover assembly 11 is made from a moulded plastic material and the pivot pins 150 are formed proximal to a rear edge of the cover assembly 11 during the moulding process. The pivot pins 150 allow the cover assembly 11 to pivot about the end plates 102 between a closed position, where the cartridge unit 10 is secured within the cradle unit 12 , and an open position, where the cartridge unit 10 can be removed from the cradle unit 12 and replaced. A latch 152 is provided in a front edge 153 of the cover assembly 11 . The latch 152 , has a flexible clip element 154 which is received within a recess 155 provided in the cartridge unit support member 114 when the cover assembly 11 is in the closed position, as shown in FIG. 81 . The flexible clip element 154 is spring loaded via a spring element (not shown) such that the clip element 154 can be readily depressed to release engagement between it and the recess 155 provided in the cartridge unit support member 114 so that the cover assembly 11 can be pivoted into an open position, as shown in FIG. 80 .
[0567] Positioned adjacent the pivot pins 150 , on the inside of the cover assembly 11 , are a pair of posts 156 . The posts 156 are arranged substantially alongside the pivot pins 150 , towards the front edge 153 of the cover assembly 11 . The posts 156 are configured such that they are a greater length than the pivot pins 150 and hence extend inwardly a greater distance, to contact the spring element 135 of the arms 129 which support the PCB 125 .
[0568] In this regard, the act of opening and closing the cover assembly 11 also performs the function of bringing the contacts 128 provided on the surface of the PCB 125 , into contact with the corresponding dimpled contacts 53 provided on the flex PCB 52 of the printhead assembly 22 . To achieve this, the cover assembly 11 and the arms 129 are arranged as shown in FIG. 79 .
[0569] As shown, the cover assembly 11 is attached to the end plates 102 such that the posts 156 extend between the upwardly extending finger portion 134 and the spring element 135 at each end thereof. When the cover assembly 11 is moved to the open position, as shown in FIG. 80 , the posts 156 act against the upwardly extending finger portion 134 of the arms 129 causing the arms 129 , and the PCB 125 , to pivot away from contact with the dimpled contacts 53 of the flex PCB 52 of the cartridge unit 22 . This movement is due to the swing action of the cover assembly 11 when opened which in turn causes the posts 156 to move in an arcuate direction towards the rear of the print engine 1 . When the cover assembly 11 moves to the closed position as shown in FIG. 81 , the cover assembly 11 pivots about the pivot pins 150 , causing the posts 156 to move in an arcuate direction towards the front of the print engine 1 . As the posts 156 move, they contact the upright portion of the spring element 135 , causing the PCB 125 and the arms 129 to pivot forward. The spring element 135 has considerable rigidity to transfer the force exerted upon it by the posts 156 into forward movement of the PCB 125 and arms 129 which results in the contacts 128 on the outward lower portion of the PCB 125 to contact the corresponding dimpled contacts 53 provided on the flex PCB 52 of the cartridge unit 10 , which is positioned and supported on the flex PCB backer 37 . As the cover assembly 11 is secured in place by the clip element 154 gripping the recessed portion 155 of the cartridge unit support member 114 , the contacts 128 remain in aligned contact with the dimpled contacts 53 , ensuring that power and data can be transmitted between the SoPEC devices 126 and the integrated circuits 50 of the printhead assembly 22 . Due to the fact that the posts 156 act against the upright portion of the spring element 135 , with the corresponding horizontal portion of the spring element 135 being secured against the arms 129 , there is a return force stored in the spring element 135 such that when the latch 152 of the cover assembly 11 is released the PCB 125 and the arms 129 will begin to pivot away from contact with the dimpled contacts 53 of the flex PCB 52 , breaking electrical contact therebetween and allowing ready removal of the cartridge unit 10 .
[0570] As shown in FIGS. 78 a - 78 c , the cover assembly 11 includes a centrally located docking port 157 in the form of a hole formed through the cover assembly 11 . The docking port 157 is shaped to enable a refill unit 200 to pass therethrough to dock with the cartridge unit 10 thereby enabling refilling of the cartridge unit 10 with ink, in a manner which will be described below. The docking port 157 has a rim portion 158 upon which a portion of the base of the refill unit 200 is received. Formed within the rim portion 158 of the docking port 157 is an engagement means 159 which engages with the refill unit 200 to retain the refill unit securely in position to facilitate refilling of the cartridge unit 12 . A QA chip reader 160 is also formed in the rim 158 of the docking port 157 to mate with a corresponding QA chip provided in the refill unit 200 to ensure integrity of the refill unit. The manner in which the engagement means 159 and the QA chip reader 160 functions will be described in more detail later in the description.
[0571] Projecting into the docking port 157 via a hole 161 formed in the wall of the rim portion 158 , as shown in FIG. 78 c , is a push rod 162 . As shown more clearly in FIG. 82 , the push rod 162 is in the form of an elongate bar member having an end 163 of reduced cross section which extends through the hole 161 in the wall of the rim portion 158 ; and an end having a foot portion 164 , a part of which extends perpendicular to the length of the push rod 162 . The body of the push rod 162 , proximal the foot portion 164 , has a slot 165 formed therein which enables the push rod 162 to be secured to the underside of the cover assembly 11 by way of a screw or the like upon which a push clip 166 is secured. The push clip 166 allows the push rod 162 to move longitudinally with respect to the push clip 166 but prevents any sideways or downward movement of the push rod 162 . A retainer 167 is also provided in the underside of the cover assembly 11 proximal the docking port 157 to retain the push rod in position and to prevent any non-longitudinal movement of the push rod 162 . In this configuration, the pushrod 162 is free to move in a longitudinal direction with respect to its length, such that the end 163 of reduced cross section can enter and be withdrawn from the docking port 157 . A spring element 168 is provided in the slot 165 formed in the push rod 162 and acts to bias the push rod 162 into position, such that its natural position is to have its end 163 extend into the docking port 157 .
[0572] The foot portion 164 of the push rod 162 is shown in more detail in FIG. 83 . The part of the foot portion 164 which extends perpendicular to the length of the push rod, has a groove 169 formed therein. The surface 170 of the groove is angled towards the end 163 of the push rod, as shown. The foot portion 164 is positioned at the side edge of the cover assembly 11 and extends in a downward direction with respect to the cover assembly 11 . In this position the actuator arm 112 of the refill solenoid assembly 111 mounted on the cradle unit 12 is orientated such that it is aligned with the groove 169 of the foot portion 164 . As the actuator arm 112 is raised by the solenoid assembly 111 in a vertical direction, it travels along the surface 170 of the groove 169 thereby causing the push rod 162 to retract such that the end 163 of the push rod 162 no longer extends into the docking port 157 . Lowering of the actuator arm 112 by the solenoid assembly 111 results in the push rod 162 returning to its naturally biased position under the action of the spring element 168 , whereby the end 163 extends into the docking port 157 . The manner in which the end 163 of the push rod interacts with the refill assembly 200 will be discussed in more detail below, however it should be appreciated that the position of the push rod is controlled by the SoPEC device 126 with regard to the state of operation of the printer unit.
Refill Unit
[0573] FIG. 84 illustrates one embodiment of an ink refill unit 200 . The ink refill unit 200 generally comprises a base assembly 202 which houses internal ink refilling components and a lid assembly 204 which fits onto the base assembly 202 . The base and lid assemblies may be moulded from a plastics material and the base assembly may be moulded as a single piece or in sections (as shown in FIG. 88 ).
[0574] As mentioned previously, the refill unit 200 contains ink and is intended to be used as a means for refilling the ink storage compartments 24 within the cartridge unit 10 . The refill unit 200 is configured to dock with the surface of the cartridge unit 10 in order to transfer the ink it contains into the ink storage compartments 24 of the cartridge unit 10 . For this purpose, the cover assembly 11 of the cradle unit 12 has a docking port 157 formed therein through which the refill unit 200 is able to pass to dock with the upper surface of the print cartridge 10 .
[0575] As discussed previously in relation to the lid assembly 21 of the cartridge unit 10 , the upper surface 60 of the lid assembly 21 has a plurality of ink refill ports 61 formed therein, with each of the individual ink refill ports 61 being in fluid communication with one of the ink storage compartments 24 to deliver ink to that compartment. The position of the individual ink refill ports 61 on the surface of the cartridge unit 10 is specific to the type or colour of ink stored by the cartridge unit, and the position and configuration of the ink refill ports 61 is consistent between different cartridge units. In this regard, each refill unit 200 is configured with a plurality of outlets 206 located in a bottom section 202 a of the base assembly 202 for docking with the cartridge unit. However in each instance, only one of the outlets is in fluid communication with the supply of ink for distributing ink to an ink storage compartment of the cartridge unit through the corresponding ink refill port, the position of the outlet being dependant upon the type or colour of ink to be supplied from the refill unit. As shown in FIG. 88 , the refill unit 200 is arranged with one working outlet 208 for the distribution of the particular coloured ink contained in the refill unit to the ink refill port 61 of the correspondingly coloured ink storage compartment 24 in the cartridge unit 10 . That is, if the refill unit 200 contains cyan ink, the working outlet 208 is positioned so as to correspond to the ink refill port 61 of the cyan ink chamber of the cartridge unit 10 when the refill unit is docked with the cartridge unit.
[0576] A clip arrangement 210 is provided on at least one side of the base assembly 202 of the refill unit 200 for securing the refill unit to the print engine during the refilling operation. This ensures reliable and efficient transfer of ink from the refill unit 200 to the cartridge unit as the refill unit 200 is substantially immovable from the print engine until the clip arrangement 210 is disengaged, thereby ensuring a complete seal between the refill unit and the cartridge unit and preventing the possibility of ink spillage or air ingress between the outlet and the ink refill port.
[0577] In this regard, the clip arrangement 210 is formed as a resilient section of the side wall of the base assembly 202 and is movable with respect the remainder of the side wall so as to engage and disengage with a corresponding engagement means 159 provided in the docking port 157 of the cover assembly 11 of the cradle unit. The clip arrangement includes clip portions 212 in the form of projections that project from a resilient arm 214 , the arm 214 being depressible to move into and out of a recess 216 about a pivot region 218 , the pivot region 218 being a weakened region in the surface of the base assembly 202 . In this way, when the bottom section 202 a of the base assembly 202 is moved into docking engagement with the surface of the cartridge unit by being passed through the docking port 157 of the cover assembly, the engagement means 159 of the cover assembly comes into contact with the clip portions 212 . This contact causes the arm 214 to deflect into the recess 216 as the refill unit is pushed into docking position with the cartridge unit, until the clip portions pass the engagement means 159 of the cover assembly. At this point, the arm 214 is no longer in contact with the engagement means 159 and hence returns to its original position thereby engaging the clip portions 212 with the lip of the engagement means 159 .
[0578] The clip and engagement means of the refill unit and the cover assembly, respectively, are configured so that in the docked (refilling) position, the outlets 206 , and most importantly the working outlet 208 , of the refill unit 200 is snugly positioned on the refill ports of the cartridge unit.
[0579] Once refilling has been completed, the refill unit 200 can be removed from docking engagement with the cartridge unit, by depressing the resilient arm 214 such that the clip portions 212 disengage with the lip of the engagement means. Suitable detail ridges 222 may be provided on the resilient arm 214 to provide grip for a user's finger(s) to manipulate the clip arrangement 210 .
[0580] The clip arrangement 210 and corresponding engagement portion 110 may be provided on only one side of the refill unit 200 and cover assembly, or may be provided on both (opposite) sides.
[0581] Within the refill unit 200 the ink is stored in a syringe-type assembly 224 . The syringe-type assembly 224 is mounted within the base assembly 202 of the refill unit 200 so as to be covered by the lid assembly 204 . The syringe-type assembly 224 has the necessary capacity to store the amount of ink required for refilling of the ink storage compartments of the cartridge unit. The components of the syringe assembly 224 are most clearly seen in FIG. 90 .
[0582] A tank 226 is provided in the syringe assembly 224 for storing the ink within the refill unit 200 . The tank 226 has at one end an ejection port 228 through which the ink is ejected for distribution and is sealed at the other end by a syringe seal 230 . The syringe seal 230 is mounted on a plunger 232 which is received within the hollow internal space of the tank 226 to expel the stored ink from the ejection port 228 . The plunger 232 is arranged to be driven into the hollow internal space of the tank 226 under action of a compression spring 234 . The compression spring is provided within the plunger 232 and projects from the plunger to contact with the internal end wall of the base assembly 202 (i.e., opposite the internal end wall adjacent the ejection port 228 of the tank 226 ). In this way, the compression spring 234 applies a constant force to the plunger 232 urging it plunge towards the interior of the tank 226 when the syringe assembly 224 is housed in the base assembly 202 .
[0583] Control of the plunging operation, and hence control of the delivery of the ink from the refill unit, is provided by ratchet arrangement of the syringe assembly 224 . The ratchet arrangement comprises an actuator rod 236 which mounts at its upper end and an intermediate position towards its lower end to mounting slots 238 provided on the tank 226 . The rod 236 has a pawl 240 projecting from one side thereof between the positions mounted through the slots 238 . The pawl 240 is engageable with a series of grooves providing a ratchet 242 on a side surface of the plunger 232 .
[0584] The rod 236 is rotatable about its long axis so as to engage and disengage the pawl 240 with the ratchet 242 . An actuator spring 244 is provided at the upper end of the rod 236 which acts against the side surface of the plunger 232 so as to bias the pawl 240 into the ratchet 242 . The engagement of the pawl 240 and the ratchet 242 provides sufficient resistance against the plunging of the plunger 232 into the interior of the tank 226 under action of the compression spring 234 .
[0585] Thus, upon initial use of the refill unit 200 , the pawl 240 is engaged with the first groove of the ratchet 242 , thereby preventing the plunger from substantially entering the interior of the tank 226 and in turn providing maximum ink storage capacity within the tank 226 . In order to commence refilling of the cartridge unit, ink must be ejected from the tank 226 through the ejection port 228 . This is achieved through rotation of the rod 236 which disengages the pawl from the first groove. The plunger 232 then enters into the interior of the tank 226 under action of the compression spring, causing ink to be ejected out the ejection port 228 . The pawl 240 , following disengagement with the first groove, engages with the next groove of the ratchet 242 through the return action of the actuator spring 244 against the initial rotation the rod 236 . This causes movement of the plunger 232 within the interior of the tank 226 to stop, thereby stopping delivery of ink from the ejection port 228 . More ink can be ejected from the tank 226 by repeated rotation of the rod 236 and engagement/disengagement of the pawl 240 with the ratchet 242 , thereby providing incremental delivery of ink in controlled amounts. This continues until the pawl engages with the final groove of the ratchet, at which point the ink within the tank 226 has been depleted.
[0586] The rotation of the rod 236 to disengage the pawl 240 is caused by action of an actuator shaft 246 on an arm 248 which projects from the rod. The actuator shaft 246 is housed within the base assembly 202 , as shown in FIG. 93 , so as to be slidable along its long axis. One end of the actuator shaft 246 is slidable to contact the arm 248 of the rod 236 when the syringe assembly 224 is mounted into the base assembly 202 and the other end of the actuator shaft is slidable to be exposed to the outside of the base assembly through a hole 202 b formed in one of its end walls.
[0587] In order to performing the refilling operation, the exposed end of the actuator shaft 246 comes into contact with the end of the push rod provided on the underside of the cover assembly, which projects into the docking port of the cover assembly. The manner in which the push rod operates has been discussed in detail above; however, when the refill unit 200 is in its refill position, the solenoid assembly can cause the push rod to extend and push the actuator shaft 246 into contact with the arm 248 of the rod 236 so as to disengage the pawl 240 with the ratchet 242 , following which the push rod returns to its retracted position. Then, once the pawl 240 re-engages through action of the actuator spring 244 , the arm 248 of the rod 236 pushes the actuator shaft 246 back so as to be exposed again for subsequent contact by the push rod.
[0588] More ink is refilled from the refill unit 200 through repeated actuation of the push rod by the solenoid assembly, delivering controlled amounts of refill ink each time. As such, the refill cartridge is provided with the ability to perform multiple refilling operations.
[0589] The status of the amount of the ink stored within the refill unit 200 is monitored by a quality assurance (QA) control chip 250 provided in the base assembly 202 . Initially, the QA chip 250 may store information in a memory thereof such as the ink capacity of the tank 226 (e.g., about 50 ml), the amount of ink which will be ejected from the tank with each pawl/ratchet 240 / 242 shift (e.g., about 6 ml), the colour of the ink stored within the tank and the position of the working outlet 208 .
[0590] In this regard, a sensor or other means is provided connected to the QA chip 250 which senses either the position of the pawl/ratchet or the number of times the rod 236 has been rotated by the actuator shaft 246 or some other mechanism which informs the QA chip 250 of the remaining capacity/number of refills of the refill unit. In this regard, the memory of the QA chip 250 is provided as a rewritable memory.
[0591] The QA chip 250 is provided in an exposed position on the end surface of the base assembly 202 , such as in the vicinity of the hole 202 b for the actuator shaft 246 (see FIG. 88 ), so as to align and connect with the corresponding QA chip reader provided within the rim of the docking port of the cover assembly.
[0592] The QA chip reader is connected to a QA chip and/or controller of the print engine. In this way, the QA chip 250 is able to communicate the above-described information to the print engine. For example, the controller of the print engine is able to check whether the ink storage compartment of the cartridge unit containing the ink colour/type which matches the refill unit 200 requires refilling by the amount of at least one pawl/ratchet shift. In response to such determinations, the controller controls the solenoid assembly so as to operate the push rod the appropriate number of times to refill the corresponding ink chamber.
[0593] This communication between the refill unit 200 and the print engine ensures that the correct type/colour of ink and the correct amount of ink is refilled into the correct ink storage compartment. Other checks can be performed also, such as correct positioning of the working outlet 208 on the appropriate refill port of the cartridge unit.
[0594] In order to deliver the refill ink into the refill ports, the working outlet 208 of the refill unit comprises a syringe needle 252 which is connected to the ejection port 228 of the tank 226 through a fluid channel 254 provided on the inner side and bottom surfaces of the base assembly 202 . Sealing between the ejection port 228 and the fluid channel 254 is provided by an O-ring 256 . The syringe needle 252 is arranged to penetrate the valve fittings provided within the corresponding ink refill ports so as to allow the flow of ink into the ink storage compartments.
[0595] As previously mentioned, the valve fittings may be provided as an elastomeric seal which seals the ink storage compartments from the surroundings, thus preventing dust and the like entering the chambers and providing an elastically walled channel through which the syringe needle 252 can pass.
[0596] Sealing between the working outlet 208 and the valve fittings is provided by a seal ring 258 which surrounds the syringe needle 252 . In the refill unit's isolated state, the syringe needle 252 is protected by the seal ring 258 within the working outlet 208 (see FIG. 88 ). Whereas, in the refill position, the syringe needle 252 is exposed to the valve fitting by action of valve's upper surface on the seal ring 258 to push the seal ring into the working outlet 208 . The seal ring 258 is able to ‘ride’ up the syringe needle 252 and upon release from the refill position, the seal ring is returned to its protection position via action of a seal spring 260 situated between the seal ring and the inner surface of the fluid channel 254 above the syringe needle. The seal spring 260 is held to the seal ring 258 with a support washer 262 .
[0597] An exemplary refilling operation is illustrated in FIGS. 94 a to 94 c.
[0598] In FIG. 94 a , the refill unit 200 is in its refilling position with the syringe needle 252 penetrating the valve fittings of an ink storage compartment of the cartridge unit. At the stage shown, ink 264 stored within the tank 226 has been primed into the fluid channel 254 and the syringe needle 252 . Alternatively, the fluid channel 254 may comprise air or other gas at this stage, e.g., before the first refilling operation for the refill unit has been performed. The ink is held within this fluid path without escaping through the syringe needle due to vacuum pressure created in the fluid path.
[0599] Alternatively, a cap may be provided to be either manually or automatically fitted within the working outlet so as to cap the end of the syringe needle. Such a cap additionally provides a means of ensuring that the stored ink does not dry out before the first application and between multiple refill applications.
[0600] In FIG. 94 b , the actuator arm of the solenoid assembly of the cradle unit is operated to extend the push bar into contact with the actuator shaft 246 , moving the actuator shaft 246 into contact against the arm 248 of the rod 236 . Immediately after this, the push bar returns to its retracted position of FIG. 94 a . The pawl 240 is then disengaged from the ratchet groove 242 , thus causing the compression spring 234 to depress the plunger 232 into the tank 224 in the direction of arrow A. As a result, ink 264 is ejected from the ejection port 228 and thus through the syringe needle 252 into the ink storage compartment in the direction of arrow B.
[0601] In FIG. 94 c , the plunger 232 has moved sufficiently for the pawl 240 to engage with the next ratchet groove 242 . At this point, the plunger 232 is stopped and as such the ejection of the ink 264 from the syringe needle 252 ceases.
[0602] The above process may be repeated until the ink storage compartment 24 is deemed refilled by the controller of the printer unit or until the refill unit 200 is depleted of ink. The status of the amount of ink in the refill unit 200 can be relayed to a user through the operation of an indicator light 266 , such as an LED, provided on the lid assembly 204 . The indicator light 266 is connected to the QA chip 250 when the lid assembly 204 is fitted to the base assembly 202 , and may be operated to illuminate during the refilling operation and cease illumination when this operation is finished and when the refill unit 200 is depleted. Alternatively, the indicator light 266 may be capable of multi-coloured illumination, such that different light colours are used to indicate the particular status of the refill unit 200 , e.g., a green light during refilling; a red light when the refill unit is depleted.
[0603] Power for the indicator light 266 and the QA chip 250 may be provided via the connection with the QA chip reader. Alternatively, a battery may be provided within the refill unit 200 having a power capacity sufficient for operating the unit until the ink is depleted.
[0604] An alternative embodiment of a syringe assembly 268 housed within the refill cartridge 200 is illustrated in FIGS. 95 to 99 . Like the syringe assembly 224 of the previous embodiment, the syringe assembly 268 is mounted within the base assembly 202 of the refill unit 200 so as to be covered by the lid assembly 204 and has the necessary capacity to store and distribute the amount of ink required for refilling to the print cartridge 102 through the working outlet 208 .
[0605] Like the syringe assembly of the previous embodiment, the syringe assembly 268 is provided with the tank 226 for storing the ink within the refill unit 200 . The tank 226 has at one end the ejection port 228 through which the ink is ejected for distribution and is sealed at the other end by the syringe seal 230 . The syringe seal 230 is mounted on the plunger 232 which plunges into the hollow internal space of the tank 226 to drive the stored ink out of the ejection port 228 .
[0606] The plunger 232 is plunged into the tank 226 through action of a compression spring 270 which is attached at one and about the circumference of the body 232 a of the plunger 232 . The other end of the spring 270 acts against a ring 232 b fixed between posts 272 which project from the lower internal surface of the base assembly 202 . In this arrangement, due to the nature compression spring 270 , it acts to constantly bias the plunger 232 towards the interior of the tank 226 when the syringe assembly 268 is housed in the base assembly 202 , as did the earlier described embodiment.
[0607] In this instance, control of the plunging operation is provided by a pawl and ratchet arrangement of the syringe assembly 268 . The pawl and ratchet arrangement comprises an actuator rod 274 which is mounted via pins 274 a , between its upper and lower ends, to mounting slots 276 which project from the lower internal surface of the base assembly 202 . In this way, the rod 274 is able to swing or pivot about the mounted pins 274 a.
[0608] The rod 274 has a pawl 278 at its upper end which is engageable with a series of teeth of a ratchet 280 provided in a circular arrangement at one end of a feed member 282 (best illustrated in FIG. 98 ). The swinging of the rod 274 enables the pawl to engage and disengage with the ratchet. An actuator spring 284 is provided between a boss 274 b , which projects from the lower end of the rod 274 , and an internal surface of the base assembly to bias the pawl into the ratchet.
[0609] The feed member 282 is in the form of a cylindrical wheel and is mounted at either end to the posts 272 via pins 272 a which project into axial holes (not shown) in the ends of the feed member 282 . In this way, the feed member 282 is able to rotate about its longitudinal axis. The feed member 282 further comprises a grooved thread 286 about its circumference at the end opposite the ratchet 280 . The grooved thread 286 is used to train a rope 288 about the feed member 282 . One end of the rope is attached to the end of the grooved thread and the other end of the rope attached to, or through, the plunger body 232 a.
[0610] Prior to shipment of the refill unit 200 , the combination of the rope 288 and grooved thread 286 and the ratchet and pawl arrangement is used to initially retract the plunger 232 from the tank 226 so as to provide a space in which to store the ink. In this regard, the feed member 282 is provided with a gear 290 which is able to mesh with an external motor gear or the like. Action of the motor gear rotates the feed member (in a clockwise direction in the arrangement shown in FIG. 97 ) whilst the pawl is not engaged with the ratchet which causes the rope to be wound about the grooved thread, thus retracting the plunger from the tank 226 against the action of the spring 270 .
[0611] Sufficient rotational force is required to compress the spring 270 and sufficient strength is required in the rope to hold the plunger in place whilst the spring is compressed. Once the plunger has been pulled out of the tank in which position the spring is substantially fully compressed, the pawl is engaged with the nearest tooth of the ratchet. This engagement provides sufficient resistance against the plunging of the plunger 232 into the interior of the tank 226 through action of the compression spring 270 . The tank 226 can then be primed with ink for shipment.
[0612] Thus, upon first use of the refill unit 200 , the pawl 278 is engaged with the tooth of the ratchet 280 which provides maximum ink storage capacity within the tank 226 . As ink is required to be ejected from the tank 226 through the ejection port 228 during a refilling operation, the rod 274 is swung to disengage the pawl with the tooth of the ratchet. This causes the plunger 232 to advance into the tank 226 a set distance thereby ejecting a measured portion of the stored ink through the ejection port 228 . Ejection stops when the pawl 278 engages with the next tooth of the ratchet 280 , which occurs through action of the actuator spring 284 swinging the rod 274 into engagement with the ratchet.
[0613] Additional measured portions of ink can be ejected from the tank 226 by repeated swinging of the rod 274 thereby causing engagement/disengagement of the pawl with the ratchet. This continues until the rope 288 and the compression spring 270 are fully extended at which point the ink within the tank 226 is depleted and the refill unit 200 is spent.
[0614] Similar to the previous embodiment, the swinging of the rod 274 to disengage the pawl 278 can be controlled by way of a slider element provided on the underside of the cover assembly 11 contacting the lower surface of the rod opposite the boss 274 b . As discussed in relation to the previous embodiment, the lid assembly can be configured such that an end of the slider element projects into the docking port 157 and through a hole 202 c formed in one of the side walls of the base assembly 202 when the refill unit is docked with the cartridge unit 10 . The other end of the slider element may be connected to a refill solenoid assembly which is attached to the cradle unit as described previously.
[0615] In this way, when the refill unit 200 is docked with the cartridge unit 10 and is in a refill position, the slider element can be operated to push the rod 274 so as to disengage the pawl 278 with the ratchet 280 . Then, once the pawl re-engages through action of the actuator spring 284 , the lower end of the rod 274 is repositioned for subsequent contact by the slider element.
[0616] More ink is refilled from the refill unit 200 through repeated sliding of the slider element. Equally, multiple refill operations using the one refill unit 200 can be performed if any one refill operation does not deplete the ink contained therein. As such, the refill unit is provided with the ability to perform multiple refilling operations.
[0617] The clip arrangement 210 and the arrangement of the syringe needle 252 in the working outlet 208 and the QA chip 250 is the same for the refill cartridge incorporating this alternative syringe assembly 268 as that of the previous embodiment.
[0618] With this alternative embodiment of the syringe assembly 268 a larger volume of ink can be stored within the tank 226 of the refill unit 200 (e.g., about 50 ml) whilst retaining a similarly size to that in the previous embodiment. This is because, the space occupied by the pawl and ratchet arrangement is minimised whilst retaining a sufficient number of steps for controlled ejection of ink for refilling.
[0619] FIGS. 100 to 106 illustrate yet another embodiment of an ink refill unit 400 suitable for use with the print engine of the present invention.
[0620] The ink refill unit 400 generally comprises a body assembly 402 , for housing the various internal components necessary for storing and delivering the refill ink, and an end cap assembly 404 which fits onto and caps an end of the body assembly 402 . The body and cap assemblies may be moulded from a plastics material.
[0621] As in the embodiments described above, the refill unit 400 contains ink and is intended to be used as a means for refilling ink storage compartments 24 provided within the cartridge unit 10 . In this regard, the refill unit 400 is configured to dock with the uppermost surface 60 of the cartridge unit 10 to transfer the ink contained therein into one or more of the ink storage compartments 24 of the cartridge unit 10 in the manner as discussed previously.
[0622] In this regard, the refill unit 400 is also arranged with at least one working outlet 408 (see FIG. 102 ) for distributing a particular colour or type of ink contained in the refill unit to the corresponding ink refill port 61 associated with the desired ink storage compartment 24 of the cartridge unit 10 . That is, if the refill unit 400 contains cyan ink, the working outlet 408 is positioned so as to correspond to the ink refill port 61 associated with the cyan ink storage compartment of the cartridge unit 10 when the refill unit is in its refilling position.
[0623] Although not shown in the drawings, a clip arrangement similar to that of the earlier described embodiment may be provided on the body assembly 402 and within the rim portion 158 of the docking port 157 , to ensure reliable and efficient transfer of ink from the refill unit 400 to the cartridge unit 10 .
[0624] The body assembly 402 of the ink refill unit 400 has capacity to store a sufficient amount of ink required to refill the ink storage compartments 24 of the cartridge unit 10 . The internal components of the body assembly 402 are most clearly seen in FIGS. 103 to 106 .
[0625] A compressible bellows tank 410 is provided in the body assembly 402 for storing the ink. In this regard, the bellows tank is sealed at one end and is provided with an ejection port 412 at the other end (being the end adjacent the end wall of the body assembly) through which the ink is ejected for distribution. The sealed end of the bellows tank 410 abuts a plunger 414 which is arranged to compress the bellows tank against the end wall of the body assembly to expel the stored ink out of the ejection port 412 .
[0626] The plunger 414 compresses the bellows tank 410 through action of a gear and thread arrangement. The gear and thread arrangement comprises a helical geared thread 416 provided about the circumference of the substantially circular plunger 414 which mates with an elongate drive gear 418 which is mounted within the body assembly 402 and extends along the length thereof, and an internal lead screw thread 420 provided in the substantially cylindrical internal wall of the body assembly (see FIG. 106 ). The lead screw thread 420 is provided with a gap along the length of the body assembly 402 in which the drive gear 418 sits and is able to come into contact with the gear teeth in the gear thread 416 of the plunger 414 . An elongate protruded region 422 of the body assembly 402 is provided to accommodate the drive gear 418 in this position.
[0627] In this gear and thread arrangement, the plunger 414 is able to rotate so as to move along the lead screw thread 420 . This movement provides the plunging operation of the plunger against the bellows tank. The rotation of the plunger is provided by rotation of the drive gear 418 being imparted to the geared thread 416 of the plunger. The drive gear 418 is held within the protruded region 422 by a pin 418 a provided on one end of the drive gear which slides into a depression or hole within the internal end wall of the body assembly 402 and a pin 404 a provided in a corresponding position on the internal surface of the end cap assembly 404 which slides into a corresponding depression 418 b provided on the other end of the drive gear. Other arrangements are possible however, so long as the drive gear is free to rotate about its long axis.
[0628] The rotation of the drive gear 418 is driven by a motor gear 124 which meshes with the teeth of the drive gear. The motor gear 124 is driven by a motor which may be mounted to the underside of the cover assembly 11 of the cradle unit 12 . In this arrangement, similar to those described in the above alternative embodiments, the motor gear 124 is arranged to project from the surface of the cover assembly to engage with the drive gear 418 through a slot 422 a in the protruded region 422 . Those of ordinary skill in the art will understand that the motorisation of the gear and thread arrangement may also be provided within the refill unit 400 itself instead of in the cover assembly 11 .
[0629] Control of the plunging operation is provided by the controlling the operation of the motor responsible for rotating the motor gear 124 , and a suitable gearing ratio may be provided for reasonably fine control of the plunger movement. As will be appreciated, the plunging operation provides controlled release of the ink from the bellows tank 410 through its ejection port 412 .
[0630] Upon first use of the refill unit 400 , plunger 414 is fully retracted so as to provide full extension of the bellows tank and hence maximum ink storage capacity in the refill unit 400 . Of course, suitably sized bellows tanks can be provided within the same sized refill units 400 for provided different storage amounts, e.g., 30 ml as opposed to 50 ml, depending on application, the colour of the ink, etc. Then, as ink is required to be ejected from the bellows tank 410 during a refilling operation, the motor may be controlled to rotate the motor gear 124 and the drive gear 418 thereby causing the plunger 414 to compress the bellows tank to eject some of the stored ink through the ejection port 412 . The amount of ink ejected per rotation of the motor gear 124 can be readily ascertained to provide metered release of ink into the cartridge unit 10 as necessary.
[0631] The plunging is continued until the required amount of ink has been ejected into the ink storage compartments of the cartridge unit 10 . For example, in a single-use refill operation, the entire contents of the refill unit 400 would be ejected, however in a multiple-use refill operation, only part of the refill unit's capacity of ink may be required at one time. In such a multiple-use regime, more ink can be ejected from the bellows tank by repeated plunging operations until the ink within the bellows tank has been depleted. The ink may be dispensed in a series of preselected amounts, e.g., by a series of preselected numbers of turns of the plunger 414 , until the necessary amount of ink has been dispensed, or the plunger 414 may be simply turned until it is determined that the ink chamber has been replenished.
[0632] In order to ensure that the ink does not leak from the ejection port 412 after a refilling operation has been performed and ink remains in the bellows tank for subsequent refills, suitable fluid pressure is retained within the bellows tank 410 at all times. This is achieved by backing-up the plunger 414 by a suitable amount once the refilling operation is complete. This is done by rotating the plunger in the opposite direction so as to allow slight re-expansion of the bellows tank 410 . In this regard, the sealed end of the bellows tank is preferably attached to the plunger and the motor provided in the cover assembly 11 is preferably a bi-directional motor.
[0633] Like the previous embodiments, the status of the amount of the ink stored within the refill unit 400 is monitored by a QA control chip 424 provided in the body assembly 402 . The QA chip 424 is provided in an exposed position on the surface of the end cap assembly 404 , or alternatively on the end surface of the body assembly 402 , so as to align and connect with a QA chip reader 160 provided in the docking port 157 of the cover assembly 11 . The QA chip reader is in turn connected to the SoPEC devices 126 of the cradle unit 12 to enable control of the overall refill operation. In the present embodiment, the QA chip 424 is used to provide information on the amount of ink (and colour, etc) stored in the refill unit 400 at any instant to the SoPEC devices 126 , so that the SoPEC devices can control the motor to rotate the motor gear 124 the appropriate number of times to refill the corresponding ink storage compartment 24 .
[0634] In this regard, a sensor or other means may be connected to the QA chip 424 to sense either the position of the plunger 414 or the number of times the plunger 414 has been rotated by the drive gear 418 which informs the QA chip 424 of the remaining capacity/number of refills of the refill unit 400 .
[0635] As with the first embodiment, the working outlet 408 of the refill unit 400 comprises a syringe needle 426 which is connected to the ejection port 412 of the bellows tank 410 through a fluid channel 428 provided on the outer sides of the body assembly 402 (see FIG. 102 ). Sealing between the ejection port 412 and the fluid channel 428 is provided by an O-ring 430 . The syringe needle 426 is arranged to penetrate the valve fittings 62 provided within the ink refill ports 61 of the cartridge unit 10 so as to allow the flow of ink into the ink storage compartments 24 . The arrangement and operation of the syringe needle 426 is otherwise the same as in the first embodiment.
[0636] An indicator light (not shown) may be provided on the body assembly 402 of the refill unit 400 connected to the QA chip 424 so as to indicate the status of the amount of ink in the refill unit to a user. Power for the indicator light and the QA chip may be provided via the connection to the contact 130 of the print cradle 100 . Alternatively, a battery may be provided within the refill unit 400 having a power capacity sufficient for operating the unit until the ink is depleted.
[0637] While the present invention has been illustrated and described with reference to exemplary embodiments thereof, various modifications will be apparent to and might readily be made by those skilled in the art without departing from the scope and spirit of the present invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the description as set forth herein, but, rather, that the claims be broadly construed. | A refill unit for a fluid container is provided. The unit has a housing defining a fluid path in fluid communication with an outlet and configured to be operatively engaged with the fluid container, a fluid reservoir having an ejection port arranged in fluid communication with the fluid path inside the housing, and an ejector assembly having a piston and cylinder reservoir, said piston having a thread which engages a screw thread in an internal wall of the cylinder, the piston rotationally biased by a wound spring and the ejector assembly having a pawl-and-ratchet detent preventing the biased piston threading into the reservoir until the pawl is actuated by operative engagement of the fluid container with the housing to incrementally eject fluid from | 1 |
FIELD OF THE INVENTION
[0001] This invention relates in general to tools for running casing hangers in subsea wells, and in particular to a high capacity tool that sets and internally tests a casing hanger packoff in one trip.
BACKGROUND OF THE INVENTION
[0002] A subsea well of the type concerned herein will have a wellhead supported on the subsea floor. One or more strings of casing will be lowered into the wellhead from the surface, each supported on a casing hanger. The casing hanger is a tubular member that is secured to the threaded upper end of the string of casing. The casing hanger lands on a landing shoulder in the wellhead, or on a previously installed casing hanger having larger diameter casing. Cement is pumped down the string of casing to flow back up the annulus around the string of casing. Afterward, a packoff is positioned between the wellhead bore and an upper portion of the casing hanger. This seals the casing hanger annulus.
[0003] Casing hanger running tools perform many functions such as running and landing casing strings, cementing strings into place, and installing and testing packoffs. Testing the packoff is traditionally performed by pressuring under the blow out preventer (BOP) stack, but more recent casing hanger running tool designs incorporate an “internal” or “down the drill pipe” test which isolates the test pressure to a small volume just above the hanger. An internal test has several benefits including reducing the annular pressure end load reacted against the hanger and making leak detection more direct, which is especially beneficial for sub-mudline casing strings which can be located several thousand feet from the BOP stack. The cost of the added functionality is complexity in the form of additional ports and seals.
[0004] Virtually all casing hanger running tools to date incorporate a cam that acts as a mechanical program for the tool. Rotational inputs to the cam drive it axially, causing it to drive engaging elements such as dogs radially, allows seal-setting pistons to communicate with the stem, and opens up additional ports for internal testing. Typically, cams occupy the radial space between the stem and the body of the running tool and must be thick enough to withstand radial loads generated by the dogs and pressure loads from setting and testing packoffs. If the cam could be eliminated, the radial space it normally occupied could be used to thicken up the body and the stem, thus increasing the hanging capacity of the tool. A need exists for a technique that addresses increased hanging capacity of a running tool, coupled with the ability to internally test a packoff. The following technique may solve one or more of these problems.
SUMMARY OF THE INVENTION
[0005] In an embodiment of the present technique, a high capacity running tool sets and internally tests a casing hanger packoff during the same trip. The running tool is comprised of a body and a stem. The body is secured by threads to the stem of the running tool so that rotation of the stem relative to the body will cause the stem to move longitudinally. An engagement element connects the tool body to the casing hanger by engaging an inner surface of the casing hanger. Longitudinal movement of the stem relative to the body moves the engaging element between an inner and outer position, thereby securely engaging the running tool and the casing hanger. Longitudinal movement of the stem relative to the body also lines up ports in the stem and the body for setting and testing functions, much like a cam in previous running tools.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a sectional view of a high capacity running tool constructed in accordance with the present technique with the piston cocked and the engagement element retracted.
[0007] FIG. 2 is a sectional view of the high capacity running tool of FIG. 1 in the running position with the engagement element engaged.
[0008] FIG. 3 is a sectional view of the high capacity running tool of FIG. 1 in the setting position.
[0009] FIG. 4 is a sectional view of the high capacity running tool of FIG. 1 in the seal testing position.
[0010] FIG. 5 is a sectional view of the high capacity running tool of FIG. 1 in the unlocked position with the engagement element disengaged.
DETAILED DESCRIPTION OF THE INVENTION
[0011] Referring to FIG. 1 , there is generally shown an embodiment for a high capacity running tool 11 that is used to set and internally test a casing hanger packoff. The high capacity running tool 11 is comprised of a stem 13 . Stem 13 is a tubular member with an axial passage 14 extending therethrough. Stem 13 connects on its upper end to a string of drill pipe (not shown). Stem 13 has an upper stem port 15 and a lower stem port 17 positioned in and extending therethrough that allow fluid communication between the exterior and axial passage of the stem 13 . A lower portion of the stem 13 has threads 19 in its outer surface. The outer diameter of an upper portion of stem 13 is greater than the outer diameter of the lower portion of stem 13 containing threads 19 . As such, a downward facing shoulder 21 is positioned adjacent threads 19 . A recessed pocket 23 is positioned in the outer surface of the stem 13 at a select distance above the downward facing shoulder 21 .
[0012] Running tool 11 has a body 25 that surrounds stem 13 , as stem 13 extends axially through the body 25 . Body 25 has an upper body portion 27 and a lower body portion 29 . The upper portion 27 of body 25 is a thin sleeve located between an outer sleeve 30 and stem 13 . Outer sleeve 30 is rigidly attached to stem 13 . A latch device (not shown) is housed in a slot 32 located within the outer sleeve 30 . The lower body portion 29 of body 25 has threads 31 along its inner surface that are engaged with threads 19 on the outer surface of stem 13 . Body 25 has an upper body port 33 and a lower body port 35 positioned in and extending therethrough that allow fluid communication between the exterior and interior of the stem body 25 . The lower portion 29 of body 25 houses an engaging element 37 . In this particular embodiment, engaging element 37 is a set of dogs having a smooth inner surface and a contoured outer surface. The contoured outer surface is adapted to engage a complimentary contoured surface on the inner surface of a casing hanger 39 when the engagement element 37 is engaged with the casing hanger 39 . Although not shown, a string of casing is attached to the lower end of casing hanger 39 . The inner surface of the engaging element 37 is initially in contact with the threads 19 on the inner surface of stem 13 .
[0013] A piston 41 surrounds the stem 13 and substantial portions of the body 25 . Referring to FIG. 3 , a piston chamber 42 is formed between upper body portion 27 , outer sleeve 30 , and piston 41 . Piston 41 is initially in a and upper or “cocked” position relative to stem 13 , meaning that the area of piston chamber 42 is at its smallest possible value, allowing for piston 41 to be driven downward. A piston locking ring 43 extends around the outer peripheries of the inner surface of the piston 41 . Locking ring 43 works in conjunction with the latch device (not shown) contained within outer sleeve slot 32 to restrict movement of the piston during certain running tool functions. A casing hanger packoff seal 45 is carried by the piston 41 and is positioned along the lower end portion of piston 41 . Packoff seal 45 will act to seal the casing hanger 39 to the wellbore (not shown) when properly set. While piston 41 is in the upper or “cocked” position, packoff seal 45 is spaced above casing hanger 39 .
[0014] A dart landing sub 47 is connected to the lower end of stem 13 . The landing sub 47 will act as a landing point for an object, such as a dart, that will be lowered into the stem 13 . When the object or dart lands within the landing sub 47 , it will act as a seal, effectively sealing the lower end of stem 13 .
[0015] Referring to FIG. 1 , in operation, the high capacity running tool 11 is initially positioned such that it extends axially through a casing hanger 39 . The piston 41 is in a “cocked” position, and the stem ports 15 , 17 and body ports 33 , 35 are axially offset from one another. Casing hanger packoff seal 45 is carried by the piston 41 . The running tool 11 is lowered into the casing hanger 39 until the outer surface of the body 25 of running tool 11 slidingly engages the inner surface of casing hanger 39 .
[0016] Referring to FIG. 2 , once the running tool 11 and casing hanger 39 are in abutting contact with one another, the stem 13 is rotated four revolutions. As the stem 13 is rotated relative to the body 25 , the stem 13 and piston 41 move longitudinally downward relative to body 25 . As the stem 13 moves longitudinally, the shoulder 21 on the outer surface of stem 13 makes contact with the engaging element 37 , forcing it radially outward and in engaging contact with the inner surface of casing hanger 29 , thereby locking body 25 to casing hanger 39 . As stem 13 moves longitudinally, stem ports 15 , 17 and body ports 33 , 35 also move relative to one another.
[0017] Referring to FIG. 3 , once the running tool 11 and casing hanger 39 are locked to one another, the running tool 11 and casing hanger 39 are lowered down the riser into the subsea wellhead housing (not shown) until the casing hanger 39 comes to rest. Referring to FIG. 3 , a solid dart 49 is then dropped or lowered into the axial passage 14 of stem 13 . The solid dart 49 lands in the landing sub 47 , thereby sealing the lower end of stem 13 . The stem 13 is then rotated four additional revolutions in the same direction. As the stem 13 is rotated relative to the body 25 , the stem 13 and piston 41 move further longitudinally downward relative to body 25 and casing hanger 39 . As the stem 13 moves longitudinally, stem ports 15 , 17 and body ports 33 , 35 also move relative to one another. Upper stem port 15 aligns with upper body port 33 , but lower stem port 17 is still positioned above lower body port 35 . This position allows fluid communication from the axial passage 14 of stem 13 , through stem 13 , into and through body 25 , and into piston 41 . Fluid pressure is applied down the drill pipe and travels through the axial passage 14 of stem 13 before passing through upper stem port 15 , upper body port 33 , and into chamber 42 , driving piston 41 downward relative to the stem 13 . As the piston 41 moves downward, the movement of piston 41 sets the packoff seal 45 between an outer portion of casing hanger 39 and the inner diameter of the subsea wellhead housing.
[0018] Referring to FIG. 4 , once the piston 41 is driven downward and packoff seal 45 is set, the stem 13 is then rotated four additional revolutions in the same direction. As the stem 13 is rotated relative to the body 25 , the stem 13 moves further longitudinally downward relative to body 25 and casing hanger 39 . Stem 13 also moves downward at this point relative to piston 41 . As the stem 13 moves longitudinally, stem ports 15 , 17 and body ports 33 , 35 also move relative to one another. Lower stem port 17 aligns with lower body port 35 ; allowing fluid communication from the axial passage 14 of stem 13 , through stem 13 , into and through body 25 , and into an isolated volume above packoff seal 45 . Upper stem port 15 is still aligned with upper body port 33 . The latch device located with the slot 32 on the outer sleeve 30 is activated by the movement of the stem 13 and will act in conjunction with piston locking ring 43 to restrict the upward movement of piston 41 beyond the latch device. Pressure is applied down the drill pipe and travels through the axial passage 14 of stem 13 before passing through lower stem port 15 , lower body port 33 , and into an isolated volume above packoff seal 45 , thereby testing packoff seal 45 . The same pressure is applied to piston 41 , creating an upward force, however, movement of the piston 41 in an upward direction is restricted by the engagement of the piston locking ring 43 and the latch device (not shown) positioned in the slot 32 on outer sleeve 30 . In an alternate embodiment, the size of the fluid chambers in the piston 41 and seal 45 areas could be sized such that the larger sized fluid chamber in the seal 45 area maintains a downward force on piston 41 , thereby eliminating the need for the latch device and the piston locking ring 43 . An elastomeric seal 51 is mounted to the exterior of piston 41 for sealing against the inner diameter of the wellhead housing. Seal 51 defines the isolated volume above packoff seal 45 . If packoff seal 45 is not properly set, a drop in fluid pressure held in the drill pipe will be observed as the fluid passes through the seal area.
[0019] Referring to FIG. 5 , once the packoff seal 45 has been tested, the stem 13 is then rotated four additional revolutions in the same direction. As the stem 13 is rotated relative to the body 25 , the stem 13 moves further longitudinally downward relative to the body 25 , casing hanger 39 , and piston 41 . As the stem 13 moves longitudinally downward, the engagement element 37 is freed and moves radially inward into recessed pocket 23 on the outer surface of stem 13 , thereby unlocking the body 25 from casing hanger 39 . Upper stem port 15 remains aligned with upper body port 33 . Lower stem port 17 remains aligned with lower body port 35 . The lower stem port 17 and lower body port 35 vent the column of fluid in the drill pipe, allowing dry retrieval of the running tool 11 . Running tool 11 can then be removed from the wellbore.
[0020] The technique has significant advantages. The elimination of a cam provides fewer leak paths and an increased hanging capacity due to the increase radial space within the running tool.
[0021] While the technique has been shown in only one 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 technique. | A high capacity running tool sets and internally tests a casing hanger packoff during the same trip. The running tool has a stem and a body. The body is secured by threads to the stem of the running tool so that rotation of the stem relative to the body will cause the stem to move longitudinally. An engagement element connects the tool body to the casing hanger by engaging the inner surface of the casing hanger. Longitudinal movement of the stem relative to the body moves the engaging element between inner and outer positions and lines up ports in the stem and in the body for setting and testing functions. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to new kinase inhibitors, more specifically ROCK inhibitors, compositions, in particular pharmaceuticals, comprising such inhibitors, and to uses of such inhibitors in the treatment and prophylaxis of disease. In particular, the present invention relates to new ROCK inhibitors, compositions, in particular pharmaceuticals, comprising such inhibitors, and to uses of such inhibitors in the treatment and prophylaxis of disease.
BACKGROUND OF THE INVENTION
[0002] The serine/threonine protein kinase ROCK consists in humans of two isoforms ROCK I and ROCK II. ROCK I is encoded on chromosome 18 whereas ROCK II, also called Rho-kinase, is located on chromosome 12. They both have a molecular weight close to 160 kDa. They share an overall homology of 65% while being 95% homologous in their kinase domains. Despite their sequence similarity, they differ by their tissue distributions. The highest levels of expression for ROCK I are observed in heart, lung and skeletal tissues whereas ROCK II is mostly expressed in brain. Recent data indicate that these two isoforms are partially function redundant, ROCK I being more involved in immunological events, ROCK II in smooth muscle function. The term ROCK refers to ROCK I (ROK-β, p160ROCK, or Rho-kinase β) and ROCK II (ROCK-α or Rho-kinase α).
[0003] ROCK activity has been shown to be enhanced by GTPase RhoA that is a member of the Rho (Ras homologous) GTP-binding proteins. The active GTP-bound state of RhoA interacts with Rho-binding domain (RBD) of ROCK that is located in an autoinhibitory carboxyl-terminal loop. Upon binding, the interactions between the ROCK negative regulatory domain and the kinase domain are disrupted. The process enables the kinase to acquire an open conformation in which it is fully active. The open conformation is also induced by the binding of lipid activators such as arachidonic acid to the PH domain in the kinase carboxyl-terminal domain. Another activation mechanism has been described during apoptosis and involves the cleavage of carboxyl terminus by caspase-3 and -2 (or granzyme B) for ROCK I and II, respectively.
[0004] ROCK plays an important role in various cellular functions such as smooth muscle contraction, actin cytoskeleton organization, platelet activation, downregulation of myosin phosphatase cell adhesion, -migration, -proliferation and survival, thrombin-induced responses of aortic smooth muscle cells, hypertrophy of cardiomyocytes, bronchial smooth muscle contraction, smooth muscle contraction and cytoskeletal reorganization of non-muscle cells, activation of volume-regulated anion channels, neurite retraction, wound healing, cell transformation and gene expression. ROCK also acts in several signaling pathways that are involved in auto-immunity and inflammation. ROCK has been shown to play a part in the activation of NF-κB, a critical molecule that leads to the production of TNF and other inflammatory cytokines. ROCK inhibitors are reported to act against TNF-alpha and IL-6 production in lipopolysaccharide (LPS)-stimulated THP-1 macrophages. Therefore, ROCK inhibitors provide a useful therapy to treat autoimmune and inflammatory diseases as well as oxidative stress.
[0005] In conclusion, ROCK is a major control point in smooth muscle cell function and a key signaling component involved in inflammatory processes in various inflammatory cells as well as fibrosis and remodeling in many diseased organs. In addition, ROCK has been implicated in various diseases and disorders including eye diseases; airway diseases; cardiovascular and vascular diseases; inflammatory diseases; neurological and CNS disorders: proliferative diseases; kidney diseases; sexual dysfunction; blood diseases; bone diseases; diabetes; benign prostatic hyperplasia, transplant rejection, liver disease, systemic lupus erythmatosis, spasm, hypertension, chronic obstructive bladder disease, premature birth, infection, allergy, obesity, pancreatic disease and AIDS.
[0006] ROCK appears to be a safe target, as exemplified by knockout models and a large number of academic studies. These KO mice data, in combination with post-marketing surveillance studies with Fasudil, a moderately potent ROCK inhibitor used for the treatment of vasospasm after subarachnoid hemorrhage, indicate that ROCK is a genuine and significant drug target.
[0007] ROCK inhibitors would be useful as therapeutic agents for the treatment of disorders implicated in the ROCK pathway. Accordingly, there is a great need to develop ROCK inhibitors that are useful in treating various diseases or conditions associated with ROCK activation, particularly given the inadequate treatments currently available for the majority of these disorders. Some non-limiting examples are glaucoma, asthma and COPD.
[0008] Glaucoma is a neurodegenerative disease that is the second most important cause of irreversible blindness. This disease is characterized by a raised intra-ocular pressure (IOP) and by progressive retinal ganglion cell apoptosis, resulting in irreversible visual field loss. Current treatment of this disease is directed towards the reduction of IOP, which is the main—but not only—risk factor for glaucoma. There is a need for improved treatment as the current therapy does only control and not cure the disease and further suffers from irritation, local and systemic side effects. In addition, additional positive effects, as the anti-inflammatory and nerve regenerating components of ROCK inhibitors, would be highly preferred. Reference ROCK inhibitors, such as Y-27632 cause changes in cell shape and decrease stress fibers, focal adhesions and MLC phosphorylation in cultured human TM cells; they relax human trabecular meshwork in vitro, relax human Schlemm's canal endothelial cells in vitro and when topically applied to animals give a significant increase in trabecular outflow, resulting into a strong lowering of intra ocular pressure.
[0009] Allergic asthma is a chronic inflammatory airway disorder that results from maladaptive immune responses to ubiquitous environmental proteins in genetically susceptible persons. Despite reasonably successful therapies, the prevalence increases as these therapies do not cure; there are still exacerbations and an increasing number of non-responders. New, effective and steroid-sparing treatments that tackle all components of the disease are required.
[0010] Chronic Obstructive Pulmonary Disease (COPD) represents a group of diseases characterized by irreversible limitation of airflow, associated with abnormal inflammatory response, bronchoconstriction and remodeling and destruction of the tissue of the lung. It is one of the leading causes of death worldwide, with a steadily increasing prevalence. There is an urgent need for novel therapeutic approaches as the current regimen is inadequate. Until now only bronchodilators are used, since glucocorticoids have limited or no effect. Reference ROCK inhibitors, such as Y-27632 relax human isolated bronchial preparations, inhibit increases in airway resistance in anaesthetised animals, potentiate relaxing effects of β-agonists in vitro and in vivo and give rapid bronchodilatation upon inhalation. In addition, ROCK inhibitors block tracheal smooth muscle contractions induced by H 2 O 2 , the clinical marker for oxidative stress.
[0011] Related to airway inflammation, ROCK inhibitors counteract the increase in trans-endothelial permeability mediated by inflammatory agents, maintain the endothelial barrier integrity, inhibit the influx of eosinophils after ovalbumin challenge in vivo, protect against lung edema formation and neutrophile migration, suppress airway HR to metacholine and serotonin in allergic mice and block LPS-induced TNF release. With respect to airway fibrosis and remodeling, ROCK inhibitors block the induced migration of airway smooth muscle cells. In vitro evidences for the role of ROCK in airway remodeling were obtained in human lung carcinoma cell line, bovine tracheal smooth muscle cells and human airway smooth muscle. In vivo proof for a role of ROCK in fibrosis in general was generated with mice which exhibited attenuated myocardial fibrosis in response to the partial deletion of ROCK. The attenuation of myocardial fibrosis by Y-27632 in response to myocardial infarction and by fasudil in the case of congestive heart failure in a chronic hypertensive rat model brings additional indications of ROCK importance in remodeling. Finally, ROCK inhibitors increase apoptotic cell loss of smooth muscle cells.
[0012] Several different classes of ROCK inhibitors are known. The current focus is oncology and cardiovascular applications. Until now, the outstanding therapeutic potential of ROCK inhibitors has only been explored to a limited extent. The reason is the fact that ROCK is such a potent and widespread biochemical regulator, that systemic inhibition of ROCK leads to strong biological effects that are considered as being side effects for the treatment of most of the diseases. Indeed, the medical use of ROCK inhibitors to treat diseases with a strong inflammatory component is hampered by the pivotal role of ROCK in the regulation of the tonic phase of smooth muscle cell contraction. Systemically available ROCK inhibitors induce a marked decrease in blood pressure. Therefore, ROCK inhibitors with different properties are highly required.
[0013] For the target specific treatment of disorders by regulating smooth muscle function and/or inflammatory processes and/or remodeling, it is highly desired to deliver a ROCK inhibitor to the target organ and to avoid significant amounts of these drugs to enter other organs. Therefore, local or topical application is desired. Typically, topical administration of drugs has been applied for the treatment of airway-, eye, sexual dysfunction and skin disorders. In addition, local injection/infiltration into diseased tissues further extend the potential medical use of locally applied ROCK inhibitors. Given certain criteria are fulfilled, these local applications allow high drug concentration to be reached in the target tissue. In addition, the incorporation of ROCK inhibitors into implants and stents can further expand the medical application towards the local treatment of CV diseases such as atherosclerosis, coronary diseases and heart failure.
[0014] Despite the fact that direct local application is preferred in medical practice, there are concerns regarding drug levels reached into the systemic circulation. For example the treatment of airway diseases by local delivery by for instance inhalation, poses the risk of systemic exposure due to large amounts entering the GI tract and/or systemic absorption through the lungs. For the treatment of eye diseases by local delivery, also significant amounts enter the GI tract and/or systemic circulation due to the low permeability of the cornea, low capacity for fluid, efficient drainage and presence of blood vessels in the eyelids. Also for dermal applications, local injections and implantable medical devices, there is a severe risk of leakage into the systemic circulation. Therefore, in addition to local application, the compounds should preferably have additional properties to avoid significant systemic exposure.
[0015] Soft drugs are biologically active compounds that are inactivated once they enter the systemic circulation. This inactivation can be achieved in the liver, but the preferred inactivation should occur in the blood. These compounds, once applied locally to the target tissue/organ exert their desired effect locally. When they leak out of this tissue into the systemic circulation, they are very rapidly inactivated. Thus, soft drugs of choice are sufficiently stable in the target tissue/organ to exert the desired biological effect, but are rapidly degraded in the blood to biologically inactive compounds. In addition, it is highly preferable that the soft drugs of choice have retention at their biological target. This property will limit the number of daily applications and is highly desired to reduce the total load of drug and metabolites and in addition will significantly increase the patient compliance.
[0016] In conclusion, there is a continuing need to design and develop soft ROCK inhibitors for the treatment of a wide range of disease states. The compounds described herein and pharmaceutically acceptable compositions thereof are useful for treating or lessening the severity of a variety of disorders or conditions associated with ROCK activation. More specifically, the compounds of the invention are preferably used in the prevention and/or treatment of at least one disease or disorder, in which ROCK is involved, such as diseases linked to smooth muscle cell function, inflammation, fibrosis, excessive cell proliferation, excessive angiogenesis, hyperreactivity, barrier dysfunction, neurodegeration and remodeling. For example, the compounds of the invention may be used in the prevention and/or treatment of diseases and disorders such as:
Eye diseases or disorders: including but not limited to retinopathy, optic neuropathy, glaucoma and degenerative retinal diseases such as macular degeneration, proliferative vitreoretinopathy, proliferative diabetic retinopathy retinitis pigmentosa and inflammatory eye diseases (such as anterior uveitis, panuveitis, intermediate uveitis and posterior uveitis), glaucoma filtration surgery failure, dry eye, allergic conjunctivitis, posterior capsule opacification, abnormalities of corneal wound healing and ocular pain. Airway diseases; including but not limited to pulmonary fibrosis, emphysema, chronic bronchitis, asthma, fibrosis, pneumonia, cytsic fibrosis, chronic obstructive pulmonary disease (COPD); bronchitis and rhinitis and respiratory distress syndrome Throat, Nose and Ear diseases: including but not limited to sinus problems, hearing problems, toothache, tonsillitis, ulcer and rhinitis, Skin diseases: including but not limited to hyperkeratosis, parakeratosis, hypergranulosis, acanthosis, dyskeratosis, spongiosis and ulceration. Intestinal diseases; including but not limited to inflammatory bowel disease (IBD), colitis, gastroenteritis, ileus, ileitis, appendicitis and Crohn's disease. Cardiovascular and vascular diseases: including but not limited to, pulmonary hypertension and pulmonary vasoconstriction. Inflammatory diseases: including but not limited to contact dermatitis, atopic dermatitis, psoriasis, rheumatoid arthritis, juvenile rheumatoid arthritis, ankylosing spondylitis, psoriatic arthritis, inflammatory bowel disease, Crohn's disease and ulcerative colitis. Neurological disorders: including but not limited to neuropathic pain. The present compounds are therefore suitable for preventing neurodegeneration and stimulating neurogeneration in various neurological disorders. Proliferative diseases: such as but not limited to cancer of, breast, colon, intestine, skin, head and neck, nerve, uterus, kidney, lung, ovary, pancreas, prostate, or thyroid gland; Castleman disease; sarcoma; malignoma; and melanoma. Kidney diseases: including but not limited to renal fibrosis or renal dysfunction Sexual dysfunction: is meant to include both male and female sexual dysfunction caused by a defective vasoactive response. The soft ROCK inhibitors of the present invention may also be used to treat sexual dysfunction arising from a variety of causes. For example, in an embodiment, the soft ROCK inhibitors may be used to treat sexual dysfunction associated with hypogonadism and more particularly, wherein the hypogonadism is associated with reduced levels of androgen hormones. In another embodiment, the soft ROCK inhibitors may be used to treat sexual dysfunction associated with a variety of causes including, but not limited to, bladder disease, hypertension, diabetes, or pelvic surgery. In addition, the soft ROCK inhibitors may be used to treat sexual dysfunction associated with treatment using certain drugs, such as drugs used to treat hypertension, depression or anxiety. Bone diseases: including but not limited to osteoporosis and osteoarthritis In addition, the compounds of the invention may be used in the prevention and/or treatment of diseases and disorders such as benign prostatic hyperplasia, transplant rejection, spasm, chronic obstructive bladder disease, and allergy.
SUMMARY OF THE INVENTION
[0030] We have surprisingly found that the compounds described herein act as inhibitors of ROCK, in particular as soft ROCK inhibitors. The compounds of the present invention are very rapidly converted into functionally inactive compounds for example by carboxylic ester hydrolases (EC 3.1.1) such as Cholinesterase or Paraoxonase 1 (PON1) or by plasma proteins displaying pseudoesterase activity such as Human serum albumin. Carboxylic ester hydrolases (EC 3.1.1) represent a large group of enzymes involved in the degradation of carboxylic esters into alcohols and carboxylic acids. As such, enzymes displaying this catalytic activity are of potential interest for the design of soft kinase inhibitors. EC 3.1.1 includes the following sub-classes:
[0000] EC 3.1.1.1 carboxylesterase
EC 3.1.1.2 arylesterase
EC 3.1.1.3 triacylglycerol lipase
EC 3.1.1.4 phospholipase A2
EC 3.1.1.5 lysophospholipase
EC 3.1.1.6 acetylesterase
EC 3.1.1.7 acetylcholinesterase
EC 3.1.1.8 cholinesterase
EC 3.1.1.10 tropinesterase
EC 3.1.1.11 pectinesterase
EC 3.1.1.13 sterol esterase
EC 3.1.1.14 chlorophyllase
EC 3.1.1.15 L-arabinonolactonase
[0031] EC 3.1.1.17 gluconolactonase
EC 3.1.1.19 uronolactonase
EC 3.1.1.20 tannase
EC 3.1.1.21 retinyl-palmitate esterase
EC 3.1.1.22 hydroxybutyrate-dimer hydrolase
EC 3.1.1.23 acylglycerol lipase
EC 3.1.1.24 3-oxoadipate enol-lactonase
EC 3.1.1.25 1,4-lactonase
EC 3.1.1.26 galactolipase
EC 3.1.1.27 4-pyridoxolactonase
EC 3.1.1.28 acylcarnitine hydrolase
EC 3.1.1.29 aminoacyl-tRNA hydrolase
EC 3.1.1.30 D-arabinonolactonase
[0032] EC 3.1.1.31 6-phosphogluconolactonase
EC 3.1.1.32 phospholipase A1
EC 3.1.1.33 6-acetylglucose deacetylase
EC 3.1.1.34 lipoprotein lipase
EC 3.1.1.35 dihydrocoumarin hydrolase
EC 3.1.1.36 limonin-D-ring-lactonase
EC 3.1.1.37 steroid-lactonase
EC 3.1.1.38 triacetate-lactonase
EC 3.1.1.39 actinomycin lactonase
EC 3.1.1.40 orsellinate-depside hydrolase
EC 3.1.1.41 cephalosporin-C deacetylase
EC 3.1.1.42 chlorogenate hydrolase
EC 3.1.1.43 α-amino-acid esterase
EC 3.1.1.44 4-methyloxaloacetate esterase
EC 3.1.1.45 carboxymethylenebutenolidase
EC 3.1.1.46 deoxylimonate A-ring-lactonase
EC 3.1.1.471-alkyl-2-acetylglycerophosphocholine esterase
EC 3.1.1.48 fusarinine-C ornithinesterase
EC 3.1.1.49 sinapine esterase
EC 3.1.1.50 wax-ester hydrolase
EC 3.1.1.51 phorbol-diester hydrolase
EC 3.1.1.52 phosphatidylinositol deacylase
EC 3.1.1.53 sialate O-acetylesterase
EC 3.1.1.54 acetoxybutynylbithiophene deacetylase
EC 3.1.1.55 acetylsalicylate deacetylase
EC 3.1.1.56 methylumbelliferyl-acetate deacetylase
EC 3.1.1.57 2-pyrone-4,6-dicarboxylate lactonase
EC 3.1.1.58 N-acetylgalactosaminoglycan deacetylase
EC 3.1.1.59 juvenile-hormone esterase
EC 3.1.1.60 bis(2-ethylhexyl)phthalate esterase
EC 3.1.1.61 protein-glutamate methylesterase
EC 3.1.1.63 11-cis-retinyl-palmitate hydrolase
EC 3.1.1.64 all-trans-retinyl-palmitate hydrolase
EC 3.1.1.65 L-rhamnono-1,4-lactonase
EC 3.1.1.66 5-(3,4-diacetoxybut-1-ynyl)-2,2′-bithiophene deacetylase
EC 3.1.1.67 fatty-acyl-ethyl-ester synthase
EC 3.1.1.68 xylono-1,4-lactonase
EC 3.1.1.70 cetraxate benzylesterase
EC 3.1.1.71 acetylalkylglycerol acetylhydrolase
EC 3.1.1.72 acetylxylan esterase
EC 3.1.1.73 feruloyl esterase
EC 3.1.1.74 cutinase
EC 3.1.1.75 poly(3-hydroxybutyrate) depolymerase
EC 3.1.1.76 poly(3-hydroxyoctanoate) depolymerase
EC 3.1.1.77 acyloxyacyl hydrolase
EC 3.1.1.78 polyneuridine-aldehyde esterase
EC 3.1.1.79 hormone-sensitive lipase
EC 3.1.1.80 acetylajmaline esterase
EC 3.1.1.81 quorum-quenching N-acyl-homoserine lactonase
EC 3.1.1.82 pheophorbidase
EC 3.1.1.83 monoterpene ε-lactone hydrolase
EC 3.1.1.84 cocaine esterase
EC 3.1.1.85 mannosylglycerate hydrolase
[0033] Cholinesterases are enzymes that are primarily known for their role in the degradation of the neurotransmitter acetylcholine. Acetylcholinesterase (EC 3.1.1.7) is also known as Choline esterase I, true cholinesterase, RBC cholinesterase, erythrocyte cholinesterase, or acetylcholine acetylhydrolase. As suggested by some of its alternative names, acetylcholinesterase is not only found in brain, but also in the erythrocyte fraction of blood. In addition to its action on acetylcholine, acetylcholinesterase hydrolyzes a variety of acetic esters, and also catalyzes transacetylations. Acetylcholinesterase usually displays a preference for substrates with short acid chains, as the acetyl group of acetylcholine. Butyrylcholinesterase (EC 3.1.1.8) is also known as benzoylcholinesterase, choline esterase II, non-specific cholinesterase, pseudocholinesterase, plasma cholinesterase or acylcholine acylhydrolase, While being found primarily in liver, butyrylcholinesterase is also present in plasma. As indicated by some of its alternative names, it is less specific than acetylcholinesterase and will typically carry out the hydrolysis of substrates with larger acid chains (such as the butyryl group of butyrylcholine or the benzoyl group of benzolylcholine) at a faster rate than acetylcholinesterase. In addition to its action on acetylcholine, butyrylcholinesterase is known to participate in the metabolism of several ester drugs, such as procaine.
[0034] Human serum albumin (HSA) is a major component of blood plasma, accounting for approximately 60% of all plasma proteins. HSA has been found to catalyze the hydrolysis of various compounds such as aspirin, cinnamoylimidazole, p-nitrophenyl acetate, organophosphate insecticides, fatty acid esters or nicotinic esters. HSA displays multiple nonspecific catalytic sites in addition to its primary reactive site. The catalytic efficiency of these sites is however low, and HSA has often been described not as a true esterase, but as a pseudoesterase, In spite of its low catalytic efficiency, HSA can still play a significant role in the metabolism of drug-like compounds, because of its high concentration in plasma.
[0035] Paraoxonase 1 (PON1) is also known as arylesterase (EC 3.1.1.2) or A-esterase. PON1 is a Ca 2+ dependent serum class A esterase, which is synthesized in the liver and secreted in the blood, where it associates exclusively with high-density lipoproteins (HDLs). Furthermore, it is able to cleave a unique subset of substrates including organophosphates, arylesters, lactones and cyclic carbonates. Therefore, the R 2 substituent of the compounds of the present invention, generally represented by formula I hereinbelow, can be selected to comprise a substituent selected from the group of arylesters, lactones and cyclic carbonates, more specifically from arylesters and lactones.
[0036] Unless a context dictates otherwise, asterisks are used herein to, indicate the point at which a mono- or bivalent radical depicted is connected to the structure to which it relates and of which the radical forms part.
[0037] Viewed from a first aspect, the invention provides a compound of Formula I or a stereoisomer, tautomer, racemic, metabolite, pro- or predrug, salt, hydrate, or solvate thereof,
[0000]
Wherein,
[0038] X is hydrogen or halogen;
R 1 is selected form the group comprising hydrogen, alkyl, and cycloalkyl;
Y is —NH—C(═O)— or —C(═O)—NH—;
[0039] Ar is optionally substituted aryl or optionally substituted heteroaryl:
m is 0 or 1;
n is an integer from 0 to 3; and
R 2 is an optionally substituted group selected from the group consisting of alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl, and heterocyclyl; and R 3 is hydrogen; or
R 2 taken together with R 3 form a cyclic ester (lactone) comprising from 4 to 9 carbon atoms in the cyclic ester ring.
[0040] Viewed from a further aspect, the invention provides the use of a compound of the invention, or a composition comprising such a compound, for inhibiting the activity of at least one kinase, in vitro or in vivo.
[0041] Viewed from a further aspect, the invention provides the use of a compound of the invention, or a composition comprising such a compound, for inhibiting the activity of at least one ROCK kinase, for example ROCKII and/or ROCKI isoforms.
[0042] Viewed from a further aspect, the invention provides a pharmaceutical and/or veterinary composition comprising a compound of the invention.
[0043] Viewed from a still further aspect, the invention provides a compound of the invention for use in human or veterinary medicine.
[0044] Viewed from a still further aspect, the invention provides the use of a compound of the invention in the preparation of a medicament for the prevention and/or treatment of at least one disease and/or disorder selected from the group comprising eye diseases; airway diseases; throat, nose and ear diseases; intestinal diseases; cardiovascular and vascular diseases; inflammatory diseases; neurological and CNS disorders: proliferative diseases; kidney diseases; sexual dysfunction; bone diseases; benign prostatic hyperplasia, transplant rejection, spasm, chronic obstructive bladder disease, and allergy.
DETAILED DESCRIPTION OF THE INVENTION
[0045] The present invention will now be further described. In the following passages, different aspects of the invention are defined in more detail. Each aspect so defined may be combined with any other aspect or aspects unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature or features indicated as being preferred or advantageous.
[0046] Unless a context dictates otherwise, asterisks are used herein to indicate the point at which a mono- or bivalent radical depicted is connected to the structure to which it relates and of which the radical forms part.
[0047] Undefined (racemic) asymmetric centers that may be present in the compounds of the present invention are interchangeably indicated by drawing a wavy bonds or a straight bond in order to visualize the undefined steric character of the bond.
[0048] As already mentioned hereinbefore, in a first aspect the present invention provides compounds of Formula I
[0000]
[0049] Wherein, X, R 1 , Y, Ar, m, n, R 2 and R 3 are as defined hereinbefore, including the stereo-isomeric forms, solvates, and pharmaceutically acceptable addition salts thereof.
[0050] When describing the compounds of the invention, the terms used are to be construed in accordance with the following definitions, unless a context dictates otherwise:
[0051] The term “alkyl” by itself or as part of another substituent refers to a fully saturated hydrocarbon of Formula C x H 2x+1 wherein x is a number greater than or equal to 1. Generally, alkyl groups of this invention comprise from 1 to 20 carbon atoms. Alkyl groups may be linear or branched and may be substituted as indicated herein. When a subscript is used herein following a carbon atom, the subscript refers to the number of carbon atoms that the named group may contain. Thus, for example, C 1-4 alkyl means an alkyl of one to four carbon atoms. Examples of alkyl groups are methyl, ethyl, n-propyl, i-propyl, butyl, and its isomers (e.g. n-butyl, i-butyl and t-butyl); pentyl and its isomers, hexyl and its isomers, heptyl and its isomers, octyl and its isomers, nonyl and its isomers; decyl and its isomers. C 1 -C 6 alkyl includes all linear, branched, or cyclic alkyl groups with between 1 and 6 carbon atoms, and thus includes methyl, ethyl, n-propyl, i-propyl, butyl and its isomers (e.g. n-butyl, i-butyl and t-butyl); pentyl and its isomers, hexyl and its isomers, cyclopentyl, 2-, 3-, or 4-methylcyclopentyl, cyclopentylmethylene, and cyclohexyl.
[0052] The term “optionally substituted alkyl” refers to an alkyl group optionally substituted with one or more substituents (for example 1 to 4 substituents, for example 1, 2, 3, or 4 substituents or 1 to 2 substituents) at any available point of attachment. Non-limiting examples of such substituents include halo, hydroxyl, oxo, carbonyl, nitro, amino, amido, oxime, imino, azido, hydrazino, cyano, aryl, heteroaryl, cycloalkyl, heterocyclyl, acyl, alkylamino, alkoxy, haloalkoxy, haloalkyl, thiol, alkylthio, carboxylic acid, acylamino, alkyl esters, carbamate, thioamido, urea, sullfonamido and the like.
[0053] The term “alkylamino”, as used herein refers to an amino group substituted with one or more alkyl chain(s). This definition includes quaternary ammonium derivatives.
[0054] The term “alkenyl”, as used herein, unless otherwise indicated, means straight-chain, cyclic, or branched-chain hydrocarbon radicals containing at least one carbon-carbon double bond. Examples of alkenyl radicals include ethenyl, E- and Z-propenyl, isopropenyl, E- and Z-butenyl, E- and Z-isobutenyl, E- and Z-pentenyl, E- and Z-hexenyl, E,E-, E,Z-, Z,E-, Z,Z-hexadienyl, and the like. An optionally substituted alkenyl refers to an alkenyl having optionally one or more substituents (for example 1, 2, 3 or 4), selected from those defined above for substituted alkyl.
[0055] The term “alkynyl”, as used herein, unless otherwise indicated, means straight-chain or branched-chain hydrocarbon radicals containing at least one carbon-carbon triple bond. Examples of alkynyl radicals include ethynyl, E- and Z-propynyl, isopropynyl, E- and Z-butynyl, E- and Z-isobutynyl, E- and Z-pentynyl, E, Z-hexynyl, and the like. An optionally substituted alkynyl refers to an alkynyl having optionally one or more substituents (for example 1, 2, 3 or 4), selected from those defined above for substituted alkyl.
[0056] The term “cycloalkyl” by itself or as part of another substituent is a cyclic alkyl group, that is to say, a monovalent, saturated, or unsaturated hydrocarbyl group having 1, 2, or 3 cyclic structure. Cycloalkyl includes all saturated or partially saturated (containing 1 or 2 double bonds) hydrocarbon groups containing 1 to 3 rings, including monocyclic, bicyclic, or polycyclic alkyl groups. Cycloalkyl groups may comprise 3 or more carbon atoms in the ring and generally, according to this invention comprise from 3 to 15 atoms. The further rings of multi-ring cycloalkyls may be either fused, bridged and/or joined through one or more spiro atoms. Cycloalkyl groups may also be considered to be a subset of homocyclic rings discussed hereinafter. Examples of cycloalkyl groups include but are not limited to cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, adamantanyl, bicyclo(2.2.1)heptanyl and cyclodecyl with cyclopropyl, cyclopentyl, cyclohexyl, adamantanyl, and bicyclo(2.2.1)heptanyl being particularly preferred. An “optionally substituted cycloalkyl” refers to a cycloalkyl having optionally one or more substituents (for example 1 to 3 substituents, for example 1, 2, 3 or 4 substituents), selected from those defined above for substituted alkyl. When the suffix “ene” is used in conjunction with a cyclic group, hereinafter also referred to as “Cycloalkylene”, this is intended to mean the cyclic group as defined herein having two single bonds as points of attachment to other groups. Cycloalkylene groups of this invention preferably comprise the same number of carbon atoms as their cycloalkyl radical counterparts.
[0057] Where alkyl groups as defined are divalent, i.e., with two single bonds for attachment to two other groups, they are termed “alkylene” groups. Non-limiting examples of alkylene groups includes methylene, ethylene, methylmethylene, trimethylene, propylene, tetramethylene, ethylethylene, 1,2-dimethylethylene, pentamethylene and hexamethylene. Similarly, where alkenyl groups as defined above and alkynyl groups as defined above, respectively, are divalent radicals having single bonds for attachment to two other groups, they are termed “alkenylene” and “alkynylene” respectively.
[0058] Generally, alkylene groups of this invention preferably comprise the same number of carbon atoms as their alkyl counterparts. Where an alkylene or cycloalkylene biradical is present, connectivity to the molecular structure of which it forms part may be through a common carbon atom or different carbon atom, preferably a common carbon atom. To illustrate this applying the asterisk nomenclature of this invention, a C 3 alkylene group may be for example *—CH 2 CH 2 CH 2 —*, *—CH(—CH 2 CH 3 )—*, or *—CH 2 CH(—CH 3 )—*. Likewise a C 3 cycloalkylene group may be
[0000]
[0059] Where a cycloalkylene group is present, this is preferably a C 3 -C 6 cycloalkylene group, more preferably a C 3 cycloalkylene (i.e. cyclopropylene group) wherein its connectivity to the structure of which it forms part is through a common carbon atom. Cycloalkylene and alkylene biradicals in compounds of the invention may be, but preferably are not, substituted.
[0060] The terms “heterocyclyl” or “heterocyclo” as used herein by itself or as part of another group refer to non-aromatic, fully saturated or partially unsaturated cyclic groups (for example, 3 to 13 member monocyclic, 7 to 17 member bicyclic, or 10 to 20 member tricyclic ring systems, or containing a total of 3 to 10 ring atoms) which have at least one heteroatom in at least one carbon atom-containing ring. Each ring of the heterocyclic group containing a heteroatom may have 1, 2, 3 or 4 heteroatoms selected from nitrogen atoms, oxygen atoms and/or sulfur atoms, where the nitrogen and sulfur heteroatoms may optionally be oxidized and the nitrogen heteroatoms may optionally be quaternized. The heterocyclic group may be attached at any heteroatom or carbon atom of the ring or ring system, where valence allows. The rings of multi-ring heterocycles may be fused, bridged and/or joined through one or more Spiro atoms. An optionally substituted heterocyclyl refers to a heterocyclyl having optionally one or more substituents (for example 1 to 4 substituents, or for example 1, 2, 3 or 4), selected from those defined for substituted aryl.
[0061] Exemplary heterocyclic groups include piperidinyl, azetidinyl, imidazolinyl, imidazolidinyl, isoxazolinyl, oxazolidinyl, isoxazolidinyl, thiazolidinyl, isothiazolidinyl, piperidyl, succinimidyl, 3H-indolyl, isoindolinyl, chromenyl, isochromanyl, xanthenyl, 2H-pyrrolyl, 1-pyrrolinyl, 2-pyrrolinyl, 3-pyrrolinyl, pyrrolidinyl, 4H-quinolizinyl, 4aH-carbazolyl, 2-oxopiperazinyl, piperazinyl, homopiperazinyl, 2-pyrazolinyl, 3-pyrazolinyl, pyranyl, dihydro-2H-pyranyl, 4H-pyranyl, 3,4-dihydro-2H-pyranyl, phthalazinyl, oxetanyl, thietanyl, 3-dioxolanyl, 1,3-dioxanyl, 2,5-dioximidazolidinyl, 2,2,4-piperidonyl, 2-oxopiperidinyl, 2-oxopyrrolodinyl, 2-oxoazepinyl, indolinyl, tetrahydropyranyl, tetrahydrofuranyl, tetrehydrothienyl, tetrahydroquinolinyl, tetrahydroisoquinolinyl, thiomorpholinyl, thiomorpholinyl sulfoxide, thiomorpholinyl sulfone, 1,3-dioxolanyl, 1,4-oxathianyl, 1,4-dithianyl, 1,3,5-trioxanyl, 6H-1,2,5-thiadiazinyl, 2H-1,5,2-dithiazinyl, 2H-oxocinyl, 1H-pyrrolizinyl, tetrahydro-1,1-dioxothienyl, N-formylpiperazinyl, and morpholinyl.
[0062] The term “aryl” as used herein refers to a polyunsaturated, aromatic hydrocarbyl group having a single ring (i.e. phenyl) or multiple aromatic rings fused together (e.g. naphthalene or anthracene) or linked covalently, typically containing 6 to 10 atoms; wherein at least one ring is aromatic. The aromatic ring may optionally include one to three additional rings (either cycloalkyl, heterocyclyl, or heteroaryl) fused thereto. Aryl is also intended to include the partially hydrogenated derivatives of the carbocyclic systems enumerated herein. Non-limiting examples of aryl comprise phenyl, biphenylyl, biphenylenyl, 5- or 6-tetralinyl, 1-, 2-, 3-, 4-, 5-, 6-, 7-, or 8-azulenyl, 1- or 2-naphthyl, 1-, 2-, or 3-indenyl, 1-, 2-, or 9-anthryl, 1-2-, 3-, 4-, or 5-acenaphtylenyl, 3-, 4-, or 5-acenaphtenyl, 1-, 2-, 3-, 4-, or 10-phenanthryl, 1- or 2-pentalenyl, 1,2-, 3-, or 4-fluorenyl, 4- or 5-indanyl, 5-, 6-, 7-, or 8-tetrahydronaphthyl, 1,2,3,4-tetrahydronaphthyl, 1,4-dihydronaphthyl, dibenzo[a,d]cylcoheptenyl, and 1-, 2-, 3-, 4-, or 5-pyrenyl.
[0063] The aryl ring can optionally be substituted by one or more substituents. An “optionally substituted aryl” refers to an aryl having optionally one or more substituents (for example 1 to 5 substituents, for example 1, 2, 3 or 4) at any available point of attachment. Non-limiting examples of such substituents are selected from halogen, hydroxyl, oxo, nitro, amino, hydrazine, aminocarbonyl, azido, cyano, alkyl, cycloalkyl, alkenyl, alkynyl, cycloalkylalkyl, alkylamino, alkoxy, —SO 2 —NH 2 , aryl, heteroaryl, aralkyl, haloalkyl, haloalkoxy, alkoxycarbonyl, alkylaminocarbonyl, heteroarylalkyl, alkylsulfonamide, heterocyclyl, alkylcarbonylaminoalkyl, aryloxy, alkylcarbonyl, acyl, arylcarbonyl, aminocarbonyl, alkylsulfoxide, —SO 2 R a , alkylthio, carboxyl, and the like, wherein R a is alkyl or cycloalkyl.
[0064] Where a carbon atom in an aryl group is replaced with a heteroatom, the resultant ring is referred to herein as a heteroaryl ring.
[0065] The term “heteroaryl” as used herein by itself or as part of another group refers but is not limited to 5 to 12 carbon-atom aromatic rings or ring systems containing 1 to 3 rings which are fused together or linked covalently, typically containing 5 to 8 atoms; at least one of which is aromatic in which one or more carbon atoms in one or more of these rings can be replaced by oxygen, nitrogen or sulfur atoms where the nitrogen and sulfur heteroatoms may optionally be oxidized and the nitrogen heteroatoms may optionally be quaternized. Such rings may be fused to an aryl, cycloalkyl, heteroaryl or heterocyclyl ring. Non-limiting examples of such heteroaryl, include: pyrrolyl, furanyl, thiophenyl, pyrazolyl, imidazolyl, oxazolyl, isoxazolyl, thiazolyl, isothiazolyl, triazolyl, oxadiazolyl, thiadiazolyl, tetrazolyl, oxatriazolyl, thiatriazolyl, pyridinyl, pyrimidyl, pyrazinyl, pyridazinyl, oxazinyl, dioxinyl, thiazinyl, triazinyl, imidazo[2,1-b][1,3]thiazolyl, thieno[3,2-b]furanyl, thieno[3,2-b]thiophenyl, thieno[2,3-d][1,3]thiazolyl, thieno[2,3-d]imidazolyl, tetrazolo[1,5-a]pyridinyl, indolyl, indolizinyl, isoindolyl, benzofuranyl, benzopyranyl, 1(4H)-benzopyranyl, 1(2H)-benzopyranyl, 3,4-dihydro-1(2H)-benzopyranyl, 3,4-dihydro-1(2H)-benzopyranyl, isobenzofuranyl, benzothiophenyl, isobenzothiophenyl, indazolyl, benzimidazolyl, 1,3-benzoxazolyl, 1,2-benzisoxazolyl, 2,1-benzisoxazolyl, 1,3-benzothiazolyl, 1,2-benzoisothiazolyl, 2,1-benzoisothiazolyl, benzotriazolyl, 1,2,3-benzoxadiazolyl, 2,1,3-benzoxadiazolyl, 1,2,3-benzothiadiazolyl, 2,1,3-benzothiadiazolyl, thienopyridinyl, purinyl, imidazo[1,2-a]pyridinyl, 6-oxo-pyridazin-1(6H)-yl, 2-oxopyridin-[(2H)-yl, 6-oxo-pyridazin-1(6H)-yl, 2-oxopyridin-[(2H)-yl, 1,3-benzodioxolyl, quinolinyl, isoquinolinyl, cinnolinyl, quinazolinyl, quinoxalinyl, 7-azaindolyl, 6-azaindolyl, 5-azaindolyl, 4-azaindolyl.
[0066] The term “pyrrolyl” (also called azolyl) as used herein includes pyrrol-1-yl, pyrrol-2-yl and pyrrol-3-yl. The term “furanyl” (also called “furyl”) as used herein includes furan-2-yl and furan-3-yl (also called furan-2-yl and furan-3-yl). The term “thiophenyl” (also called “thienyl”) as used herein includes thiophen-2-yl and thiophen-3-yl (also called thien-2-yl and thien-3-yl). The term “pyrazolyl” (also called 1H-pyrazolyl and 1,2-diazolyl) as used herein includes pyrazol-1-yl, pyrazol-3-yl, pyrazol-4-yl and pyrazol-5-yl. The term “imidazolyl” as used herein includes imidazol-1-yl, imidazol-2-yl, imidazol-4-yl and imidazol-5-yl. The term “oxazolyl” (also called 1,3-oxazolyl) as used herein includes oxazol-2-yl; oxazol-4-yl and oxazol-5-yl. The term “isoxazolyl” (also called 1,2-oxazolyl), as used herein includes isoxazol-3-yl, isoxazol-4-yl, and isoxazol-5-yl. The term “thiazolyl” (also called 1,3-thiazolyl), as used herein includes thiazol-2-yl, thiazol-4-yl and thiazol-5-yl (also called 2-thiazolyl, 4-thiazolyl and 5-thiazolyl). The term “isothiazolyl” (also called 1,2-thiazolyl) as used herein includes isothiazol-3-yl, isothiazol-4-yl, and isothiazol-5-yl. The term “triazolyl” as used herein includes 1H-triazolyl and 4H-1,2,4-triazolyl, “1H-triazolyl” includes 1H-1,2,3-triazol-1-yl, 1H-1,2,3-triazol-4-yl, 1H-1,2,3-triazol-5-yl, 1H-1,2,4-triazol-1-yl, 1H-1,2,4-triazol-3-yl and 1H-1,2,4-triazol-5-yl. “4H-1,2,4-triazolyl” includes 4H-1,2,4-triazol-4-yl, and 4H-1,2,4-triazol-3-yl. The term “oxadiazolyl” as used herein includes 1,2,3-oxadiazol-4-yl, 1,2,3-oxadiazol-5-yl, 1,2,4-oxadiazol-3-yl, 1,2,4-oxadiazol-5-yl, 1,2,5-oxadiazol-3-yl and 1,3,4-oxadiazol-2-yl. The term “thiadiazolyl” as used herein includes 1,2,3-thiadiazol-4-yl, 1,2,3-thiadiazol-5-yl, 1,2,4-thiadiazol-3-yl, 1,2,4-thiadiazol-5-yl, 1,2,5-thiadiazol-3-yl (also called furazan-3-yl) and 1,3,4-thiadiazol-2-yl. The term “tetrazolyl” as used herein includes 1H-tetrazol-1-yl, 1H-tetrazol-5-yl, 2H-tetrazol-2-yl, and 2H-tetrazol-5-yl. The term “oxatriazolyl” as used herein includes 1,2,3,4-oxatriazol-5-yl and 1,2,3,5-oxatriazol-4-yl. The term “thiatriazolyl” as used herein includes 1,2,3,4-thiatriazol-5-yl and 1,2,3,5-thiatriazol-4-yl. The term “pyridinyl” (also called “pyridyl”) as used herein includes pyridin-2-yl, pyridin-3-yl and pyridin-4-yl (also called 2-pyridyl, 3-pyridyl and 4-pyridyl). The term “pyrimidyl” as used herein includes pyrimid-2-yl, pyrimid-4-yl, pyrimid-5-yl and pyrimid-6-yl. The term “pyrazinyl” as used herein includes pyrazin-2-yl and pyrazin-3-yl. The term “pyridazinyl as used herein includes pyridazin-3-yl and pyridazin-4-yl. The term “oxazinyl” (also called “1,4-oxazinyl”) as used herein includes 1,4-oxazin-4-yl and 1,4-oxazin-5-yl. The term “dioxinyl” (also called “1,4-dioxinyl”) as used herein includes 1,4-dioxin-2-yl and 1,4-dioxin-3-yl. The term “thiazinyl” (also called “1,4-thiazinyl”) as used herein includes 1,4-thiazin-2-yl, 1,4-thiazin-3-yl, 1,4-thiazin-4-yl, 1,4-thiazin-5-yl and 1,4-thiazin-6-yl. The term “triazinyl” as used herein includes 1,3,5-triazin-2-yl, 1,2,4-triazin-3-yl, 1,2,4-triazin-5-yl, 1,2,4-triazin-6-yl, 1,2,3-triazin-4-yl and 1,2,3-triazin-5-yl. The term “imidazo[2,1-b][1,3]thiazolyl” as used herein includes imidazo[2,1-b][1,3]thiazol-2-yl, imidazo[2,1-b][1,3]thiazol-3-yl, imidazo[2,1-b][1,3]thiazol-5-yl and imidazo[2,1-b][1,3]thiazol-6-yl. The term “thieno[3,2-b]furanyl” as used herein includes thieno[3,2-b]furan-2-yl, thieno[3,2-b]furan-3-yl, thieno[3,2-b]furan-4-yl, and thieno[3,2-b]furan-5-yl. The term “thieno[3,2-b]thiophenyl” as used herein includes thieno[3,2-b]thien-2-yl, thieno[3,2-b]thien-3-yl, thieno[3,2-b]thien-5-yl and thieno[3,2-b]thien-6-yl. The term “thieno[2,3-d][1,3]thiazolyl” as used herein includes thieno[2,3-d][1,3]thiazol-2-yl, thieno[2,3-d][1,3]thiazol-5-yl and thieno[2,3-d][1,3]thiazol-6-yl. The term “thieno[2,3-d]imidazolyl” as used herein includes thieno[2,3-d]imidazol-2-yl, thieno[2,3-d]imidazol-4-yl and thieno[2,3-d]imidazol-5-yl. The term “tetrazolo[1,5-a]pyridinyl” as used herein includes tetrazolo[1,5-a]pyridine-5-yl, tetrazolo[1,5-a]pyridine-6-yl, tetrazolo[1,5-a]pyridine-7-yl, and tetrazolo[1,5-a]pyridine-8-yl. The term “indolyl” as used herein includes indol-1-yl, indol-2-yl, indol-3-yl, indol-4-yl, indol-5-yl, indol-6-yl and indol-7-yl. The term “indolizinyl” as used herein includes indolizin-1-yl, indolizin-2-yl, indolizin-3-yl, indolizin-5-yl, indolizin-6-yl, indolizin-7-yl, and indolizin-8-yl. The term “isoindolyl” as used herein includes isoindol-1-yl, isoindol-2-yl, isoindol-3-yl, isoindol-4-yl, isoindol-5-yl, isoindol-6-yl and isoindol-7-yl. The term “benzofuranyl” (also called benzo[b]furanyl) as used herein includes benzofuran-2-yl, benzofuran-3-yl, benzofuran-4-yl; benzofuran-5-yl, benzofuran-6-yl and benzofuran-7-yl. The term “isobenzofuranyl” (also called benzo[c]furanyl) as used herein includes isobenzofuran-1-yl, isobenzofuran-3-yl, isobenzofuran-4-yl, isobenzofuran-5-yl, isobenzofuran-6-yl and isobenzofuran-7-yl. The term “benzothiophenyl” (also called benzo[b]thienyl) as used herein includes 2-benzo[b]thiophenyl, 3-benzo[b]thiophenyl, 4-benzo[b]thiophenyl, 5-benzo[b]thiophenyl, 6-benzo[b]thiophenyl and -7-benzo[b]thiophenyl (also called benzothien-2-yl, benzothien-3-yl, benzothien-4-yl, benzothien-5-yl, benzothien-6-yl and benzothien-7-yl). The term “isobenzothiophenyl” (also called benzo[c]thienyl) as used herein includes isobenzothien-1-yl, isobenzothien-3-yl, isobenzothien-4-yl, isobenzothien-5-yl, isobenzothien-6-yl and isobenzothien-7-yl. The term “indazolyl” (also called 1H-indazolyl or 2-azaindolyl) as used herein includes 1H-indazol-1-yl, 1H-indazol-3-yl, 1H-indazol-4-yl, 1H-indazol-5-yl, 1H-indazol-6-yl, 1H-indazol-7-yl, 2H-indazol-2-yl, 2H-indazol-3-yl, 2H-indazol-4-yl, 2H-indazol-5-yl, 2H-indazol-6-yl, and 2H-indazol-7-yl. The term “benzimidazolyl” as used herein includes benzimidazol-1-yl, benzimidazol-2-yl, benzimidazol-4-yl, benzimidazol-5-yl, benzimidazol-6-yl and benzimidazol-7-yl. The term “1,3-benzoxazolyl” as used herein includes 1,3-benzoxazol-2-yl, 1,3-benzoxazol-4-yl, 1,3-benzoxazol-5-yl, 1,3-benzoxazol-6-yl and 1,3-benzoxazol-7-yl. The term “1,2-benzisoxazolyl” as used herein includes 1,2-benzisoxazol-3-yl, 1,2-benzisoxazol-4-yl, 1,2-benzisoxazol-5-yl, 1,2-benzisoxazol-6-yl and 1,2-benzisoxazol-7-yl. The term “2,1-benzisoxazolyl” as used herein includes 2,1-benzisoxazol-3-yl, 2,1-benzisoxazol-4-yl, 2,1-benzisoxazol-5-yl, 2,1-benzisoxazol-6-yl and 2,1-benzisoxazol-7-yl. The term “1,3-benzothiazolyl” as used herein includes 1,3-benzothiazol-2-yl, 1,3-benzothiazol-4-yl, 1,3-benzothiazol-5-yl, 1,3-benzothiazol-6-yl and 1,3-benzothiazol-7-yl. The term “1,2-benzoisothiazolyl” as used herein includes 1,2-benzisothiazol-3-yl, 1,2-benzisothiazol-4-yl, 1,2-benzisothiazol-5-yl, 1,2-benzisothiazol-6-yl and 1,2-benzisothiazol-7-yl. The term “2,1-benzoisothiazolyl” as used herein includes 2,1-benzisothiazol-3-yl, 2,1-benzisothiazol-4-yl, 2,1-benzisothiazol-5-yl, 2,1-benzisothiazol-6-yl and 2,1-benzisothiazol-7-yl. The term “benzotriazolyl” as used herein includes benzotriazol-1-yl, benzotriazol4-yl, benzotriazol-5-yl, benzotriazol-6-yl and benzotriazol-7-yl. The term “1,2,3-benzoxadiazolyl” as used herein includes 1,2,3-benzoxadiazol-4-yl, 1,2,3-benzoxadiazol-5-yl, 1,2,3-benzoxadiazol-6-yl and 1,2,3-benzoxadiazol-7-yl. The term “2,1,3-benzoxadiazolyl” as used herein includes 2,1,3-benzoxadiazol-4-yl, 2,1,3-benzoxadiazol-5-yl, 2,1,3-benzoxadiazol-6-yl and 2,1,3-benzoxadiazol-7-yl. The term “1,2,3-benzothiadiazolyl” as used herein includes 1,2,3-benzothiadiazol-4-yl, 1,2,3-benzothiadiazol-5-yl, 1,2,3-benzothiadiazol-6-yl and 1,2,3-benzothiadiazol-7-yl. The term “2,1,3-benzothiadiazolyl” as used herein includes 2,1,3-benzothiadiazol-4-yl, 2,1,3-benzothiadiazol-5-yl, 2,1,3-benzothiadiazol-6-yl and 2,1,3-benzothiadiazol-7-yl. The term “thienopyridinyl” as used herein includes thieno[2,3-b]pyridinyl, thieno[2,3-c]pyridinyl, thieno[3,2-c]pyridinyl and thieno[3,2-b]pyridinyl. The term “purinyl” as used herein includes purin-2-yl, purin-6-yl, purin-7-yl and purin-8-yl. The term “imidazo[1,2-a]pyridinyl”, as used herein includes imidazo[1,2-a]pyridin-2-yl, imidazo[1,2-a]pyridin-3-yl, imidazo[1,2-a]pyridin-4-yl, imidazo[1,2-a]pyridin-5-yl, imidazo[1,2-a]pyridin-6-yl and imidazo[1,2-a]pyridin-7-yl. The term “1,3-benzodioxolyl”, as used herein includes 1,3-benzodioxol-4-yl, 1,3-benzodioxol-5-yl, 1,3-benzodioxol-6-yl, and 1,3-benzodioxol-7-yl. The term “quinolinyl” as used herein includes quinolin-2-yl, quinolin-3-yl, quinolin-4-yl, quinolin-5-yl, quinolin-6-yl, quinolin-7-yl and quinolin-8-yl. The term “isoquinolinyl” as used herein includes isoquinolin-1-yl, isoquinolin-3-yl, isoquinolin-4-yl, isoquinolin-5-yl, isoquinolin-6-yl, isoquinolin-7-yl and isoquinolin-8-yl. The term “cinnolinyl” as used herein includes cinnolin-3-yl, cinnolin-4-yl, cinnolin-5-yl, cinnolin-6-yl, cinnolin-7-yl and cinnolin-8-yl. The term “quinazolinyl” as used herein includes quinazolin-2-yl, quiriazolin-4-yl, quinazolin-5-yl, quinazolin-6-yl, quinazolin-7-yl and quinazolin-8-yl. The term “quinoxalinyl”. as used herein includes quinoxalin-2-yl, quinoxalin-5-yl, and quinoxalin-6-yl. The term “7-azaindolyl” as used herein refers to 1H-Pyrrolo[2,3-b]pyridinyl and includes 7-azaindol-1-yl, 7-azaindol-2-yl, 7-azaindol-3-yl, 7-azaindol-4-yl, 7-azaindol-5-yl, 7-azaindol-6-yl. The term “6-azaindolyl” as used herein refers to 1H-Pyrrolo[2,3-c]pyridinyl and includes 6-azaindol-1-yl, 6-azaindol-2-yl, 6-azaindol-3-yl, 6-azaindol-4-yl, 6-azaindol-5-yl, 6-azaindol-7-yl. The term “5-azaindolyl” as used herein refers to 1H-Pyrrolo[3,2-c]pyridinyl and includes 5-azaindol-1-yl, 5-azaindol-2-yl, 5-azaindol-3-yl, 5-azaindol-4-yl, 5-azaindol-6-yl, 5-azaindol-7-yl. The term “4-azaindolyl” as used herein refers to 1H-Pyrrolo[3,2-b]pyridinyl and includes 4-azaindol-1-yl, 4-azaindol-2-yl, 4-azaindol-3-yl, 4-azaindol-5-yl, 4-azaindol-6-yl, 4-azaindol-7-yl.
[0067] For example, non-limiting examples of heteroaryl can be 2- or 3-furyl, 2- or 3-thienyl, 1-, 2- or 3-pyrrolyl, 1-, 2-, 4- or 5-imidazolyl, 1-, 3-, 4- or 5-pyrazolyl, 3-, 4- or 5-isoxazolyl, 2-, 4- or 5-oxazolyl, 3-, 4- or 5-isothiazolyl, 2-, 4- or 5-thiazolyl, 1,2,3-triazol-1-, -4- or -5-yl, 1,2,4-triazol-1-, -3-, -4- or -5-yl, 1H-tetrazol-1-, or -5-yl, 2H-tetrazol-2-, or -5-yl, 1,2,3-oxadiazol-4- or -5-yl, 1,2,4-oxadiazol-3- or -5-yl, 1,2,5-oxadiazolyl, 1,3,4-oxadiazolyl, 1,2,3-thiadiazol-4- or -5-yl, 1,2,4-thiadiazol-3- or -5-yl, 1,2,5-thiadiazol-3- or -4-yl, 1,3,4-thiadiazolyl, 1- or 5-tetrazolyl, 2-, 3- or 4-pyridyl, 3- or 4-pyridazinyl, 2-, 4-, 5- or 6-pyrimidyl, 2-, 3-, 4-, 5-6-2H-thiopyranyl, 2-, 3- or 4-4H-thiopyranyl, 4-azaindol-1-, 2-, 3-, 5-, or 7-yl, 5-azaindol-1-, or 2-, 3-, 4-, 6-, or 7-yl, 6-azaindol-1,2-, 3-, 4-, 5-, or 7-yl, 7-azaindol-1-, 2-, 3-, 4,5-, or 6-yl, 2-, 3-, 4-, 5-, 6- or 7-benzofuryl, 1-, 3-, 4- or 5-isobenzofuryl, 2-, 3-, 4-, 5-, 6- or 7-benzothienyl, 1-, 3-, 4- or 5-isobenzothienyl, 1-, 2-, 3-, 4-, 5-, 6- or 7-indolyl, 2- or 3-pyrazinyl, 1,4-oxazin-2- or -3-yl, 1,4-dioxin-2- or -3-yl, 1,4-thiazin-2- or -3-yl, 1,2,3-triazinyl, 1,2,4-triazinyl, 1,3,5-triazin-2-, -4- or -6-yl, thieno[2,3-b]furan-2-, -3-, -4-, or -5-yl, benzimidazol-1-yl, -2-yl, -4-yl, -5-yl, -6-yl, or -7-yl, 1-, 3-, 4-, 5-, 6- or 7-benzopyrazolyl, 3-, 4-, 5-, 6- or 7-benzisoxazolyl, 2-, 4-, 5-, 6- or 7-benzoxazolyl, 3-, 4-, 5-, 6- or 7-benzisothiazolyl, 1,3-benzothiazol-2-yl, -4-yl, -5-yl, -6-yl or -7-yl, 1,3-benzodioxol-4-yl, -5-yl, -6-yl, or -7-yl, benzotriazol-1-yl, -4-yl, -5-yl, -6-yl or -7-yl1-, 2-thianthrenyl, 3-, 4- or 5-isobenzofuranyl, 1-, 2-, 3-, 4- or 9-xanthenyl, 1-, 2-, 3- or 4-phenoxathiinyl, 2-, 3-pyrazinyl, 1-, 2-, 3-, 4-, 5-, 6-, 7- or 8-indolizinyl, 2-, 3-, 4- or 5-isoindolyl, 1H-indazol-1-yl, 3-yl, -4-yl, -5-yl, -6-yl, or -7-yl, 2H-indazol-2-yl, 3-yl, -4-yl, -5-yl, -6-yl, or -7-yl, imidazo[2,1-b][1,3][1,3]thiazoi-2-yl, imidazo[2,1-b][1,3]thiazol-3-yl, imidazo[2,1-b][1,3]thiazol-5-yl or imidazo[2,1-b][1,3]thiazol-6-yl, imidazo[1,2-a]pyridin-2-yl, imidazo[1,2-a]pyridin-3-yl, imidazo[1,2-a]pyridin-4-yl, imidazo[1,2-a]pyridin-5-yl, imidazo[1,2-a]pyridin-6-yl or imidazo[1,2-a]pyridin-7-yl, tetrazolo[1,5-a]pyridine-5-yl, tetrazolo[1,5-a]pyridine-6-yl, tetrazolo[1,5-a]pyridine-7-yl, or tetrazolo[1,5-a]pyridine-8-yl, 2-, 6-, 7- or 8-purinyl, 4-, 5- or 6-phthalazinyl, 2-, 3- or 4-naphthyridinyl, 2-, 5- or 6-quinoxalinyl, 2-, 4-, 5-, 6-, 7- or 8-quinazolinyl, 1-, 2-, 3- or 4-quinolizinyl, 2-, 3-, 4-, 5-, 6-, 7-, or 8-quinolinyl(quinolyl), 2-, 4-, 5-, 6-, 7- or 8-quinazolyl, 1-, 3-, 4-, 5-, 6-, 7- or 8-isoquinolinyl(isoquinolyl), 3-, 4-, 5-, 6-, 7- or 8-cinnolinyl, 2-, 4-, 6- or 7-pteridinyl, 1-, 2-, 3-, 4- or 9-carbazolyl, 1-, 2-, 3-, 4-, 5-, 6-, 7-, 8- or 9-carbolinyl, 1-, 2-, 3-, 4-, 5-, 6-, 7-, 8-, 9- or 10-phenanthridinyl, 1-, 2-, 3- or 4-acridinyl, 1-, 2-, 3-, 4-, 5-, 6-, 7-, 8- or 9-perimidinyl, 2-, 3-, 4-, 5-, 6-, 7-, 8-, 9- or 10-(1,7)phenanthrolinyl, 1- or 2-phenazinyl, 1-, 2-, 3-, 4-, or 10-phenothiazinyl, 3- or 4-furazanyl, 1-, 2-, 3-, 4-, or 10-phenoxazinyl, or additionally substituted derivatives thereof.
[0068] An “optionally substituted heteroaryl” refers to a heteroaryl having optionally one or more substituents (for example 1 to 4 substituents, for example 1, 2, 3 or 4), selected from those defined above for substituted aryl.
[0069] The term “oxo” as used herein refers to the group ═O.
[0070] The term “alkoxy” or “alkyloxy” as used herein refers to a radical having the Formula —OR b wherein R b is alkyl. Preferably, alkoxy is C 1 -C 10 alkoxy, C 1 -C 6 alkoxy, or C 1 -C 4 alkoxy. Non-limiting examples of suitable alkoxy include methoxy, ethoxy, propoxy, isopropoxy, butoxy, isobutoxy, sec-butoxy, tert-butoxy, pentyloxy and hexyloxy. Where the oxygen atom in an alkoxy group is substituted with sulfur, the resultant radical is referred to as thioalkoxy. “Haloalkoxy” is an alkoxy group wherein one or more hydrogen atoms in the alkyl group are substituted with halogen. Non-limiting examples of suitable haloalkoxy include fluoromethoxy, difluoromethoxy, trifluoromethoxy, 2,2,2-trifluoroethoxy, 1,1,2,2-tetrafluoroethoxy, 2-fluoroethoxy, 2-chloroethoxy, 2,2-difluoroethoxy, 2,2,2-trichloroethoxy; trichloromethoxy, 2-bromoethoxy, pentafluoroethyl, 3,3,3-trichloropropoxy, 4,4,4-trichlorobutoxy.
[0071] The term “aryloxy” as used herein denotes a group —O-aryl, wherein aryl is as defined above.
[0072] The term “arylcarbonyl” or “aroyl” as used herein denotes a group —C(O)-aryl, wherein aryl is as defined above.
[0073] The term “cycloalkylalkyl” by itself or as part of another substituent refers to a group having one of the aforementioned cycloalkyl groups attached to one of the aforementioned alkyl chains. Examples of such cycloalkylalkyl radicals include cyclopropylmethyl, cyclobutylmethyl, cyclopentylmethyl, cyclohexylmethyl, 1-cyclopentylethyl, 1-cyclohexylethyl, 2-cyclopentylethyl, 2-cyclohexylethyl, cyclobutylpropyl, cyclopentylpropyl, 3-cyclopentylbutyl, cyclohexylbutyl and the like.
[0074] The term “heterocyclyl-alkyl” by itself or as part of another substituents refers to a group having one of the aforementioned heterocyclyl group attached to one of the aforementioned alkyl group, i.e., to a group —R d -R c wherein R d is alkylene or alkylene substituted by alkyl group and R c is a heterocyclyl group.
[0075] The term “carboxy” or “carboxyl” or “hydroxycarbonyl” by itself or as part of another substituent refers to the group —CO 2 H. Thus, a carboxyalkyl is an alkyl group as defined above having at least one substituent that is —CO 2 H.
[0076] The term “alkoxycarbonyl” by itself or as part of another substituent refers to a carboxy group linked to an alkyl radical i.e. to form —C(═O)OR e , wherein R e is as defined above for alkyl. The term “alkylcarbonyloxy” by itself or as part of another substituent refers to a —O—C(═O)R e wherein R e is as defined above for alkyl.
[0077] The term “alkylcarbonylamino” by itself or as part of another substituent refers to an group of Formula —NH(C═O)R or —NR′(C═O)R, wherein R and R′ are each independently alkyl or substituted alkyl.
[0078] The term “thiocarbonyl” by itself or as part of another substituent refers to the group —C(═S)—.
[0079] The term “alkoxy” by itself or as part of another substituent refers to a group consisting of an oxygen atom attached to one optionally substituted straight or branched alkyl group, cycloalkyl group, aralkyl, or cycloalkylalkyl group. Non-limiting examples of suitable alkoxy group include methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, iso-butoxy, sec-butoxy, tert-butoxy, hexanoxy, and the like.
[0080] The term “halo” or “halogen” as a group or part of a group is generic for fluoro, chloro, bromo, or iodo.
[0081] The term “haloalkyl” alone or in combination, refers to an alkyl radical having the meaning as defined above wherein one or more hydrogens are replaced with a halogen as defined above. Non-limiting examples of such haloalkyl radicals include chloromethyl, 1-bromoethyl, fluoromethyl, difluoromethyl, trifluoromethyl, 1,1,1-trifluoroethyl, and the like.
[0082] The term “haloaryl” alone or in combination, refers to an aryl radical having the meaning as defined above wherein one or more hydrogens are replaced with a halogen as defined above.
[0083] The term “haloalkoxy” alone or in combination refers to a group of Formula —O-alkyl wherein the alkyl group is substituted by 1, 2, or 3 halogen atoms. For example, “haloalkoxy” includes —OCF 3 , —OCHF 2 , —OCH 2 F, —O—CF 2 —CF 3 , —O—CH 2 —CF 3 , —O—CH 2 —CHF 2 , and —O—CH 2 —CH 2 F.
[0084] Whenever the term “substituted” is used in the present invention, it is meant to indicate that one or more hydrogens on the atom indicated in the expression using “substituted” is replaced with a selection from the indicated group, provided that the indicated atom's normal valency is not exceeded, and that the substitution results in a chemically stable compound, i.e. a compound that is sufficiently robust to survive isolation to a useful degree of purity from a reaction mixture, and formulation into a therapeutic agent.
[0085] As used herein the terms such as “alkyl, aryl, or cycloalkyl, each being optionally substituted with” or “alkyl, aryl, or cycloalkyl, optionally substituted with” refers to optionally substituted alkyl, optionally substituted aryl and optionally substituted cycloalkyl.
[0086] As described herein, some of the compounds of the invention may contain one or more asymmetric carbon atoms that serve as a chiral center, which may lead to different optical forms (e.g. enantiomers or diastereoisomers). The invention comprises all such optical forms in all possible configurations, as well as mixtures thereof.
[0087] More generally, from the above, it will be clear to the skilled person that the compounds of the invention may exist in the form of different isomers and/or tautomers, including but not limited to geometrical isomers, conformational isomers, E/Z-isomers, stereochemical isomers (i.e. enantiomers and diastereoisomers) and isomers that correspond to the presence of the same substituents on different positions of the rings present in the compounds of the invention. All such possible isomers, tautomers and mixtures thereof are included within the scope of the invention.
[0088] Whenever used in the present invention the term “compounds of the invention” or a similar term is meant to include the compounds of general Formula I and any subgroup thereof. This term also refers to the compounds as depicted in Tables 1 to 11, their derivatives, N-oxides, salts, solvates, hydrates, stereoisomeric forms, racemic mixtures, tautomeric forms, optical isomers, analogues, pro-drugs, esters, and metabolites, as well as their quaternized nitrogen analogues. The N-oxide forms of said compounds are meant to comprise compounds wherein one or several nitrogen atoms are oxidized to the so-called N-oxide.
[0089] As used in the specification and the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. By way of example, “a compound” means one compound or more than one compound.
[0090] The terms described above and others used in the specification are well understood to those in the art.
[0091] In a further embodiment, the present invention provides compounds of formula I
[0000] wherein;
X is hydrogen or halogen;
R 1 is selected form the group comprising hydrogen, alkyl, or cycloalkyl; in particular hydrogen,
C 1-6 alkyl, or C 3-6 alkyl;
Y is —NH—C(═O)— or —C(═O)—NH—;
[0092] Ar is optionally substituted aryl or optionally substituted heteroaryl:
m is 0 or 1;
n is an integer from 0 to 3; and
R 2 is an optionally substituted group selected from the group consisting of alkyl, alkynyl, cycloalkyl, aryl, heteroaryl, and heterocyclyl; in particular an optionally substituted group selected from the group consisting of C 1-20 alkyl, C 3-20 alkynyl, C 3-8 cycloalkyl, aryl, heteroaryl, and heterocyclyl; and R 3 is hydrogen; or
R 2 taken together with R 3 form a cyclic ester (lactone) comprising from 4 to 9 carbon atoms in the cyclic ester ring; in particular the cyclic ester ring comprises from 4 to 5 carbon atoms.
[0093] In a preferred embodiment, the present invention provides compounds of formula I
[0000] wherein;
X is hydrogen or halogen; in particular halogen;
R 1 is selected form the group comprising hydrogen, alkyl or cycloalkyl; in particular hydrogen;
Y is —NH—C(═O)— or —C(═O)—NH—;
[0094] Ar is optionally substituted aryl or optionally substituted heteroaryl: in particular heteroaryl or optionally substituted aryl; more in particular aryl substituted with halo or alkyl, or heteroaryl;
m is 0 or 1;
n is an integer from 0 to 3; in particular n is 0 or 1; and
R 2 is an optionally substituted group selected from the group consisting of alkyl, alkynyl cycloalkyl, aryl, heteroaryl, heterocyclyl; in particular R 2 is an optionally substituted group selected from the group consisting of C 1-20 alkyl, C 3-20 alkynyl, C 3-8 cycloalkyl, and aryl; and R 3 is hydrogen; or
R 2 taken together with R 3 form a cyclic ester (lactone) comprising from 4 to 9 carbon atoms in the cyclic ester ring; in particular the cyclic ester ring comprises from 4 to 5 carbon atoms; more in particular R 2 taken together with R 3 form a cyclic ester comprising 4 carbon atoms in the cyclic ester ring.
[0095] In an even further embodiment, the present invention provides compounds of formula I
[0000] wherein;
X is hydrogen or halogen; in particular halogen; more in particular fluoro;
R 1 is selected form the group comprising hydrogen, alkyl or cycloalkyl; in particular hydrogen;
Y is —NH—C(═O)— or —C(═O)—NH—;
[0096] Ar is optionally substituted aryl or optionally substituted heteroaryl: in particular heteroaryl or optionally substituted aryl; more in particular Ar is aryl substituted with fluoro or methyl, or 5- or 6-membered heteroaryl;
m is 0 or 1;
n is an integer from 0 to 3; in particular n is 0 or 1; and
R 2 is an optionally substituted group selected from the group consisting of alkyl, alkynyl cycloalkyl, aryl, heteroaryl, heterocyclyl; in particular R 2 is an optionally substituted group selected from the group consisting of C 1-20 alkyl, C 3-20 alkynyl, C 3-8 cycloalkyl, and aryl; more in particular R 2 is an optionally substituted group selected from the group consisting of C 1-6 alkyl, C 3-5 alkynyl, C 3-6 cycloalkyl, and aryl; and R 3 is hydrogen; or
R 2 taken together with R 3 form a cyclic ester (lactone) comprising from 4 to 9 carbon atoms in the cyclic ester ring; in particular the cyclic ester ring comprises from 4 to 5 carbon atoms; more in particular R 2 taken together with R 3 form a cyclic ester comprising 4 carbon atoms in the cyclic ester ring.
[0097] In yet another embodiment, the present invention provides compounds of formula I
[0000] wherein;
X is hydrogen or halogen; in particular halogen; more in particular fluoro;
R 1 is selected form the group comprising hydrogen, alkyl or cycloalkyl; in particular hydrogen;
Y is —NH—C(═O)— or —C(═O)—NH—;
[0098] Ar is optionally substituted aryl or optionally substituted heteroaryl: in particular Ar is aryl substituted with fluoro or methyl, or heteroaryl; more in particular Ar is selected from the group consisting of phenyl substituted with fluoro or methyl, pyridinyl, thiazolyl, oxadiazolyl, and furan;
m is 0 or 1;
n is an integer from 0 to 3; in particular n is 0 or 1; and
R 2 is an optionally substituted group selected from the group consisting of alkyl, alkynyl cycloalkyl, aryl, heteroaryl, heterocyclyl; in particular R 2 is an optionally substituted group selected from the group consisting of C 1-20 alkyl, C 3-20 alkynyl, C 3-8 cycloalkyl, and aryl; more in particular R 2 is an optionally substituted group selected from the group consisting of C 1-5 alkyl, C 3-5 alkynyl, C 3-8 cycloalkyl, and phenyl; and R 3 is hydrogen; or
R 2 taken together with R 3 form a cyclic ester (lactone) comprising from 4 to 9 carbon atoms in the cyclic ester ring; in particular the cyclic ester ring comprises from 4 to 5 carbon atoms; more in particular R 2 taken together with R 3 form a cyclic ester comprising 4 carbon atoms in the cyclic ester ring.
[0099] In yet another embodiment, the present invention provides compounds of formula I wherein one or more of the following restrictions apply:
X is hydrogen or halogen; in particular halogen; more in particular fluoro; R 1 is selected form the group comprising hydrogen, alkyl or cycloalkyl; in particular hydrogen; Y is —NH—C(═O)— or —C(═O)—NH—; Ar is optionally substituted aryl or optionally substituted heteroaryl: in particular heteroaryl or optionally substituted aryl; more in particular aryl substituted with halo or alkyl, or heteroaryl; Ar is aryl substituted with fluoro or methyl, or 5- or 6-membered heteroaryl; more in particular Ar is selected from the group consisting of phenyl substituted with fluoro or methyl, pyridinyl, thiazolyl, oxadiazolyl, and furan; m is 0 or 1; n is an integer from 0 to 3; in particular n is 0 or 1; R 2 is an optionally substituted group selected from the group consisting of alkyl, alkenyl, alkynyl, cycloalkyl, aryl, heteroaryl, heterocyclyl; in particular R 2 is an optionally substituted group selected from the group consisting of C 1-20 alkyl, C 3-20 alkenyl, C 3-20 alkynyl, C 3-8 cycloalkyl, and aryl; more in particular R 2 is an optionally substituted group selected from the group consisting of C 1-18 alkyl, C 3-10 alkenyl, C 3-18 alkynyl, C 3-8 cycloalkyl, and aryl; and R 3 is hydrogen; R 2 is an optionally substituted group selected from the group consisting of alkyl, alkynyl, cycloalkyl, aryl, heteroaryl, and heterocyclyl; in particular C 1-10 alkyl, C 3-10 alkynyl, C 3-8 cycloalkyl, aryl, heteroaryl, and heterocyclyl; more in particular alkyl, alkynyl, cycloalkyl, and aryl; and R 3 is hydrogen; R 2 is an optionally substituted group selected from the group consisting of C 1-20 alkyl, C 3-20 alkynyl, C 3-8 cycloalkyl, and aryl; in particular R 2 is an optionally substituted group selected from the group consisting of C 1-5 alkyl, C 3-5 alkynyl, C 3-8 cycloalkyl, and phenyl; and R 3 is hydrogen; R 2 taken together with R 3 form a cyclic ester (lactone) comprising from 4 to 9 carbon atoms in the cyclic ester ring; in particular the cyclic ester ring comprises from 4 to 5 carbon atoms; more in particular R 2 taken together with R 3 form a cyclic ester comprising 4 carbon atoms in the cyclic ester ring.
[0111] The compounds of the present invention can be prepared according to the reaction schemes provided in the examples hereinafter, but those skilled in the art will appreciate that these are only illustrative for the invention and that the compounds of this invention can be prepared by any of several standard synthetic processes commonly used by those skilled in the art of organic chemistry.
[0112] In a preferred embodiment, the compounds of the present invention are useful as kinase inhibitors, more in particular for the inhibition of at least one ROCK kinase, selected from ROCKI and ROCKII, in particular soft ROCK inhibitors.
[0113] The present invention further provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound, as a human or veterinary medicine, in particular for prevention and/or treatment of at least one disease or disorder, in which ROCK is involved, such as diseases linked to smooth muscle cell function, inflammation, fibrosis, excessive cell proliferation, excessive angiogenesis, hyperreactivity, barrier dysfunction, neurodegeration, function, inflammation, fibrosis, excessive cell proliferation, excessive angiogenesis, hyperreactivity, barrier dysfunction, neurodegeration and remodeling.
[0114] In a further embodiment, the invention provides the use of a compound as defined hereinbefore, or the use of a composition comprising said compound in the prevention and/or treatment of at least one disease or disorder selected from the group comprising eye diseases; airway diseases; throat, nose and ear diseases; intestinal diseases; cardiovascular and vascular diseases; inflammatory diseases; neurological and CNS disorders: proliferative diseases; kidney diseases; sexual dysfunction; bone diseases; benign prostatic hyperplasia, transplant rejection, spasm, hypertension, chronic obstructive bladder disease, and allergy.
[0115] In a preferred embodiment, the invention provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound in the prevention and/or treatment of eyes diseases including but not limited to retinopathy, optic neuropathy, glaucoma and degenerative retinal diseases such as macular degeneration, retinitis pigmentosa and inflammatory eye diseases (such as anterior uveitis, panuveitis, intermediate uveitis and posterior uveitis), and/or for preventing, treating and/or alleviating complications and/or symptoms associated therewith.
[0116] In another preferred embodiment, the invention provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound in the prevention and/or treatment of airway diseases; including but not limited to pulmonary fibrosis, emphysema, chronic bronchitis, asthma, fibrosis, pneumonia, cytsis fibrosis, chronic obstructive pulmonary disease (COPD); bronchitis and rhinitis and respiratory distress syndrome, and/or for preventing, treating and/or alleviating complications and/or symptoms associated therewith.
[0117] In a further embodiment, the invention provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound in the prevention and/or treatment of cardiovascular and vascular diseases: including but not limited to pulmonary hypertension and pulmonary vasoconstriction, and/or for preventing, treating and/or alleviating complications and/or symptoms associated therewith and/or alleviating complications and/or symptoms associated therewith.
[0118] In a further embodiment, the invention provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound in the prevention and/or treatment of throat, nose and ear diseases: including but not limited to sinus problems, hearing problems, toothache, tonsillitis, ulcer and rhinitis,
[0119] In a further embodiment, the invention provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound in the prevention and/or treatment of skin diseases: including but not limited to hyperkeratosis, parakeratosis, hypergranulosis, acanthosis, dyskeratosis, spongiosis and ulceration.
[0120] In a further embodiment, the invention provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound in the prevention and/or treatment of intestinal diseases; including but not limited to inflammatory bowel disease (IBD), colitis, gastroenteritis, ileus, ileitis, appendicitis and Crohn's disease.
[0121] In yet another embodiment, the invention provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound in the prevention and/or treatment of inflammatory diseases: including but not limited to contact dermatitis, atopic dermatitis, psoriasis, rheumatoid arthritis, juvenile rheumatoid arthritis, ankylosing spondylitis, psoriatic arthritis, inflammatory bowel disease, Crohn's disease and ulcerative colitis, and/or for preventing, treating and/or alleviating complications and/or symptoms and/or inflammatory responses associated therewith.
[0122] In another embodiment, the invention provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound in the prevention, treatment and/or management of neurological and CNS disorders: including but not limited to neuropathic pain. The present compounds are therefore suitable for preventing neurodegeneration and stimulating neurogeneration in various neurological disorders, and/or for preventing, treating and/or alleviating complications and/or symptoms associated therewith.
[0123] In another embodiment, the invention provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound in the prevention and/or treatment of proliferative diseases: such as but not limited to cancer of breast, colon, intestine, skin, head and neck, nerve, uterus, kidney, lung, ovary, pancreas, prostate, or thyroid gland; Castleman disease; sarcoma; malignoma; and melanoma; and/or for preventing, treating and/or alleviating complications and/or symptoms and/or inflammatory responses associated therewith.
[0124] In another embodiment, the invention provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound in the prevention and/or treatment of kidney diseases: including but not limited to renal fibrosis or renal dysfunction; and/or for preventing, treating and/or alleviating complications and/or symptoms and/or inflammatory responses associated therewith.
[0125] In another embodiment, the invention provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound in the prevention and/or treatment of sexual dysfunction: including but not limited to hypogonadism, bladder disease, hypertension, diabetes, or pelvic surgery; and/or to treat sexual dysfunction associated with treatment using certain drugs, such as drugs used to treat hypertension, depression or anxiety.
[0126] In another embodiment, the invention provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound in the prevention and/or treatment of bone diseases: including but not limited to osteoporosis and osteoarthritis; and/or for preventing, treating and/or alleviating complications and/or symptoms and/or inflammatory responses associated therewith.
[0127] In another embodiment, the invention provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound in the prevention and/or treatment of diseases and disorders such as benign prostatic hyperplasia, transplant rejection, spasm, chronic obstructive bladder disease, and allergy, and/or for preventing, treating and/or alleviating complications and/or symptoms associated therewith.
[0128] In a preferred embodiment the present invention provides the use of a compound as defined hereinbefore or the use of a composition comprising said compound in the prevention and/or treatment of eye diseases.
Method of Treatment
[0000]
The present invention further provides a method for the prevention and/or treatment of at least one disease or disorder selected from the group comprising eye diseases; airway diseases; cardiovascular and vascular diseases; inflammatory diseases; neurological and CNS disorders: proliferative diseases; kidney diseases; sexual dysfunction; bone diseases; benign prostatic hyperplasia; transplant rejection; spasm; hypertension; chronic obstructive bladder disease; and allergy; said method comprising administering to a subject in need thereof a therapeutic effective amount of a compound or a composition as defined herein.
In a preferred embodiment, the invention provides a method for the prevention and/or treatment of eye diseases including but not limited to retinopathy, optic neuropathy, glaucoma and degenerative retinal diseases such as macular degeneration, retinitis pigmentosa and inflammatory eye diseases (such as anterior uveitis, panuveitis, intermediate uveitis and posterior uveitis); said method comprising administering to a subject in need thereof a therapeutic effective amount of a compound or a composition as defined herein.
In another preferred embodiment, the invention provides a method for the prevention and/or treatment of airway diseases including but not limited to pulmonary fibrosis, emphysema, chronic bronchitis, asthma, fibrosis, pneumonia, cystic fibrosis, chronic obstructive pulmonary disease (COPD) bronchitis, rhinitis, and respiratory distress syndrome; said method comprising administering to a subject in need thereof a therapeutic effective amount of a compound or a composition as defined herein.
In another embodiment, the invention provides a method for the prevention and/or treatment of cardiovascular and vascular diseases: including but not limited to pulmonary hypertension and pulmonary vasoconstriction; said method comprising administering to a subject in need thereof a therapeutic effective amount of a compound or a composition as defined herein.
In another embodiment, the invention provides a method for the prevention and/or treatment of inflammatory diseases: including but not limited to contact dermatitis, atopic dermatitis, psoriasis, rheumatoid arthritis, juvenile rheumatoid arthritis, ankylosing spondylitis, psoriatic arthritis, inflammatory bowel disease, Crohn's disease and ulcerative colitis; said method comprising administering to a subject in need thereof a therapeutic effective amount of a compound or a composition as defined herein.
In another embodiment, the invention provides a method for the prevention and/or treatment of neurological and CNS disorders: including but not limited to neuropathic pain. The present compounds are therefore suitable for preventing neurodegeneration and stimulating neurogeneration in various neurological disorders; said method comprising administering to a subject in need thereof a therapeutic effective amount of a compound or a composition as defined herein.
In another embodiment, the invention provides a method for the prevention and/or treatment of proliferative diseases: such as but not limited to cancer of breast, colon, intestine, skin, head and neck, nerve, uterus, kidney, lung, liver, ovary, pancreas, prostate, or thyroid gland; Castleman disease; leukemia; sarcoma; lymphoma; malignoma; and melanoma; said method comprising administering to a subject in need thereof a therapeutic effective amount of a compound or a composition as defined herein.
In another embodiment, the invention provides a method for the prevention and/or treatment of kidney diseases: including but not limited to renal fibrosis or renal dysfunction; said method comprising administering to a subject in need thereof a therapeutic effective amount of a compound or a composition as defined herein.
In another embodiment, the invention provides a method for the prevention and/or treatment of sexual dysfunction: including but not limited to hypogonadism, bladder disease, hypertension, diabetes, or pelvic surgery; and/or to treat sexual dysfunction associated with treatment using certain drugs, such as drugs used to treat hypertension, depression or anxiety; said method comprising administering to a subject in need thereof a therapeutic effective amount of a compound or a composition as defined herein.
In another embodiment, the invention provides a method for the prevention and/or treatment of bone diseases: including but not limited to osteoporosis and osteoarthritis; said method comprising administering to a subject in need thereof a therapeutic effective amount of a compound or a composition as defined herein.
In another embodiment, the invention provides a method for the prevention and/or treatment of diseases and disorders such as benign prostatic hyperplasia, transplant rejection, spasm, chronic obstructive bladder disease, and allergy; said method comprising administering to a subject in need thereof a therapeutic effective amount of a compound or a composition as defined herein.
In a preferred embodiment, the invention provides a method for the prevention and/or treatment of glaucoma, asthma, sexual dysfunction or COPD; said method comprising administering to a subject in need thereof a therapeutic effective amount of a compound or a composition as defined herein.
[0141] In the invention, particular preference is given to compounds of Formula I or any subgroup thereof that in the inhibition assay for ROCK described below inhibit ROCK with an IC 50 value of less than 10 μM, preferably less than 1 μM, even more preferably less than 0.1 NM.
[0142] Said inhibition may be effected in vitro and/or in vivo, and when effected in vivo, is preferably effected in a selective manner, as defined above.
[0143] The term “ROCK-mediated condition” or “disease”, as used herein, means any disease or other deleterious condition in which is known to play a role. The term “ROCK-mediated condition” or “disease” also means those diseases or conditions that are alleviated by treatment with a ROCK inhibitor. Accordingly, another embodiment of the present invention relates to treating or lessening the seventy of one or more diseases in which ROCK is known to play a role.
[0144] For pharmaceutical use, the compounds of the invention may be used as a free acid or base, and/or in the form of a pharmaceutically acceptable acid-addition and/or base-addition salt (e.g. obtained with non-toxic organic or inorganic acid or base), in the form of a hydrate, solvate and/or complex, and/or in the form or a pro-drug or pre-drug, such as an ester. As used herein and unless otherwise stated, the term “solvate” includes any combination which may be formed by a compound of this invention with a suitable inorganic solvent (e.g. hydrates) or organic solvent, such as but not limited to alcohols, ketones, esters and the like. Such salts, hydrates, solvates, etc. and the preparation thereof will be clear to the skilled person; reference is for instance made to the salts, hydrates, solvates, etc. described in U.S. Pat. No. 6,372,778, U.S. Pat. No. 6,369,086, U.S. Pat. No. 6,369,087 and U.S. Pat. No. 6,372,733.
[0145] The pharmaceutically acceptable salts of the compounds according to the invention, i.e. in the form of water-, oil-soluble, or dispersible products, include the conventional non-toxic salts or the quaternary ammonium salts which are formed, e.g., from inorganic or organic acids or bases. Examples of such acid addition salts include acetate, adipate, alginate, aspartate, benzoate, benzenesulfonate, bisulfate, butyrate, citrate, camphorate, camphorsulfonate, cyclopentanepropionate, digluconate, dodecylsulfate, ethanesulfonate, fumarate, glucoheptanoate, glycerophosphate, hemisulfate, heptanoate, hexanoate, hydrochloride, hydrobromide, hydroiodide, 2-hydroxyethanesulfonate, lactate, maleate, methanesulfonate, 2-naphthalene-sulfonate, nicotinate, oxalate, palmoate, pectinate, persulfate, 3-phenylpropionate, picrate, pivalate, propionate, succinate, tartrate, thiocyanate, tosylate, and undecanoate. Base salts include ammonium salts, alkali metal salts such as sodium and potassium salts, alkaline earth metal salts such as calcium and magnesium salts, salts with organic bases such as dicyclohexylamine salts, N-methyl-D-glucamine, and salts with amino acids such as arginine, lysine, and so forth. In addition, the basic nitrogen-containing groups may be quaternized with such agents as lower alkyl halides, such as methyl, ethyl, propyl, and butyl chloride, bromides and iodides; dialkyl sulfates like dimethyl, diethyl, dibutyl; and diamyl sulfates, long chain halides such as decyl, lauryl, myristyl and stearyl chlorides, bromides and iodides, aralkyl halides like benzyl and phenethyl-bromides and others. Other pharmaceutically acceptable salts include the sulfate salt ethanolate and sulfate salts.
[0146] Generally, for pharmaceutical use, the compounds of the inventions may be formulated as a pharmaceutical preparation or pharmaceutical composition comprising at least one compound of the invention and at least one pharmaceutically acceptable carrier, diluent or excipient and/or adjuvant, and optionally one or more further pharmaceutically active compounds.
[0147] By means of non-limiting examples, such a formulation may be in a form suitable for oral administration, for parenteral administration (such as by intravenous, intramuscular or subcutaneous injection or intravenous infusion), for topical administration (including ocular), for administration by inhalation, by a skin patch, by an implant, by a suppository, etc. Such suitable administration forms—which may be solid, semi-solid or liquid, depending on the manner of administration—as well as methods and carriers, diluents and excipients for use in the preparation thereof, will be clear to the skilled person; reference is again made to for instance U.S. Pat. No. 6,372,778, U.S. Pat. No. 6,369,086, U.S. Pat. No. 6,369,087 and U.S. Pat. No. 6,372,733, as well as to the standard handbooks, such as the latest edition of Remington's Pharmaceutical Sciences.
[0148] Some preferred, but non-limiting examples of such preparations include tablets, pills, powders, lozenges, sachets, cachets, elixirs, suspensions, emulsions, solutions, syrups, aerosols, ointments, creams, lotions, soft and hard gelatin capsules, suppositories, eye drops, sterile injectable solutions and sterile packaged powders (which are usually reconstituted prior to use) for administration as a bolus and/or for continuous administration, which may be formulated with carriers, excipients, and diluents that are suitable per se for such formulations, such as lactose, dextrose, sucrose, sorbitol, mannitol, starches, gum acacia, calcium phosphate, alginates, tragacanth, gelatin, calcium silicate, microcrystalline cellulose, polyvinylpyrrolidone, polyethylene glycol, cellulose, (sterile) water, methylcellulose, methyl- and propylhydroxybenzoates, talc, magnesium stearate, edible oils, vegetable oils and mineral oils or suitable mixtures thereof. The formulations can optionally contain other pharmaceutically active substances (which may or may not lead to a synergistic effect with the compounds of the invention) and other substances that are commonly used in pharmaceutical formulations, such as lubricating agents, wetting agents, emulsifying and suspending agents, dispersing agents, desintegrants, bulking agents, fillers, preserving agents, sweetening agents, flavoring agents, flow regulators, release agents, etc. The compositions may also be formulated so as to provide rapid, sustained or delayed release of the active compound(s) contained therein, for example using liposomes or hydrophilic polymeric matrices based on natural gels or synthetic polymers. In order to enhance the solubility and/or the stability of the compounds of a pharmaceutical composition according to the invention, it can be advantageous to employ α-, β- or γ-cyclodextrins or their derivatives. An interesting way of formulating the compounds in combination with a cyclodextrin or a derivative thereof has been described in EP-A-721,331. In particular, the present invention encompasses a pharmaceutical composition comprising an effective amount of a compound according to the invention with a pharmaceutically acceptable cyclodextrin.
[0149] In addition, co-solvents such as alcohols may improve the solubility and/or the stability of the compounds. In the preparation of aqueous compositions, addition of salts of the compounds of the invention can be more suitable due to their increased water solubility.
[0150] For the treatment of pain, the compounds of the invention may be used locally. For local administration, the compounds may advantageously be used in the form of a spray, ointment or transdermal patch or another suitable form for topical, transdermal and/or intradermal administration.
[0151] For ophthalmic application, solutions, gels, tablets and the like are often prepared using a physiological saline solution, gel or excipient as a major vehicle. Ophthalmic formulations should preferably be prepared at a comfortable pH with an appropriate buffer system.
[0152] More in particular, the compositions may be formulated in a pharmaceutical formulation comprising a therapeutically effective amount of particles consisting of a solid dispersion of the compounds of the invention and one or more pharmaceutically acceptable water-soluble polymers.
[0153] The term “a solid dispersion” defines a system in a solid state (as opposed to a liquid or gaseous state) comprising at least two components, wherein one component is dispersed more or less evenly throughout the other component or components. When said dispersion of the components is such that the system is chemically and physically uniform or homogenous throughout or consists of one phase as defined in thermodynamics, such a solid dispersion is referred to as “a solid solution”. Solid solutions are preferred physical systems because the components therein are usually readily bioavailable to the organisms to which they are administered.
[0154] It may further be convenient to formulate the compounds in the form of nanoparticles which have a surface modifier adsorbed on the surface thereof in an amount sufficient to maintain an effective average particle size of less than 1000 nm. Suitable surface modifiers can preferably be selected from known organic and inorganic pharmaceutical excipients. Such excipients include various polymers, low molecular weight oligomers, natural products and surfactants. Preferred surface modifiers include nonionic and anionic surfactants.
[0155] Yet another interesting way of formulating the compounds according to the invention involves a pharmaceutical composition whereby the compounds are incorporated in hydrophilic polymers and applying this mixture as a coat film over many small beads, thus yielding a composition with good bio-availability which can conveniently be manufactured and which is suitable for preparing pharmaceutical dosage forms for oral administration. Materials suitable for use as cores in the beads are manifold, provided that said materials are pharmaceutically acceptable and have appropriate dimensions and firmness. Examples of such materials are polymers, inorganic substances, organic substances, and saccharides and derivatives thereof.
[0156] The preparations may be prepared in a manner known per se, which usually involves mixing at least one compound according to the invention with the one or more pharmaceutically acceptable carriers, and, if desired, in combination with other pharmaceutical active compounds, when necessary under aseptic conditions. Reference is again made to U.S. Pat. No. 6,372,778, U.S. Pat. No. 6,369,086, U.S. Pat. No. 6,369,087 and U.S. Pat. No. 6,372,733 and the further prior art mentioned above, as well as to the standard handbooks, such as the latest edition of Remington's Pharmaceutical Sciences.
[0157] The pharmaceutical preparations of the invention are preferably in a unit dosage form, and may be suitably packaged, for example in a box, blister, vial, bottle, sachet, ampoule or in any other suitable single-dose or multi-dose holder or container (which may be properly labeled); optionally with one or more leaflets containing product information and/or instructions for use. Generally, such unit dosages will contain between 1 and 1000 mg, and usually between 5 and 500 mg, of the at least one compound of the invention, e.g. about 10, 25, 50, 100, 200, 300 or 400 mg per unit dosage.
[0158] The compounds can be administered by a variety of routes including the oral, rectal, ocular, transdermal, subcutaneous, intramuscular or intranasal routes, depending mainly on the specific preparation used and the condition to be treated or prevented, and with oral and intravenous administration usually being preferred. The at least one compound of the invention will generally be administered in an “effective amount”, by which is meant any amount of a compound of the Formula I or any subgroup thereof that, upon suitable administration, is sufficient to achieve the desired therapeutic or prophylactic effect in the individual to which it is administered. Usually, depending on the condition to be prevented or treated and the route of administration, such an effective amount will usually be between 0.001 to 1000 mg per kilogram body weight of the patient per day, more often between 0.1 and 500 mg, such as between 1 and 250 mg, for example about 5, 10, 20, 50, 100, 150, 200 or 250 mg, per kilogram body weight of the patient per day, which may be administered as a single daily dose, divided over one or more daily doses, or essentially continuously. The amount(s) to be administered, the route of administration and the further treatment regimen may be determined by the treating clinician, depending on factors such as the age, gender and general condition of the patient and the nature and severity of the disease/symptoms to be treated. Reference is again made to U.S. Pat. No. 6,372,778,U.S. Pat. No. 6,369,086, U.S. Pat. No. 6,369,087 and U.S. Pat. No. 6,372,733 and the further prior art mentioned above, as well as to the standard handbooks, such as the latest edition of Remington's Pharmaceutical Sciences.
[0159] In accordance with the method of the present invention, said pharmaceutical composition can be administered separately at different times during the course of therapy or concurrently in divided or single combination forms. The present invention is therefore to be understood as embracing all such regimes of simultaneous or alternating treatment and the term “administering” is to be interpreted accordingly.
[0160] For an oral administration form, the compositions of the present invention can be mixed with suitable additives, such as excipients, stabilizers, or inert diluents, and brought by means of the customary methods into the suitable administration forms, such as tablets, coated tablets, hard capsules, aqueous, alcoholic, or oily solutions. Examples of suitable inert carriers are gum arabic, magnesia, magnesium carbonate, potassium phosphate, lactose, glucose, or starch, in particular, corn starch. In this case, the preparation can be carried out both as dry and as moist granules. Suitable oily excipients or solvents are vegetable or animal oils, such as sunflower oil or cod liver oil. Suitable solvents for aqueous or alcoholic solutions are water, ethanol, sugar solutions, or mixtures thereof. Polyethylene glycols and polypropylene glycols are also useful as further auxiliaries for other administration forms. As immediate release tablets, these compositions may contain microcrystalline cellulose, dicalcium phosphate, starch, magnesium stearate and lactose and/or other excipients, binders, extenders, disintegrants, diluents and lubricants known in the art.
[0161] When administered by nasal aerosol or inhalation, these compositions may be prepared according to techniques well-known in the art of pharmaceutical formulation and may be prepared as solutions in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other solubilizing or dispersing agents known in the art. Suitable pharmaceutical formulations for administration in the form of aerosols or sprays are, for example, solutions, suspensions or emulsions of the compounds of the invention or their physiologically tolerable salts in a pharmaceutically acceptable solvent, such as ethanol or water, or a mixture of such solvents. If required, the formulation can also additionally contain other pharmaceutical auxiliaries such as surfactants, emulsifiers and stabilizers as well as a propellant.
[0162] For subcutaneous administration, the compound according to the invention, if desired with the substances customary therefore such as solubilizers, emulsifiers or further auxiliaries are brought into solution, suspension, or emulsion. The compounds of the invention can also be lyophilized and the lyophilizates obtained used, for example, for the production of injection or infusion preparations. Suitable solvents are, for example, water, physiological saline solution or alcohols, e.g. ethanol, propanol, glycerol, in addition also sugar solutions such as glucose or mannitol solutions, or alternatively mixtures of the various solvents mentioned. The injectable solutions or suspensions may be formulated according to known art, using, suitable non-toxic, parenterally-acceptable diluents or solvents, such as mannitol, 1,3-butanediol, water, Ringer's solution or isotonic sodium chloride solution, or suitable dispersing or wetting and suspending agents, such as sterile, bland, fixed oils, including synthetic mono- or diglycerides, and fatty acids, including oleic acid.
[0163] When rectally administered in the form of suppositories, these formulations may be prepared by mixing the compounds according to the invention with a suitable non-irritating excipient, such as cocoa butter, synthetic glyceride esters or polyethylene glycols, which are solid at ordinary temperatures, but liquefy and/or dissolve in the rectal cavity to release the drug.
[0164] In preferred embodiments, the compounds and compositions of the invention are used locally, for instance topical or in both absorbed and non-adsorbed applications.
[0165] The compositions are of value in the veterinary field, which for the purposes herein not only includes the prevention and/or treatment of diseases in animals, but also—for economically important animals such as cattle, pigs, sheep, chicken, fish, etc.—enhancing the growth and/or weight of the animal and/or the amount and/or the quality of the meat or other products obtained from the animal. Thus, in a further aspect, the invention relates to a composition for veterinary use that contains at least one compound of the invention and at least one suitable carrier (i.e. a carrier suitable for veterinary use). The invention also relates to the use of a compound of the invention in the preparation of such a composition.
[0166] The invention will now be illustrated by means of the following synthetic and biological examples, which do not limit the scope of the invention in any way.
Examples
A. Physicochemical Properties of the Compounds
A.1. Compound Purity
[0167] Unless indicated otherwise, the purity of the compounds was confirmed by liquid chromatography/mass spectrometry (LC/MS).
A.2. Attribution of the Configuration:
[0168] The Cahn-Ingold-Prelog system was used to attribute the absolute configuration of chiral center, in which the four groups on an asymmetric carbon are ranked to a set of sequences rules. Reference is made to Cahn; Ingold; Prelog Angew. Chem. Int. Ed. Engl. 1966, 5, 385-415.
A.3. Stereochemistry:
[0169] It is known by those skilled in the art that specific enantiomers (or diastereoisomers) can be obtained by different methods such as, but not limited to chiral resolution (for example, salts formed with optically active acids or bases may be used to form diastereoisomeric salts that can facilitate the separation of optically active isomers of the compounds of Formula I or any subgroup thereof), assymetric synthesis or preparative chiral chromatography (using different column such as Chiralcel OD-H (tris-3,5-dimethylphenylcarbamate, 46×250 or 100×250 mm, 5 μm), Chiralcel OJ (tris-methylbenzoate, 46×250 or 100×250 mm, 5 μm), Chiralpak AD (tris-3,5-dimethylphenylcarbamate, 46×250 mm, 10 μm) and Chiralpak AS (tris-(S)-1-phenylethylcarbamate, 46×250 mm, 10 μm) from Chiral Technologies Europe (Illkirch, France)). Whenever it is convenient, stereoisomers can be obtained starting from commercial materials with known configuration (such compounds include aminoacid for instance).
A.4. Name of the Molecules
[0170] The software MDL ISIS™/Draw 2.3 was used to assign the name of the molecules.
B. Compound Synthesis
B.1. Compounds of the Invention
[0171] The compounds of the invention can be made according to the following general procedures:
[0000]
[0172] Reaction a: To a solution of carboxylic acid (1 eq) in DMF at room temperature was added TBTU (1.5 eq), HOBt (0.3 eq) and DIEA (7 eq). After 5 min the HCl salt of the aniline (1.5 eq) was added and the mixture stirred at room temperature until completion of the reaction. Then the DMF was removed under vacuum and the residue diluted in EtOAc. The organic phase was washed with saturated NaHCO 3 , brine, dried over Na 2 SO 4 and filtered. After evaporation of the solvent, the residue was purified by flash chromatography, eluted with DCM/EtOAc (100/0 to 50/50) to give the expected product as a white powder.
[0173] Reaction b: To a suspension of methyl ester in acetonitrile/water 2/1 was added dropwise a solution 1.6M of LiOH in water (3 eq). The mixture was stirred at room temperature until completion of the reaction. Then a solution 0.5M of HCl in water was added until pH=4 and the mixture extracted with EtOAc (×3). The combined organic phases were washed with brine, dried over Na 2 SO 4 and filtered. The solvent was removed under vacuum to give the expected compound as a white powder. The compound was directly used in the next step without further purification.
[0174] Reaction c: Through a solution or suspension of Boc-amine in DCM, HCl (gas) was bubbled at room temperature for 5 min. The mixture was stirred at room temperature until completion of the reaction. The resulting precipitate was filtered, washed with Ether (×3) and dried under vacuum to give the HCl salt of the expected compound as a white powder.
[0175] Reaction d: To a solution of carboxylic acid (1 eq) in DMF at room temperature was added TBTU (1.5 eq), HOBt (0.3 eq) and DIEA (3 eq). After 5 min the alcohol (6 eq) was added and the mixture stirred at room temperature until completion of the reaction. Then the DMF was removed under vacuum and the residue diluted in EtOAc. The organic phase was washed with saturated NaHCO 3 , brine, dried over Na 2 SO 4 and filtered. After evaporation of the solvent, the residue was purified by flash chromatography, eluted with DCM/EtOAc (100/0 to 50/50) to give the expected product as a white powder.
[0176] For the preparation of the required intermediate(s), reference is made to the PCT application PCT/EP2011/053343.
[0177] In the tables that are set forth below, exemplary compounds of the invention are set out in tabulated form. In this table, an arbitrarily assigned compound number and structural information are set out.
[0000]
TABLE 1
#
Structure
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
[0000]
TABLE 2
#
R
29
Ethyl-
30
n-butyl-
31
32
Isobutyl-
33
Sec-butyl-
34
35
Benzyl-
36
37
38
Isopropyl-
39
Cyclohexyl-
40
41
42
43
44
45
Propargyl-
46
47
48
Phenyl-
49
50
Cyclopropylmethyl-
51
Cyclobutylmethyl-
[0000]
TABLE 3
#
R
52
Methyl-
53
Propyl-
C. In Vitro and In Vivo Assays
C.1. ROCK Inhibitory Activity Screening
[0178] C.1.1. Kinase inhibition (ROCKI or ROCKII)
Reagent:
[0179] Base Reaction buffer; 20 mM Hepes (pH 7.5), 10 mM MgCl2, 1 mM EGTA, 0.02% Brij35, 0.02 mg/ml BSA, 0.1 mM Na3VO4, 2 mM DTT, 1% DMSO—Required cofactors are added individually to each kinase reaction
Reaction Procedure:
[0180] 1. Prepare indicated substrate in freshly prepared Base Reaction Buffer
2. Deliver any required cofactors to the substrate solution above
3. Deliver indicated kinase into the substrate solution and gently mix
4. Deliver compounds in DMSO into the kinase reaction mixture
5. Deliver 33 P-ATP (specific activity 0.01 μCi/μl final) into the reaction mixture to initiate the reaction.
6. Incubate kinase reaction for 120 min. at room temperature
7. Reactions are spotted onto P81 ion exchange paper (Whatman #3698-915)
8. Wash filters extensively in 0.1% Phosphoric acid.
[0181] The IC 50 (ROCK II) values obtained (in accordance with the protocols set forth above) are represented as follows: “++++” means IC 50 below 0.01 μM “+++” means IC 50 below 0.1 μM, “++” means IC 50 between 0.1 μM and 1 μM; “+” means IC 50 between 1 and 10 μM and “ ” means “not determined yet”.
[0000] # Cpds IC 50 1 ++++ 2 ++++ 3 ++++ 4 ++++ 5 ++++ 6 ++++ 7 ++++ 8 ++++ 9 ++++ 10 +++ 11 ++++ 12 ++++ 13 ++++ 14 ++++ 15 ++++ 16 ++++ 17 ++++ 18 ++++ 19 ++++ 20 ++++ 21 ++++ 22 ++++
C.1.4. Myosin Light Chain Phosphorylation assay
[0182] Rat smooth muscle cell line A7r5 is used. The endogenous expression of ROCK results in a constitutive phosphorylation of the regulatory myosin light chain at T18/S19. A7r5 cells were plated in DMEM supplemented with 10% FCS in multiwall cell culture plates. After serum starvation overnight, cells were incubated with compounds in serum-free medium.
[0183] Quantification of MLC-T18/S19 phosphorylation is assessed in 96 well-plates via ELISA using a phspho-MLC-T18/S19 specific antibody and a secondary detection antibody. Raw data were converted into percent substrate phosphorylation relative to high controls, which were set to 100%. IC50 values were determined using GraphPad Prism 5.01 software using a nonlinear regression curve fit with variable hill slope.
[0000]
IC 50
(MLC,
# Cpds
nM)
1
<200
2
<200
3
<200
4
<200
6
<200
8
<200
10
<200
12
<200
17
<200
C.2. Pharmacological Characterization
[0184] C.2.1. Stability Assay in Human and/or Rat Plasma
[0185] Compounds are incubated at a concentration of 1 μM in rat (mice, dog, monkey, minipig or rabbit) or human plasma. Samples are taken at fixed time points and the remnant of compound is determined by LC-MS/MS after protein precipitation. Half life is expressed in minutes.
[0000]
t½
human
# Cpd
plasma
1
<5
5
<60
6
<60
8
<5
C.2.2. Stability Towards Drug Metabolizing Enzymes in Lung S9
[0186] A 1 μM solution of the ROCK inhibitors is incubated with a reaction mixture containing lung S9 (from smokers) as well as the cofactors NADPH, UDPGA, PAPS and GSH. Samples are collected at 0, 15, 30 and 60 minutes post incubation. Negative control samples incubated with ROCK inhibitors and S9 fraction in the absence of cofactors are run in parallel. By using LC-MS/MS analysis, the percent of ROCK compounds remaining at each time point, the metabolic half-life of the ROCK compounds (expressed in minutes) and the metabolic half-life of the control compounds are determined.
[0000]
t½ human lung
# Cpd
S9 (min)
1
>30
C.2.3. Stability Assay in Rabbit Aqueous Humor
[0187] Compounds are incubated at a concentration of 1 μM in rabbit aqueous humor (AH). Samples are taken at fixed time points and the remnant of compound is determined by LC-MS/MS after protein precipitation.
[0000]
t½ Rabbit AH
# Cpd
(min)
1
>60
8
>>60 | The present invention relates to new kinase inhibitors, more specifically ROCK inhibitors, compositions, in particular pharmaceuticals, comprising such inhibitors, and to uses of such inhibitors in the treatment and prophylaxis of disease. In particular, the present invention relates to new ROCK inhibitors, compositions, in particular pharmaceuticals, comprising such inhibitors, and to uses of such inhibitors in the treatment and prophylaxis of disease.
In addition, the invention relates to methods of treatment and use of said compounds in the manufacture of a medicament for the application to a number of therapeutic indications including sexual dysfunction, inflammatory diseases, ophthalmic diseases and Respiratory diseases. | 0 |
CLAIM OF PRIORITY
[0001] The present Application for Patent is a continuation of U.S. patent application Ser. No. 13/529,900, entitled “Methods and Systems for PDCCH Blind Decoding in Mobile Communications” filed Jun. 21, 2012, now allowed, which is a continuation of U.S. patent application Ser. No. 12/259,798, entitled “Methods and Systems for PDCCH Blind Decoding in Mobile Communications” filed Oct. 28, 2008, now granted, U.S. Pat. No. 8,238,475, issued on Aug. 7, 2012, which claims priority to Provisional Patent Application No. 60/983,907, entitled “BDCCH Blind Decoding Methods and Systems,” filed Oct. 30, 2007, both assigned to the assignee hereof and both hereby expressly incorporated by reference herein.
FIELD
[0002] This disclosure relates generally to wireless communications, and more particularly to blind decoding of the Physical Downlink Control Channel (PDCCH) for user equipment.
BACKGROUND
[0003] For the purposes of the present document, the following abbreviations apply:
[0004] AM Acknowledged Mode
[0005] AMD Acknowledged Mode Data
[0006] ARQ Automatic Repeat Request
[0007] BCCH Broadcast Control CHannel
[0008] BCH Broadcast CHannel
[0009] C- Control-
[0010] CCCH Common Control CHannel
[0011] CCH Control CHannel
[0012] CCTrCH Coded Composite Transport Channel
[0013] CP Cyclic Prefix
[0014] CRC Cyclic Redundancy Check
[0015] CTCH Common Traffic Channel
[0016] D-BCH Dynamic Broadcast CHannel
[0017] DCCH Dedicated Control CHannel
[0018] DCH Dedicated CHannel
[0019] DL DownLink
[0020] DSCH Downlink Shared CHannel
[0021] DTCH Dedicated Traffic CHannel
[0022] FACH Forward link Access CHannel
[0023] FDD Frequency Division Duplex
[0024] L 1 Layer 1 (physical layer)
[0025] L 2 Layer 2 (data link layer)
[0026] L 3 Layer 3 (network layer)
[0027] LI Length Indicator
[0028] LSB Least Significant Bit
[0029] MAC Medium Access Control
[0030] MBMS Multmedia Broadcast Multicast Service
[0031] MCCH MBMS point-to-multipoint Control CHannel
[0032] MRW Move Receiving Window
[0033] MSB Most Significant Bit
[0034] MSCH MBMS point-to-multipoint Scheduling CHannel
[0035] MTCH MBMS point-to-multipoint Traffic Channel
[0036] P-BCH Primary Broadcast CHannel
[0037] PCCH Paging Control Channel
[0038] PCFICH Physical Control Format Indicator CHannel
[0039] PCH Paging Channel
[0040] PDCCH Physical Downlink Control CHannel
[0041] PDU Protocol Data Unit
[0042] PHY PHYsical layer
[0043] PHICH Physical Hybrid-ARQ Indicator CHannel
[0044] PhyCH Physical CHannels
[0045] RACH Random Access Channel
[0046] RE Resource Element
[0047] RS Reference Signal
[0048] RLC Radio Link Control
[0049] RoHC Robust Header Compression
[0050] RRC Radio Resource Control
[0051] SAP Service Access Point
[0052] SDU Service Data Unit
[0053] SHCCH SHared channel Control CHannel
[0054] SN Sequence Number
[0055] SUFI SUper FIeld
[0056] TCH Traffic CHannel
[0057] TDD Time Division Duplex
[0058] TFI Transport Format Indicator
[0059] TM Transparent Mode
[0060] TMD Transparent Mode Data
[0061] TTI Transmission Time Interval
[0062] U- User-
[0063] UE User Equipment
[0064] UL UpLink
[0065] UM Unacknowledged Mode
[0066] UMD Unacknowledged Mode Data
[0067] UMTS Universal Mobile Telecommunications System
[0068] UTRA UMTS Terrestrial Radio Access
[0069] UTRAN UMTS Terrestrial Radio Access Network
[0070] Universal Mobile Telecommunications System (UMTS) is one of the third-generation (3G) wireless phone technologies. Currently, the most common form of UMTS uses W-CDMA as the underlying air interface. UMTS is standardized by the 3rd Generation Partnership Project (3GPP), and is sometimes marketed as 3GSM as a way of emphasizing the combination of the 3G nature of the technology and the GSM standard which it was designed to succeed.
[0071] UTRAN (UMTS Terrestrial Radio Access Network) is a collective term for the Node-B's and Radio Network Controllers which make up the UMTS radio access network. The UTRAN allows connectivity between the UE and a core network, and can include UEs, Node Bs, and Radio Network Controllers (RNCs)—noting that an RNC and Node B can be the same device, although typical implementations have a separate RNC located in a central office serving multiple Node B's.
[0072] For UMTS, a Broadcast Channel (BCH) may have a fixed pre-defined transport format and may be broadcasted over the entire coverage area of a cell. In Long Term Evolutino (LTE) which improves upon the UMTS standard, the broadcast channel may be used to transmit a “System Information field” necessary for system access. However, due to the large size of a System Information field, the BCH may be divided into two portions including a Primary Broadcast CHannel (P-BCH) and Dynamic Broadcast CHannel (D-BCH). The P-BCH may contain basic Layer 1 (physical layer)/Layer 2 (data link layer) (or “L 1 /L 2 ”) system parameters useful to demodulate the D-BCH, which in turn may contain the remaining System Information field.
[0073] It may occur that a UE may need to blindly decode a Physical Downlink Control Channel (PDCCH) from from several possible formats and associated Control Channel Elements (CCEs). Unfortunately, this may impose a substantial burden on the UE that may exceed practical hardware limitations and thus lead to increased costs and/or reduced performance of the UE.
[0074] Therefore, there is a need for addressing this issue. Accordingly, methods and systems for addressing this and other issues are disclosed herein.
SUMMARY
[0075] The foregoing needs are met, to a great extent, by the present disclosure.
[0076] In one of various aspects of the disclosure, a method to reduce the processing overhead for blind decoding a PDCCH signal is provided, comprising: estimating a suitable sized CCE segment in a PDCCH signal; generating a tree structure containing contiguous CCE aggregation levels of the estimated CCE segment, wherein the CCE aggregations are multiples of the estimated CCE segment; arranging the aggregation levels in a hierarchal order, wherein each level's initial position is coincident with all other levels' initial positions; and decoding the PDCCH signal by using boundaries defined by the tree structure, wherein the boundaries form a search path, enabling a reduced search for a blind decode.
[0077] In one of various other aspects of the disclosure, a computer-readable product is provided, containing code for: estimating a suitable sized CCE segment in a PDCCH signal; generating a tree structure containing contiguous CCE aggregation levels of the estimated CCE segment, wherein the CCE aggregations are multiples of the estimated CCE segment; arranging the aggregation levels in a hierarchal order, wherein each level's initial position is coincident with all other levels' initial positions; and decoding the PDCCH signal by using boundaries defined by the tree structure, wherein the boundaries form a search path, enabling a reduced search for a blind decode.
[0078] In one of various aspects of the disclosure, an apparatus configured to reduce the processing overhead for PDCCH blind decoding is provided, comprising: circuitry configured to blind decode a PDCCH signal, the circuitry capable of estimating a suitable sized CCE segment in a PDCCH signal; capable of generating a tree structure containing contiguous CCE aggregation levels of the estimated CCE segment, wherein the CCE aggregations are multiples of the estimated CCE segment; capable of arranging the aggregation levels in a hierarchal order, wherein each level's initial position is coincident with all other levels' initial positions; and capable of decoding the PDCCH signal by using boundaries defined by the tree structure, wherein the boundaries form a search path, enabling a reduced search for a blind decode.
[0079] In one of various aspects of the disclosure, an apparatus to reduce processing overhead for PDCCH blind decoding is provided, comprising: means for estimating a suitable sized CCE segment in a PDCCH signal; means for generating a structure containing contiguous CCE aggregation levels of the estimated CCE segment, wherein the CCE aggregations are multiples of the estimated CCE segment; means for arranging the aggregation levels in a hierarchal order, wherein each level's initial position is coincident with all other levels' initial positions; and means for decoding the PDCCH signal by using boundaries defined by the structure, wherein the boundaries form a search path, enabling a reduced search for a blind decode.
[0080] In one of various aspects of the disclosure, a method to reduce the processing overhead for PDCCH blind decoding using an initial estimate of largest-to-smallest CCEs is provided comprising: estimating a suitable largest sized CCE segment in the PDCCH signal; sorting all combinations of CCEs possible in the PDCCH into sets having a largest CCE in the beginning of its set, and smaller CCEs in the set are ordered in a largest-to-smallest order; ordering all the sorted sets into at a greatest number of elements to smallest number of elements order, or vice versus; and performing a reduced search space blind search using elements from the ordered sets, starting with the set having the smallest number of elements.
[0081] In one of various aspects of the disclosure, a computer-readable product is provided, containing instructions to reduce the processing overhead for PDCCH blind decoding using an initial estimate of largest-to-smallest CCEs, the instructions comprising: sorting all combinations of CCEs possible in the PDCCH into sets having a largest CCE in the beginning of its set, and smaller CCEs in the set are ordered in a largest-to-smallest order; ordering all the sorted sets into at a greatest number of elements to smallest number of elements order, or vice versus; and performing a reduced search space blind search using elements from the ordered sets, starting with the set having the smallest number of elements.
[0082] In one of various aspects of the disclosure, an apparatus configured to reduce the processing overhead for PDCCH blind decoding using an initial estimate of largest-to-smallest CCEs is provided, comprising: circuitry configured to blind decode a PDCCH signal, wherein an initial estimate of the number of information bits of the PDCCH signal is based on sorting all combinations of CCEs possible in the PDCCH into sets having a largest CCE in the beginning of its set, and smaller CCEs in the set are ordered in a largest-to-smallest order, the circuitry capable of ordering all the sorted sets into at least one of a greatest number of elements to smallest number of elements order, or vice versus, and the circuitry capable of performing a reduced search space blind search using elements from the ordered sets, starting with the set having the smallest number of elements.
[0083] In one of various aspects of the disclosure, an apparatus configured to reduce the processing overhead for PDCCH blind decoding using an initial estimate of largest-to-smallest CCEs, comprising: means for sorting all combinations of CCEs possible in the PDCCH into sets having a largest CCE in the beginning of its set, and smaller CCEs in the set are ordered in a largest-to-smallest order; means for ordering all the sorted sets into at a greatest number of elements to smallest number of elements order, or vice versus; and means for performing a reduced search space blind search using elements from the ordered sets, starting with the set having the smallest number of elements.
[0084] In one of various aspects of the disclosure, a method to reduce the processing overhead for PDCCH blind decoding is provided, comprising: receiving a PDCCH signal; estimating a maximum number of information bits used in the PDCCH signal; restraining a candidate number of information bits to a first set of information bits; mapping a first subset of the first set to a second set that is not in the first set; mapping a second subset of the first set to a third set that is not in the first set; restraining concatenation of elements of the sets to form largest to smallest order; and performing a blind decoding initially based on elements in the first set, and proceeding to elements of the second set and third set.
[0085] In one of various aspects of the disclosure, a computer-readable product is provided containing code for: receiving a PDCCH signal; estimating a maximum number of information bits used in the PDCCH signal; restraining a candidate number of information bits to a first set of information bits; mapping a first subset of the first set to a second set that is not in the first set; applying a second subset of the first set to a third set that is not in the first set; restraining concatenation of elements of the sets to form largest to smallest order; and performing a blind decoding initially based on elements in the first set, and proceeding to elements of the second set and third set.
[0086] In one of various aspects of the disclosure, an apparatus configured to reduce the processing overhead for PDCCH blind decoding is provided, comprising: means for receiving a PDCCH signal; means for estimating a maximum number of information bits used in the PDCCH signal; means for restraining a candidate number of information bits to a first set of information bits; means for mapping a first subset of the first set to a second set that is not in the first set; means for mapping a second subset of the first set to a third set that is not in the first set; means for restraining concatenation of elements of the sets to form largest to smallest order; and means for performing a blind decoding initially based on elements in the first set, and proceeding to elements of the second set and third set.
BRIEF DESCRIPTION OF THE DRAWINGS
[0087] FIG. 1 is an illustration of a multiple access wireless communication system.
[0088] FIG. 2 is a block diagram of an embodiment of a transmitter system and receiver system in a MIMO configuration.
[0089] FIG. 3 is an illustration of a multiple access wireless communication system.
[0090] FIG. 4A-B are diagrams illustrating a PDCCH in a 1 ms subframe and CCE hierarchy, respectively.
[0091] FIGS. 5-8 depict graphical representations of the number of PDCCHs as a function of different bandwidths, the span of the PDCCH, and a short CP.
[0092] FIG. 9 provides a graphical illustration of a contiguous and tree-based concatenation.
[0093] FIG. 10 contains a flowchart illustrating an exemplary process.
DETAILED DESCRIPTION
[0094] Various embodiments are now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of one or more embodiments. It may be evident, however, that such embodiment(s) may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing one or more embodiments.
[0095] As used in this application, the terms “component,” “module,” “system,” and the like are intended to refer to a computer-related entity, either hardware, firmware, a combination of hardware and software, software, or software in execution. For example, a component can be, but is not limited to being, a process running on a processor, a processor, an object, an executable, a thread of execution, a program, and/or a computer. By way of illustration, both an application running on a computing device and the computing device can be a component. One or more components can reside within a process and/or thread of execution and a component can be localized on one computer and/or distributed between two or more computers. In addition, these components can execute from various computer readable media having various data structures stored thereon. The components can communicate by way of local and/or remote processes such as in accordance with a signal having one or more data packets (e.g., data from one component interacting with another component in a local system, distributed system, and/or across a network such as the Internet with other systems by way of the signal).
[0096] Furthermore, various embodiments are described herein in connection with an access terminal. An access terminal can also be called a system, subscriber unit, subscriber station, mobile station, mobile, remote station, remote terminal, mobile device, user terminal, terminal, wireless communication device, user agent, user device, or user equipment (UE). An access terminal can be a cellular telephone, a cordless telephone, a Session Initiation Protocol (SIP) phone, a wireless local loop (WLL) station, a personal digital assistant (PDA), a handheld device having wireless connection capability, computing device, or other processing device connected to or utilizing a wireless modem. Moreover, various embodiments are described herein in connection with a base station. A base station can be utilized for communicating with access terminal(s) and can also be referred to as an access point, Node B, eNode B (eNB), or some other terminology. Depending on the context of the descriptions provided below, the term Node B may be replaced with eNB and/or vice versus as according to the relevant communcation system being employed.
[0097] An orthogonal frequency division multiplex (OFDM) communication system effectively partitions the overall system bandwidth into multiple (N F ) subcarriers, which may also be referred to as frequency subchannels, tones, or frequency bins. For an OFDM system, the data to be transmitted (i.e., the information bits) is first encoded with a particular coding scheme to generate coded bits, and the coded bits are further grouped into multi-bit symbols that are then mapped to modulation symbols. Each modulation symbol corresponds to a point in a signal constellation defined by a particular modulation scheme (e.g., M-PSK or M-QAM) used for data transmission. At each time interval that may be dependent on the bandwidth of each frequency subcarrier, a modulation symbol may be transmitted on each of the N F frequency subcarrier. OFDM may be used to combat inter-symbol interference (ISI) caused by frequency selective fading, which is characterized by different amounts of attenuation across the system bandwidth.
[0098] A multiple-input multiple-output (MIMO) communication system employs multiple (N T ) transmit antennas and multiple (N R ) receive antennas for data transmission. A MIMO channel formed by the N T transmit and N R receive antennas may be decomposed into N S independent channels, with N S ≦min {N T ,N R }. Each of the N S independent channels may also be referred to as a spatial subcarrier of the MIMO channel and corresponds to a dimension. The MIMO system can provide improved performance (e.g., increased transmission capacity) if the additional dimensionalities created by the multiple transmit and receive antennas are utilized.
[0099] For a MIMO system that employs OFDM (i.e., a MIMO-OFDM system), N F frequency subcarriers are available on each of the N S spatial subchannels for data transmission. Each frequency subcarrier of each spatial subchannel may be referred to as a transmission channel. There are N F ·N S transmission channels thus available for data transmission between the N T transmit antennas and N R receive antennas.
[0100] For a MIMO-OFDM system, the N F frequency subchannels of each spatial subchannel may experience different channel conditions (e.g., different fading and multipath effects) and may achieve different signal-to-noise-and-interference ratios (SNRs). Each transmitted modulation symbol is affected by the response of the transmission channel via which the symbol was transmitted. Depending on the multipath profile of the communication channel between the transmitter and receiver, the frequency response may vary widely throughout the system bandwidth for each spatial subchannel, and may further vary widely among the spatial subchannels.
[0101] Referring to FIG. 1 , a multiple access wireless communication system according to one embodiment is illustrated. An access point 100 (AP) includes multiple antenna groups, one including 104 and 106 , another including 108 and 110 , and an additional including 112 and 114 . In FIG. 1 , only two antennas are shown for each antenna group, however, more or fewer antennas may be utilized for each antenna group. Access terminal 116 (AT) is in communication with antennas 112 and 114 , where antennas 112 and 114 transmit information to access terminal 116 over forward link 120 and receive information from access terminal 116 over reverse link 118 . Access terminal 122 is in communication with antennas 106 and 108 , where antennas 106 and 108 transmit information to access terminal 122 over forward link 126 and receive information from access terminal 122 over reverse link 124 . In a FDD system, communication links 118 , 120 , 124 and 126 may use different frequency for communication. For example, forward link 120 may use a different frequency then that used by reverse link 118 .
[0102] Each group of antennas and/or the area in which they are designed to communicate is often referred to as a sector of the access point. In the embodiment, antenna groups each are designed to communicate to access terminals in a sector, of the areas covered by access point 100 .
[0103] In communication over forward links 120 and 126 , the transmitting antennas of access point 100 utilize beamforming in order to improve the signal-to-noise ratio of forward links for the different access terminals 116 and 124 . Also, an access point using beamforming to transmit to access terminals scattered randomly through its coverage causes less interference to access terminals in neighboring cells than an access point transmitting through a single antenna to all its access terminals.
[0104] An access point may be a fixed station used for communicating with the terminals and may also be referred to as an access point, a Node B, or some other terminology. An access terminal may also be called an access terminal, user equipment (UE), a wireless communication device, terminal, access terminal or some other terminology.
[0105] FIG. 2 is a block diagram of an embodiment of a transmitter system 210 (also known as the access point) and a receiver system 250 (also known as access terminal) in a MIMO system 200 . At the transmitter system 210 , traffic data for a number of data streams is provided from a data source 212 to ransmit (TX) data processor 214 .
[0106] In an embodiment, each data stream is transmitted over a respective transmit antenna. TX data processor 214 formats, codes, and interleaves the traffic data for each data stream based on a particular coding scheme selected for that data stream to provide coded data.
[0107] The coded data for each data stream may be multiplexed with pilot data using OFDM techniques. The pilot data is typically a known data pattern that is processed in a known manner and may be used at the receiver system to estimate the channel response. The multiplexed pilot and coded data for each data stream is then modulated (i.e., symbol mapped) based on a particular modulation scheme (e.g., BPSK, QSPK, M-PSK, or M-QAM) selected for that data stream to provide modulation symbols. The data rate, coding, and modulation for each data stream may be determined by instructions performed by processor 230 . Memory 232 may provide supporting memory services to processor 230 .
[0108] The modulation symbols for all data streams are then provided to a TX MIMO processor 220 , which may further process the modulation symbols (e.g., for OFDM). TX MIMO processor 220 then provides N T modulation symbol streams to N T transmitters (TMTR) 222 a through 222 t. In certain embodiments, TX MIMO processor 220 applies beamforming weights to the symbols of the data streams and to the antenna from which the symbol is being transmitted.
[0109] Each transmitter 222 receives and processes a respective symbol stream to provide one or more analog signals, and further conditions (e.g., amplifies, filters, and upconverts) the analog signals to provide a modulated signal suitable for transmission over the MIMO channel. N T modulated signals from transmitters 222 a through 222 t are then transmitted from N T antennas 224 a through 224 t, respectively.
[0110] At receiver system 250 , the transmitted modulated signals are received by N R antennas 252 a through 252 r and the received signal from each antenna 252 is provided to a respective receiver (RCVR) 254 a through 254 r. Each receiver 254 conditions (e.g., filters, amplifies, and downconverts) a respective received signal, digitizes the conditioned signal to provide samples, and further processes the samples to provide a corresponding “received” symbol stream.
[0111] An RX data processor 260 then receives and processes the N R received symbol streams from N R receivers 254 based on a particular receiver processing technique to provide N T “detected” symbol streams. The RX data processor 260 then demodulates, deinterleaves, and decodes each detected symbol stream to recover the traffic data for the data stream. The processing by RX data processor 260 is complementary to that performed by TX MIMO processor 220 and TX data processor 214 at transmitter system 210 .
[0112] A processor 270 periodically determines which pre-coding matrix to use (discussed below). Processor 270 formulates a reverse link message comprising a matrix index portion and a rank value portion. Memory 262 may provide supporting memory services to processor 270 .
[0113] The reverse link message may comprise various types of information regarding the communication link and/or the received data stream. The reverse link message is then processed by a TX data processor 238 , which also receives traffic data for a number of data streams from a data source 236 , modulated by a modulator 280 , conditioned by transmitters 254 a through 254 r, and transmitted back to transmitter system 210 .
[0114] At transmitter system 210 , the modulated signals from receiver system 250 are received by antennas 224 , conditioned by receivers 222 , demodulated by a demodulator 240 , and processed by a RX data processor 242 to extract the reserve link message transmitted by the receiver system 250 . Processor 230 then determines which pre-coding matrix to use for determining the beamforming weights and then processes the extracted message.
[0115] Referring to FIG. 3 , a multiple access wireless communication system 300 according to one aspect is illustrated. The multiple access wireless communication system 300 includes multiple regions, including cells 302 , 304 , and 306 . In the aspect of FIG. 3 , each cell 302 , 304 , and 306 may include a Node B that includes multiple sectors. The multiple sectors can be formed by groups of antennas with each antenna responsible for communication with UEs in a portion of the cell. For example, in cell 302 , antenna groups 312 , 314 , and 316 may each correspond to a different sector. In cell 304 , antenna groups 318 , 320 , and 322 each correspond to a different sector. In cell 306 , antenna groups 324 , 326 , and 328 each correspond to a different sector.
[0116] Each cell 302 , 304 and 306 can include several wireless communication devices, e.g., User Equipment or UEs, which can be in communication with one or more sectors of each cell 302 , 304 or 306 . For example, UEs 330 and 332 can be in communication with Node B 342 , UEs 334 and 336 can be in communication with Node B 344 , and UEs 338 and 340 can be in communication with Node B 346 .
[0117] Information and/or data is conveyed via channels. These channels may be represented by physical hardware, frequencies, time bands, logical connections or abstract representations, and so forth, depending on the context and use thereof. In the UMTS framework, logical channels are classified into Control Channels and Traffic Channels. Logical Control Channels comprises Broadcast Control Channel (BCCH), which is DL channel for broadcasting system control information. Paging Control Channel (PCCH), which is DL channel that transfers paging information. Multicast Control Channel (MCCH), which is Point-to-multipoint DL channel used for transmitting Multimedia Broadcast and Multicast Service (MBMS) scheduling and control information for one or several MTCHs. Generally, after establishing RRC connection this channel is only used by UEs that receive MBMS (Note: old MCCH+MSCH). Dedicated Control Channel (DCCH) is Point-to-point bi-directional channel that transmits dedicated control information and used by UEs having an RRC connection. In one aspect, Logical Traffic Channels can comprise a Dedicated Traffic Channel (DTCH), which is a point-to-point bi-directional channel, dedicated to one UE, for the transfer of user information. Also, a Multicast Traffic Channel (MTCH) for Point-to-multipoint DL channel for transmitting traffic data.
[0118] In an aspect, Transport Channels are classified into DL and UL. DL Transport Channels comprises a Broadcast Channel (BCH), Downlink Shared Data Channel (DL-SDCH) and a Paging Channel (PCH), the PCH for support of UE power saving (DRX cycle is indicated by the network to the UE), broadcasted over entire cell and mapped to PHY resources which can be used for other control/traffic channels. The UL Transport Channels comprises a Random Access Channel (RACH), a Request Channel (REQCH), a Uplink Shared Data Channel (UL-SDCH) and plurality of PHY channels. The PHY channels comprise a set of DL channels and UL channels.
[0119] The DL PHY channels comprises:
Common Pilot Channel (CPICH) Synchronization Channel (SCH) Common Control Channel (CCCH) Shared DL Control Channel (SDCCH) Multicast Control Channel (MCCH) Shared UL Assignment Channel (SUACH) Acknowledgement Channel (ACKCH) DL Physical Shared Data Channel (DL-PSDCH) UL Power Control Channel (UPCCH) Paging Indicator Channel (PICH) Load Indicator Channel (LICH)
[0131] The UL PHY Channels comprises:
Physical Random Access Channel (PRACH) Channel Quality Indicator Channel (CQICH) Acknowledgement Channel (ACKCH) Antenna Subset Indicator Channel (ASICH) Shared Request Channel (SREQCH) UL Physical Shared Data Channel (UL-PSDCH) Broadband Pilot Channel (BPICH)
[0139] In an aspect, a channel structure is provided that preserves low PAR (at any given time, the channel is contiguous or uniformly spaced in frequency) properties of a single carrier waveform.
[0140] For UMTS, a Broadcast Channel (BCH) may have a fixed pre-defined transport format and may be broadcasted over the entire coverage area of a cell. In LTE, the broadcast channel may be used to transmit a “System Information field” necessary for system access. However, due to the large size of the System Information field, the BCH may be divided into multiple portions including a Primary Broadcast CHannel (P-BCH) and Dynamic Broadcast CHannel (D-BCH). The P-BCH may contain basic Layer 1 (physical layer)/Layer 2 (data link layer) (or “L 1 /L 2 ”) system parameters useful to demodulate the D-BCH, which in turn may contain the remaining System Information field.
[0141] An example of the multiple portioning of the BCH for a downlink paging scenario is provided in FIG. 4A , where a PDCCH and PDSCH is shown in a 1 ms subframe. FIG. 4A is instructive in illustrating that the fore of the subframe contains resource elements (REs) 410 arranged in the time strips 420 . It is understood in the OFDM environment that the PDCCH structure is based on CCEs which are built from REs 410 . Depending on the system, there are 36 REs per CCE with each RE 410 based on a tone or modulation symbol. And each tone or modulation symbol corresponding to a pair of bits. That is, each CCE consists of 36 REs which in turn consist of 2 bits or 2 coded values. Therefore, for each individual CCE there is an equivalent of 72 coded bits/values. The PDCCH may accommodate multiple CCEs at different times, when the channel characteristics become degraded in order to provide better information integrity.
[0142] FIG. 4B is a diagram illustrating CCEs and their bit relationship. As apparent in FIG. 4B , the CCE combinations are in ascending pairs, i.e., 1, 2, 4, and 8. Thus, CCEs can be represented as the set of elements {1, 2, 4, 8}, with the lowest element having 72 coded bits and the highest element having 576 coded bits. As mentioned above, the PDCCH structure is formed by combinations of the CCEs. Thus, the PDCCH train may contain various combinations of the set elements defined above. For example, a PDCCH train may contain the following CCE elements—1, 8, 8, 2, 4, 1, 8, etc. Combinatorially speaking, for a given size of CCEs (X), in an unrestricted or non-constrained arrangement there are (X 1 )+(X 2 )+(X 4 )+(X 8 ) total possible bit combinations. If the size of the CCE is 32, there will be 10,554,788 possible combination of bits in the PDDCH. It should be noted that though FIG. 4B illustrates a maximum CCE size of 8, in some embodiments, there may be more or even less CCEs, according to design implementation.
[0143] It may occur that a UE may need to blindly decode a Physical Downlink Control Channel (PDCCH) from from several possible formats and associated Control Channel Elements (CCEs). Unfortunately, this may impose a substantial burden on the UE that may exceed practical hardware limitations and thus lead to increased costs and/or reduced performance of the UE. In view of this, the following exemplary approaches are presented to reducing the number of possible combinations by exploiting at least the limited pairing nature of the CCEs.
[0144] Studies are provided with a mind to understanding how the CCEs are concatenated and how a “blind” search can be performed to reduce the effort required to perform the blind decode.
[0145] One exemplary design solution may include limiting the number of information bits per PDCCH to sets of different possible numbers. Five sets being a suitable number of the possible numbers for the examples provided herein. Of course, more or less sets may be utilized according to design preference. Using five sets, as an example, the problem can be broken down into two parts, including: (1) identifying those CCEs associated with a PDCCH (decoupling the CCE associated with PHICH and PDCCH), and (2) blind decoding of the PDCCH within its associated CCE.
[0146] For the disclosed approach to PDCCH blind decoding, a number of assumptions may be made, including: (1) a UE has decoded a particular P-BCH correctly, and (2) the decoded P-BCH contains information relevant for CCE identification.
[0147] In the absence of PDCCH-less operation of a D-BCH, the relevant PDCCH CCE identification may be needed even for UEs acquiring a cell. Therefore one cannot assume any signaling on D-BCH. However, if PDCCH-less operation of D-BCH is allowed, then relevant information can be signaled on the related D-BCH.
[0148] Generally, for E-UTRA there can be three types of CCEs to consider:
[0149] Mini-CCEs,
[0150] PHICH CCEs and
[0151] PDCCH CCEs.
[0152] Mini-CCE can consist of 4 Resource elements (REs) noting that the definition might be changed to 2 REs in view of the PHICH structure occurring in long Cyclic Prefix (CP) scenarios. Mini-CCEs may be used as “building blocks” for PCFICHs, PDCCHs and PHICHs.
[0153] PHICH CCEs can consist of 12 REs noting that a short CP may include three strips of 4 RE each and a long CP may include 6 strips of 2 REs each. Note that, among the various LTE downlink control channels, the PHICH can be used to transmit ACK/NACK for uplink transmission.
[0154] A PHICH has a hybrid CDM-FDM structure. Hybrid CDM/FDM signals allows for power control between acknowledgments for different users and provides good interference averaging. In addition, it can also provide frequency diversity for different users. Thus, the Bandwidth and power load for a PHICH doesn't have to be balanced, and to identify the CCE for a PDCCH, one may able to do so by considering only the bandwidth load.
[0155] PDCCH CCEs may have four types of REs. In this example, those four types may consist of {36, 72, 144, 288} REs, respectively.
[0156] Based on the above, let N denote the number of Physical uplink shared channels (PUSCHs) to be acknowledged in downlink. Since there may be 3-bits to signal a cyclic shift for Spatial Division Multiple Access (SDMA), the theoretical maximum value of N equals 8×number of physical resource block (PRB) pairs in uplink. (2 3 =8).
[0157] In an effort to count how many CCEs are available for PDCCH (assignments), various resources can be discounted which are used for other control information. The other control information can be the DL ACKs (PHICH) and the PCFICH (Physical Control Format Indicator Channel). The relevance of this is to see how many net CCEs are available in the PDCCH, and based on constraints provided in that information tailor the blind decode accordingly.
[0158] Beginning with the definitions Nmax_prb_bw=the number of resource blocks for PUSCH transmission; and f_PHICH=the fractional use of PHICH resources (Physical HARQ Indicator Channel), let Nmax_bw_rx indicate the maximum number of PUSCHs to be acknowledged for a given bandwidth and number of Rx antennas (Nrx), then
[0000] N max — bw — rx =min( Nrx, 8)* N max — prb — bw; and Eq (1)
[0000] N≦Nmax_bw_rx Eq (2)
[0159] Design Approach: First note that a PHICH bandwidth load can be indicated in the respective PBCH. There may be 2-bits to indicate the fractional load as a function of Nmax_bw_rx so that the fractional load f_phich={1, ½, ¼, ⅛}.
[0160] The Number of REs reserved for a PHICH (Nphich_re) is an important consideration to determine, and may be calculated, depending on CP, by:
[0000] Nphich — re (short CP )=12*ceil( f — phich*N max — bw — rx/ 4) Eq (3)
[0000] Nphich — re (long CP )=12*ceil( f — phich*N max — bw — rx/ 2) Eq (4)
[0161] Note that the number of REs reserved for a PHICH needs to be consistent with the value of n indicated in the respective PCFICH. In practice, an eNB may benefit by taking this into account.
[0162] For example, for frequency=5 MHz, Nrx=4, for short CP then Nmax_bw_rx=100, the resultant f_phich=1. Therefore, using the above equations, the resultant Nphich_re(short CP)=300. When the number of OFDM symbols (n) in the PDCCH=1 then Nphich_re (number of REs available in 1st symbol)=200 which is<Nphich_re(short CP). Consequently, a significant reduction in the search possibilities is obtained.
[0163] Note that n is the number of OFDM symbols in the PDCCH spans, and for the present embodiments may equal 1, 2 or 3. Accordingly, the number of REs reserved for a PHICH (Nphich)_re can change based on different factors.
[0164] Tables 1-5 below further outline the results for Nphich_re for a variety of conditions for different CPs and different loads.
[0000]
TABLE 1
Short CP - Load = 0.125
Number
Nphich_re (Number of
Bandwidth
of Rx
Nmax_bw_rx
Load
ACKs)
1.4
MHz
2
14
0.125
12
(4)
5
MHz
2
50
0.125
24
(8)
10
MHz
2
100
0.125
48
(16)
20
MHz
2
200
0.125
84
(28)
[0000]
TABLE 2
Short CP - Load = 0.25
Number
Nphich_re (Number of
Bandwidth
of Rx
Nmax_bw_rx
Load
ACKs)
1.4
MHz
2
14
0.25
12
(4)
5
MHz
2
50
0.25
48
(16)
10
MHz
2
100
0.25
84
(28)
20
MHz
2
200
0.25
156
(52)
[0000]
TABLE 3
Short CP - Load = 0.50
Number
Nphich_re (Number of
Bandwidth
of Rx
Nmax_bw_rx
Load
ACKs)
1.4
MHz
2
14
0.5
24
(8)
5
MHz
2
50
0.5
84
(28)
10
MHz
2
100
0.5
156
(52)
20
MHz
2
200
0.5
300
(100)
[0000]
TABLE 4
Long CP - Load = 0.125
Number
Nphich_re (Number of
Bandwidth
of Rx
Nmax_bw_rx
Load
ACKs)
1.4
MHz
2
14
0.125
12
(2)
5
MHz
2
50
0.125
48
(8)
10
MHz
2
100
0.125
84
(14)
20
MHz
2
200
0.125
156
(26)
[0000]
TABLE 5
Long CP - Load = 0.25
Number
Nphich_re (Number of
Bandwidth
of Rx
Nmax_bw_rx
Load
ACKs)
1.4
MHz
2
14
0.25
24
(4)
5
MHz
2
50
0.25
84
(14)
10
MHz
2
100
0.25
156
(26)
20
MHz
2
200
0.25
300
(50)
[0165] Next, consider PHICH CCE to RE mapping. Such can be mapped “around” an RE for a given RS even if there is only one Tx antenna. This substantially simplifies the mapping. Given the following definitions:
N_re=number of resource elements Nrs_re: number of resource elements for RS (reference signal) Npcfich_re: number of resource elements for PCFICH (Physical Control Format Indicator Channel)
[0169] Interleaver mapping can be fixed as a function of Nphich_re and the Number of Tx antennas. In the following example, the net number of resources available for PDCCH (assignments) transmission is calculated, while discounting the tones (REs) that are use for other tasks (within the control region). The remaining REs can then be made available for PDCCH, and for the purpose of this disclosure can be denoted as Npdcch_re, which may be calculated by:
[0000] Npdcch — re= 36*floor(( Navail — re−Npcfich — re−Nphich — re )/36) Eq (5)
[0000] and the number of available REs calculated by:
[0000] Navail — re=N — re−Nrs — re Eq (6)
[0170] Tables 6 and 7 below are provided to demonstrate the number of Npdcch_re for short CPs and a number of different PHISH loads.
[0000]
TABLE 6
Short CP - PHICH Load = 0.125
Number
Nphich_re
Npdcch_re
Bandwidth
of Tx
n
(Number of ACKs)
(Number of Grants)
1.4
MHz
{1, 2}
1
12
(4)
0
(0)
5
MHz
{1, 2}
1
24
(8)
144
(4)
10
MHz
{1, 2}
1
48
(16)
324
(9)
20
MHz
{1, 2}
1
84
(28)
684
(19)
[0000]
TABLE 7
Short CP - PHICH Load = 0.125
Number
Nphich_re
Npdcch_re
Bandwidth
of Tx
n
(Number of ACKs)
(Number of Grants)
1.4
MHz
{1, 2}
3
12
(4)
180
(5)
5
MHz
{1, 2}
3
24
(8)
756
(21)
10
MHz
{1, 2}
3
48
(16)
1512
(42)
20
MHz
{1, 2}
3
84
(28)
3096
(86)
[0171] Continuing, FIGS. 5-8 depict graphical representations of the number of PDCCHs as a function of acknowledgments for different bandwidths, the span of the PDCCH, and assuming a short CP. Here we can see that the PDCCH size (short/long) affects the choice of CCEs. For example, a given PDCCH size (1) can translate to a CCE set {1,2}, and a given PDCCH size (2) can translate to a CCE set {4,8}. Therefore, in one exemplary embodiment, the PDCCH size operates as a metric in determining the concatenation set. With this information, the number of combinations of CCE sizes that the UE must search to blind decode can be reduced by examining the type of PDCCH (size) being transmitted.
[0172] For PDCCH blind decoding, the number of PDCCH formats may depends on the final number of information bits. Assuming embodiments that have up to 5 formats, with number of information bits ranging from 30 to 60, the potential number of PDCCHs (based on 36 REs) may be calculated as:
[0000] Npdcch _max=floor( Npdcch — re/ 36) Eq (7)
[0173] In practice, it should be appreciated that the number of blind decodes can increase drastically with Npdcch_max. For example, for Npdcch_max=3, there may be {1,1,1}, {2,1}, {1,2} 25 blind decodes, while for Npdcch_max=4, there may be {1,1,1,1}, {2,1,1}, {1,2,1}, {1,1,2}, {2,2}, {4} 40 blind decodes, and for Npdcch_max=5 there may be {1,1,1,1,1}, {2,1,1,1}, {1,2,1,1}, {1,1,2,1}, {1,1,1,2}, {1,4}, {4,1} 55 blind decodes.
[0174] Given such, it may be unreasonable to expect a given UE to monitor all possible PDCCHs. However, several observations can be made to reduce the number of possibilities.
[0175] For a native code rate of Tailbiting Convolutional Code (TBCC)=⅓ and where the number of information bits=30-60 and where there is no coding gain beyond 144 RE for all formats, one may restrict the number of REs to {36, 72, 144}.
[0176] Where there is no coding gain beyond 72 RE for less than 48 information bits, one may restrict the number of information bits=30-60 and REs to {36, 72}.
[0177] Noting that the code rate may be too high if 36 REs are used for more than 48 information bits, may restrict the number of information bits=48-60 and REs to {72, 144}. Therefore, using the above constraints either individually or in combination, and where applicable, a significant reduction in the number of REs or combinations can be achieved.
[0178] A further reduction in number of combinations can be achieved using a number of approaches, e.g., by assuring that the concatenation of REs are always done in the beginning, rather than at any arbitrary location. For example, for an Npdcch_max=4 will provide {1,1,1,1}, {2,1,1}, {2,2}, {4}, and the Npdcch_max=5 will result in {1,1,1,1,1}, {2,1,1,1}, {2,2,1}, {4,1}.
[0179] The above sets illustrate an example where the first “pairs” of identical elements are collapsed. For example, for the Npdcch_max=4 case, the first two is of the set {1,1,1,1} are collapsed into the first 2 of the following set {2,1,1}; and the following two is of the set {2,1,1} is collapsed into the second 2 of the following set {2,2}; and the first two 2s of the set {2,2} is collapsed into the set {4}. This approach, of course, can be also applied to the Npdcch_max=5 case, as well as for other Npdcch_max values. This arrangement can be considered a tree-based approach where the boundaries of the CCEs are continuous and “stacked.”
[0180] FIG. 9 provides a graphical illustration 900 of a contiguous and tree-based concatenation as described above using 16 CCEs, as an example. In this example, the largest grouping is 8 CCEs 905 , arranged to form contiguous segments. The next grouping is formed of sets of 4 CCEs 915 arranged continuous to each other, and in a “tree” above the pair of 8 CCE 905 segments where boundaries 920 for the pair of 4 CCEs 915 alternately match up to the boundaries 910 of the 8 CCE 905 segments. Similarly, the 2 CCEs 925 segments are contiguous to each other and boundaries 930 alternately match up to the boundaries 920 for the 4 CCE 915 segments. The boundaries 940 for the 1 CCE 935 segments are similarly “tree'd” to the larger lower CCE segment.
[0181] By having the CCEs contiguous and tree'd, the search algorithm can be simplified. For example, if a maximum of 4 CCEs 915 are understood to be used in the PDCCH, then using the restriction that the concatenation is contiguous and tree-based, the search algorithm can be simplified to coincide with the boundaries 920 (and 910 —as it also falls on the same boundary) of the 4 CCEs 915 . If a maximum of 2 CCEs 925 are understood to be used in the PDCCH, then the search can be simplified to the boundaries 930 of the 2 CCEs 925 . Obviously, if the CCE size is known or estimated, it eliminates the need to search or decode on the non-CCE size boundaries.
[0182] Also, it should be noted that with the above arrangement, the boundary for a given CCE coincides with a boundary of all the smaller CCE segments. This provides a significant advantage. For example, boundary 910 for the 8 CCE 905 matches up with a boundary for each of the 4 CCE 915 , 2 CCE 925 , and 1 CCE 935 . Similarly, the same can be said for the 4 CCE 915 and all smaller CCEs above it. Therefore, each larger sized CCEs' boundary also forms at least one boundary with all the smaller sized CCE's. Thus, by starting on a gross, or large boundary, any smaller CCE sizes also on that boundary can also be captured in the search.
[0183] As is apparent with contiguous/tree-based grouping, various methods for searching or sorting may applied that are known in the art to accelerate or reduce the number of possible searches, including having the order in a root form, rather than a tree form.
[0184] In another embodiment of this disclosure, let the candidate number of information bits be {32, 40, 48, 56, 64} where {32, 40, 48} bits map to {36, 72} RE and {56, 64} bits map to {72, 144} RE.
[0185] Assuming an Npdcch_max=4 the ordering of the REs become {1,1,1,1}, {2,1,1}, {2,2}, {4}, and the number of blind decodes=(4×3)+(2×5)+(1×2)=24 blind decodes, which amounts to a 40% reduction in number of blind decodes.
[0186] Assuming an Npdcch_max=5 {1,1,1,1,1}, {2,1,1,1}, {2,2,1}, {4,1}, and the number of blind decodes=(5×3)+(2×5)+(1×2)=27 blind decodes, which amounts to a 51% reduction in number of blind decodes.
[0187] Assuming an Npdcch_max=6 {1,1,1,1,1,1}, {2,1,1,1,1}, {2,2,1,1}, {2,2,2}, {4,1,1}, {4,2}, then the number of blind decodes=(6×3)+(3×5)+(1×2)=27 blind decodes. Note that this amounts to no change from the case where Npdcch_max=5.
[0188] Continuing, assuming an Npdcch_max=8, the number of blind decodes=(8×3)+(4×5)+(2×2)=48 blind decodes.
[0189] A summary of one possible implementation is detailed below.
[0190] STEP 1: Restrain the candidate number of information bits to {32, 40, 48, 56, 64} where by {32, 40, 48} bits map to {36, 72} RE, and {56, 64} bits map to {72, 144} RE.
[0191] STEP 2: Restrain RE concatenation such that it is always done in the beginning, rather than at any arbitrary location, e.g, {a, b, c, . . . } such that a≧b≧c≧ . . .
[0192] STEP 3: Restrain the number of PDCCHs monitored by a given UE to 8 or less.
[0193] For further optimization, the usage of 36 REs may be restricted to the minimum payload only, i.e., {32} bits mapping to {36, 72} RE, {40, 48} bits mapping to {72} RE, and {56, 64} bits mapping to {72, 144} RE. For example, assuming that Npdcch_max=8, the resulting number of blind decodes=(8×1)+(4×5)+(2×2)=32 blind decodes.
[0194] FIG. 10 contains a flowchart 1000 illustrating an exemplary process based on the above descriptions. The exemplary process, after initialization 1010 , constrains the candidate numbers to a finite set as shown in step 1020 . The finite set, for explanatory purposes, may be comprised of {32, 40, 48, 56, 64}, for example. Of the finite set, in step 1020 , various combinations of the elements (i.e., subsets) will map to another set of numbers that may not be a member of the finite set. For example, the subset {32, 40, 48} may be mapped to the “outside” set {36, 72} and the remaining subset {56, 64} may be mapped to the “outside” set {72, 144}. After step 1020 , the exemplary process proceeds to step 1030 where it restrains RE concatenation to a preliminary/beginning process, rather than at an arbitrary location. By this method, an ordering can be imposed on the values.
[0195] Next, the exemplary process proceeds to step 1040 where the number of PDCCHs monitored by a given UE is restrained, for example, to 8 or less. The exemplary process then terminates 1050 .
[0196] The techniques described herein may be implemented by various means. For example, these techniques may be implemented in hardware, software, or a combination thereof. For a hardware implementation, the processing units used for channel estimation may be implemented within one or more application specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices (PLDs), field programmable gate arrays (FPGAs), processors, controllers, micro-controllers, microprocessors, other electronic units designed to perform the functions described herein, or a combination thereof. With software, implementation can be through modules (e.g., procedures, functions, and so on) that perform the functions described herein. The software codes may be stored in memory unit and executed by the processors.
[0197] Moreover, various aspects or features described herein can be implemented as a method, apparatus, or article of manufacture using standard programming and/or engineering techniques. The term “article of manufacture” as used herein is intended to encompass a computer program accessible from any computer-readable product, device, carrier, or media. For example, computer-readable product can include but are not limited to magnetic storage devices (e.g., hard disk, floppy disk, magnetic strips, etc.), optical disks (e.g., compact disk (CD), digital versatile disk (DVD), etc.), smart cards, and memory devices (e.g., EPROM, card, stick, key drive, etc.). Additionally, various storage media described herein can represent one or more devices and/or other machine-readable media for storing information. The term “machine-readable medium” can include, without being limited to, wireless channels and various other media capable of storing, containing, and/or carrying instruction(s) and/or data.
[0198] What has been described above includes examples of one or more embodiments. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the aforementioned embodiments, but one of ordinary skill in the art may recognize that many further combinations and permutations of various embodiments are possible. Accordingly, the described embodiments are intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim. | Various methods and systems for efficiently performing the blind decoding of downlink signals is described. Several forms of arranging possible CCE combinations are examined and investigated. Based on PDCCH size estimation/information, CCE concatenations that are most likely (of of limited sets) can be arrived at. Tree-based concatenations are also devised using largest CCE ordering to align smaller CCE sizes to similar boundaries. By such ordering, the search space for all possible CCE ordering and sizes can be reduced to an efficient tree. Set mapping between possible lnposelstartCCElnposelend/REs are also described using a first set to secondary and tertiary sets. Various other ordering and sorting schemes are also detailed that enable a blind decode of a PDCCH channel to be efficiently performed. | 7 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims benefit of the following patent application(s) which is/are hereby incorporated by reference: 62/389,351 filed Feb. 24, 2016.
FIELD OF THE INVENTION
[0002] The present invention relates generally to handrails to support the elderly, infirm and disabled. More particularly, this invention pertains to wall-mounted handrails with side to side bracing.
BACKGROUND OF THE INVENTION
[0003] Doorways in buildings can be used as access points between areas having different floor levels. Where the difference in height between floor levels is too large for people to conveniently move through the doorway between the different floor levels, buildings may often include stairs or escalators with banisters to assist and provide support to individuals. There are occasions, however, when the floor height difference is not great warranting only a few steps on one or both sides of the doorway. At times, these doorways are created as a modification to a building such as an older house, or else the flooring on and around the stairs are insufficiently strong, or because space constraints do not allow placement of a full floor-supported banister. At times, elderly, infirm or disabled individuals may find passage through such a doorway difficult or infeasible without some kind of support.
[0004] Mounting a cantilevered handrail on a vertical building structure such as a wall without secondary vertical support along the length of the railing through, for example, a baluster or other vertical member attached to the floor or stair may provide insufficient support to withstand the forces that a large individual might generate. These forces can include forces lateral to the cantilevered handrail's mounting surface—both vertical and horizontal (side-to-side), forces perpendicular (towards or away from) the mounting surface, or torsional forces that twist the railing in some direction. Excessive forces can generate stresses on the mounting surface that crush the material of the building surface or pull the handrail off the building surface. What is needed, then, is a handrail that be mounted at a location conveniently adjacent to the doorway and distribute these forces over the mounting surface of the wall so that the handrail remains resiliently fixed to the building to provide lasting support to users.
BRIEF SUMMARY OF THE INVENTION
[0005] According to one embodiment, the present invention provides a handrail includng a rail having a first distal portion proximate to a first end, a second distal portion proximate to a second end, and a middle portion between the first and second distal portions. The first and second ends are attached to a first surface of a faceplate and the first distal portion extends perpendicularly from the first surface. The handrail can also include a cross brace spaced apart from the faceplate that extends between the first and second distal portions. A first side brace can be attached to the cross brace and extends from the cross brace across a plane formed by the first surface to a first brace mounting end.
[0006] Optionally, the handrail of this embodiment can further include a second side brace attached to the cross brace that extends towards the plane formed by the first surface to a second side brace mounting end. The handrail can have a tubular cross section and can, as a further option, be formed from a metal, wood, or a polymer. Moreover, in some embodiments the faceplate can be rectangular.
[0007] In these embodiments, the second distal portion can extend from the first surface perpendicularly. According to yet another option, a top surface of the first distal portion and the bottom surface of the second distal portion can define a handrail height and an outer surface of the middle portion and the first surface can define a handrail length perpendicular to the handrail height, and the handrail height can be less than about 42 inches. Optionally, also, the handrail length can be less than about 42 inches
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a handrail according to one embodiment of the present invention.
[0009] FIG. 2A is a front view of the handrail of FIG. 1 .
[0010] FIG. 2B is a side view of the handrail of FIG. 2A .
[0011] FIG. 2C is a top view of the handrail of FIG. 2A .
[0012] FIG. 2D is a bottom view of the handrail of FIG. 2A
[0013] FIG. 3A is a front view of an alternative embodiment of a handrail according to the present invention.
[0014] FIG. 3B is a side view of the handrail of FIG. 3A .
[0015] FIG. 4A is a front view of an alternative embodiment of a handrail according to the present invention with a single side brace.
[0016] FIG. 4B is a side view of the handrail of FIG. 4A .
[0017] FIG. 5 is a top view of an embodiment of a handrail according to the present invention positioned on a wall with respect to an exemplary door frame and underlying wall studs.
[0018] FIG. 6 is a front view of an embodiment of a handrail according to the present invention positioned on a wall with respect to a door frame.
DETAILED DESCRIPTION OF THE INVENTION
[0019] FIG. 1 is a perspective view that depicts handrail 10 according to one embodiment of the invention. In FIG. 1 , handrail 10 is shown mounted to a building wall adjacent to a door frame and can advantageously be located to provide additional support to the elderly, infirm or disabled entering or leaving through the doorway. Handrail 10 can be particularly useful where the doorway is situated between floors at different levels warranting the placement of a short flight of stairs on at least one side of the doorway to facilitate access through the doorway. Handrail 10 can be further beneficial where there is no wall or other structure, such as a banister, that is within reach to provide support to a person entering or leaving through the doorway. For various reasons, such as space limitations, providing clearer unobstructed access to the doorway and stairs and unsound floor or stair structure, a floor-mounted conventional banister may be unsuitable. In such cases, handrail 10 , when properly mounted to a generally vertical building structure, such as a wall or column, at a convenient height immediately adjacent the doorframe, can provide sufficient support for even a large elderly, infirm, or disabled person without unduly obstructing access to the entryway. When so attached to a mounting surface of a building, handrail 10 can provide enhanced support and resist forces that may be applied by a user laterally to the mounting surface (i.e. horizontally or vertically), perpendicularly to the mounting surface (i.e. towards or away from the mounting surface) as well as torsionally (with a twisting force).
[0020] Handrail 10 includes rail 1 , which has a first end and a lower second end that are rigidly attached to faceplate or mounting plate 2 . Rail 1 has a first distal portion 1 a near to, and extending from, the first end. Rail 1 also includes a second distal portion 1 c near to, and extending from the second end. As shown in FIG. 1 , middle portion 1 b joins first and second distal portions 1 a, 1 c and can include curved or bent portions in any suitable or desirable design, such as a continuous arc or a series of linear sections angled to one another. While first distal portion 1 a preferably extends perpendicularly from faceplate 2 to provide a convenient support for a user wishing to hold onto handrail 10 for support, second distal portion 1 c may not be used for such purpose so frequently and accordingly may advantageously extend from faceplate 2 in a non-perpendicular, oblique direction. However, as will be understood, first distal portion 1 a may also extend obliquely as most suited for particular applications without deviating from the scope and intent of the present invention.
[0021] Faceplate 2 can be a generally rectangular plate that supports rail 1 and provides a structure to attach rail 1 conveniently and securely to a building. Accordingly, faceplate 2 can include mounting holes 6 through which fasteners, such as faceplate mounting screws, bolts, or anchors 31 affix mounting plate 2 to a building. Those skilled in the art will understand that faceplate 2 can be affixed to a building by alternative methods, such as by applying adhesives between the faceplate and the building structure, by welding, by soldering or partially embedding faceplate 2 into a building structure. Faceplate 2 should preferably be made of such material and of appropriate dimensions to offer sufficient structural rigidity to withstand the perpendicular, lateral and torsional loads that may be applied to handrail 10 . Faceplate 2 should also preferably distribute the concentrated loads applied by rail 1 to faceplate 2 over the contact area between the faceplate 2 and the mounted surface of the building to reduce the magnitude of pressure peaks and the likelihood of structural failure of the mounted surface.
[0022] In view of structural, dimensional and design requirements, faceplate 2 will have a thickness as shown, for example, in FIGS. 1 and 2A , and while main forward-facing (or first) surface of faceplate 2 to which rail 1 is attached and the rear-facing mounting (or second) surface are shown as rectangular, the present invention should not be understood to be limited to this shape. However, it will be understood that faceplate 2 can be made from a number of suitable materials, such as metal, wood, polymeric material and composite materials of varying strengths and flexural rigidity. Accordingly, the thickness of faceplate 2 may be different for different materials and depending on the expected loading expected on handrail 10 and manufacturing convenience. The number, position and size of mounting holes 6 , if used to attach faceplate 2 to a mounting surface, can also depend on the faceplate shape and material as well as the material of the building mounting surface and fasteners 31 used to mount handrail 10 .
[0023] Handrail 10 can also include cross brace 3 that extends between first distal portion 1 a and second distal portion 1 c, but at a perpendicular distance from the plane formed by the surface of faceplate 2 . In addition to strengthening handrail 10 , cross brace 3 can also provide an attachment point for first side brace 4 and second side brace 5 . In the embodiment of FIG. 1 , first side brace 4 and second side brace 5 are attached to cross brace 3 by fastener 32 . Fastener 32 can be a nut and bolt, a rivet or other appropriate fastener known in the art. Although first side brace 4 and second side brace 5 can be attached to cross brace 3 by fastener 32 , other methods of attachment may be other suitable methods, such as welding or brazing that can provide a sufficiently strong and rigid attachment of the side braces 4 , 5 to cross brace 3 . Fasteners can advantageously be used where the side braces 4 , 5 are delivered for mounting disassembled from the rest of the handrail 10 permitting adjustment of the precise placement and positioning of side braces at the time of mounting. However, it will also be understood that one or more of first side brace 4 and second side brace 5 can also be formed integrally with cross brace 3 at the time of manufacture so that no subsequent assembly is required and the quality and strength of the side brace and cross brace joint can be controlled in manufacture.
[0024] As shown in FIG. 1 , first side brace 4 extends from cross brace 3 across the plane formed by faceplate 2 to a point on the door frame that is also laterally spaced from the cross brace. First side brace 4 thus extends in an oblique direction from rail 1 and side brace 4 and provides both lateral and additional perpendicular support for rail 1 . The end of first side brace 4 furthest from cross brace 3 can be securely attached to the door frame by fastener 30 , which can be a screw, nail, nut, bolt and the like, secured through a mounting hold in first side brace 4 to the door frame. Second side brace 5 similarly extends laterally from cross brace 3 and towards the plane formed by faceplate 2 so that the distal end of second side brace is spaced apart from cross brace 3 and rail 1 . The end of second side brace 5 furthest from cross brace 3 includes a mounting hole through which another fastener 30 can secure the end of second side brace 5 to a portion of the building structure, such as a wall. The portion of the building structure on which side brace 5 is mounted can be an extension of the same mounting surface as faceplate 2 is mounted. However, it will be understood that the surface on which second side brace 5 is mounted can be raised or recessed compared to the mounting surface of the faceplate 2 . Accordingly, second side brace 5 also extends obliquely away from side brace 3 and provides both lateral and perpendicular support for rail 1 .
[0025] FIG. 2A is a front view of an embodiment of a handrail according to the present invention. Rail 1 is connected to faceplate 2 , with first and second distal portions 1 a, 1 c extending perpendicularly from the faceplate's main, front-facing surface. The handrail length—the distance from the first faceplate surface to the outermost surface of the middle portion 1 b of rail 1 —can be up to about 42 inches. Although the second distal portion 1 c is shown extending perpendicularly from the front-facing surface of faceplate 2 , it should be understood that second distal portion 1 c can extend from faceplate 2 at an angle or may even be curved. Cross brace 3 extends between first and second distal portions 1 a, 1 c, respectively, of rail 1 , which are spaced apart. The length of cross brace 3 will depend on the distance between first distal portion 1 a and second distal portion lc at the point of attachment to cross brace 3 governed by the specific design of rail 1 .
[0026] In some applications, due to space, aesthetic or structural constraints, for example, a rail 1 with an extended middle portion 1 b and large distance between first distal portion la and second distal portion 1 c may be undesirable or inappropriate. However, a short distance between the first and second ends of rail 1 that attach to faceplate 2 may place unduly large stress at the attachment points to the faceplate when a user applies a downward lateral force near the middle portion of rail 1 . Furthermore, in such situations, a short faceplate 2 may place unduly high stress on the mounting surface of the building structure and fasteners 31 leading to premature failure. To account for these competing constraints, faceplate 2 can be lengthened and second distal portion 1 c curved or angled so that the second end of rail 1 attaches to the face plate far apart from the first end while also permitting the distance between the first distal portion and the second distal portion to narrow as it approaches the middle portion. The broad spacing between the attachment points of the first and second ends, and the longer length of faceplate 2 , can help to reduce stress in the faceplate at the rail attachment points and also reduce stress in the mounting surface of the building structure.
[0027] In FIG. 2A , first side brace 4 is shown with mounting hole 9 at one end that also passes through cross brace 3 . Fastener 32 can be used to securely attach first side brace 4 to cross brace 3 . The opposite end of first side brace 4 includes mounting hole 8 through which fastener 30 can securely attach side brace 4 to a door frame. FIG. 2B is a side view of the handrail 10 of FIG. 2A . showing second side brace 5 and first side brace 4 extending obliquely from cross brace 3 (not shown). It will be understood that side brace 5 can similarly include a mounting hole and be fastened to cross brace 3 by fastener 32 . As shown, second cross brace 5 extends laterally away from rail 1 and towards the plane formed or defined by faceplate 2 . It will be understood that in some applications where the mounting surface for the second side brace 5 is an extension of the same surface on which faceplate 2 is mounted, second side brace 5 will extend to approach that plane. However, where the mounting surface for the second side brace 5 is recessed or raised compared to the mounting surface for faceplate 2 , second side brace 5 will extend to a point beyond or short of the faceplate mounting surface, respectively. First side brace 4 , on the other hand will in most circumstances extend to a point beyond the faceplate's mounting surface so that its distal end can attached to an interior point on a door frame. In any event, the oblique lateral extension of first and second side braces 4 , 5 permit them to provide lateral support to rail 1 in a generally horizontal direction when handrail 10 is mounted.
[0028] FIG. 2C is a top view of handrail 10 showing rail 1 on faceplate 2 . In this view, the front-facing main surface of faceplate 2 is partly visible, although its central portions are obscured by rail 1 . Faceplate 2 includes mounting holes 6 . First side brace 4 and second side brace 5 extend laterally from rail 1 and cross brace 3 (not shown). In this top view, mounting hole 7 of second side brace 5 is visible. FIG. 2D is a bottom view of handrail 10 . Rail 1 is obscured, but the rear-facing main surface of faceplate 2 is fully visible, as are mounting holes 6 . Similar to FIG. 2C , first and second side braces 4 , 5 are shown extending laterally from rail 1 and cross brace 3 which are hidden from view. The distal mounting end of second side brace 5 includes mounting hole 7 .
[0029] FIGS. 3A and 3B show an alternative embodiment of a handrail according to the present invention with a rail 11 having a greater distance between first and second distal portions 11 a , 11 c , respectively and having a long middle portion 11 b in comparison to the distal portions 11 a , 11 c . When mounted on a generally vertical building mounting surface the distance between the top surface of the first distal portion 11 a and the lowest surface of the second distal portion 11 c defines a handrail height which can be up to about 42 inches. Cross brace 13 can extend between first and second distal portion 11 a and 11 c . Rail 11 is attached to a first surface of faceplate 12 . First side brace 14 and second side brace 15 can be attached to cross brace 13 using a fastener passing through mounting hole 19 that extends through first side brace 14 , cross brace 13 and also second side brace 15 . First side brace 14 can extend obliquely and laterally from cross brace 13 to a mounting point on a door frame where it can be attached via a fastener passing through mounting hole 18 . Similarly, second side brace 15 can extend obliquely and laterally to a mounting point on a building mounting surface.
[0030] FIGS. 4A and 4B show an alternative embodiment of a handrail according to the present invention with a rail 21 having a greater distance between first and second distal portions 21 a , 21 c , respectively and having a long middle portion 21 b in comparison to the distal portions 21 a , 21 c. When mounted on a generally vertical building mounting surface the distance between the top surface of the first distal portion 21 a and the lowest surface of the second distal portion 21 c defines a handrail height which can be up to about 42 inches. Cross brace 23 can extend between first and second distal portion 21 a and 21 c . Rail 21 is attached to a first surface of faceplate 22 . Unlike the embodiment shown in FIG. 3B , this embodiment uses only a first side brace 24 . First side brace 24 can be attached to cross brace 23 using a fastener passing through mounting hole 29 that extends through first side brace 24 , cross brace 23 and also second side brace 25 . First side brace 24 can extend obliquely and laterally from cross brace 23 to a mounting point on a door frame where it can be attached via a fastener passing through mounting hole 28 .
[0031] In FIG. 5 , handrail 10 of FIG. 1 is shown positioned on a building wall adjacent a door frame 35 and showing the position of the handrail with respect to vertical timber members, or studs, commonly used in some building construction methods. Handrail is preferably located close by door opening 40 in a manner consistent with prevailing laws and regulations and building codes and in a position conveniently accessible to support users passing through the door opening. In commonly used building construction methods, door frame 35 is fastened to doorway stud 36 . Stud 36 is immediately adjacent to second doorway stud 41 . First wall stud 37 may be separated from the doorway studs by some distance. The studs are generally covered by wall paneling, such as plasterboard or drywall and the doorway may be ornamented with decorative molding around doorframe 35 . According to one method, handrail 10 can be mounted on a wall over second doorway stud 41 so that mounting hole 7 of second side brace 5 is over first wall stud 37 . Fasteners 30 and 31 can attach second side brace 5 and faceplate 2 by penetrating through holes 7 and 6 , through wall paneling and into studs 37 and 41 , respectively. FIG. 6 is a front view of handrail 10 shown positioned on a building vertical surface, similar to FIG. 5 , but shown from a viewpoint inside doorway 40 that separates one side of the building 42 at one level from a lower side where handrail 10 is mounted. Rail 1 is attached to faceplate 2 and cross brace 3 extends between first and second distal portions of rail 1 . Side brace 4 can be attached to cross brace 3 via mounting hole 9 that extends through one end of side brace 4 and cross brace 3 using a fastener. A fastener can attach the other end of first side brace 4 through mounting hole 8 into door frame 35 .
[0032] The components of the handrail according to the present invention can be formed from various suitable materials known in the art, such as various metals, polymers, wood, ceramic and composites of these materials. To reduce weight and expense components such as the rail can be tubular, hollowed or profiled in various cross sectional shapes to maintain rigidity.
[0033] Thus, although there have been described particular embodiments of the present invention of a new and useful it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims. | A handrail mountable on a generally vertical building mounting surface adjacent the frame of a building doorway to support elderly, infirm or disabled enter and exit the doorway. Side braces attachable to the door frame and, optionally, a vertical wall mounting surface provide additional lateral strength to the railing and reduce stress on mounting surfaces. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a method of removing unburned carbon from fly ash, and in particular to a method of more efficiently removing unburned carbon from the fly ash which is generated in a coal fired power plant.
DESCRIPTION OF THE RELATED ART
[0002] Fly ash (FA) generated in a coal fired power plant has been used as a raw material for cement and artificial lightweight aggregate or cement admixtures.
[0003] However, because the unburned carbon contained in fly ash absorbs AE agent or water reducing agents, etc., when fly ash is used as a cement admixture, it is necessary to supply an extra amount of the AE agent or the water reducing agent, etc. after taking into consideration the absorption amount, and this is uneconomical. Furthermore, because unburned carbon has the water, repellency, it has a negative effect in that the unburned carbon separates from the concrete and floats to the top, and darker areas due to the unburned carbon are generated in the concrete-jointed portions. Also, in the case where large amounts of unburned carbon included in the fly ash are present, there is the problem that the quality of the artificial lightweight aggregate decreases because the bonding strength between the fly ash particles has decreased.
[0004] For this reason, only good quality fly ash with relatively small amounts of unburned carbon is used as a cement admixture, etc. and fly ash with a large amount of unburned carbon is used as a raw material for cement or is reclaimed as industrial waste.
[0005] However, because of a shortage of reclaimed land every year, a method for removing the unburned carbon from fly ash used as a raw material has been proposed. For example, in the specification of Japanese Patent No. 3613347, a method for removing the unburned carbon from fly ash is proposed in which flotation is performed by making the fly ash into a slurry by adding water; adding a collector such as kerosene to this slurry-state fly ash; stirring the slurry in which the collector was added with a high speed shear mixer; lipophilizing the surface of the unburned carbon included in the fly ash, and at the same time, attaching the unburned carbon of which the surface was lipophilized to the collector; generating air bubbles by adding a flother; and attaching the unburned carbon to the surface of the air bubbles through the collector.
[0006] However, because the flotation is performed in the conventional method of first adding the oil that is the collector (for example, kerosene) to the fly ash made into a slurry; stirring the slurry in which the collector was added with a high speed shear mixer; activating and lipophilizing the surface of the unburned carbon included in the fly ash, and at the same time, attaching the unburned carbon of which the surface was activated and lipophilized to the collector; furthermore, generating air bubbles by adding a foaming agent; and attaching the activated unburned carbon to the surface of the air bubbles through the collector, not only the part of the oil which is the collector attaches to the surface of the unburned carbon included in the fly ash, but also a part of the oil attaches to the surface of the activated ash content when it is stirred with a high speed shear mixer. For this reason, there is a problem in that the necessary amount of the oil which is the collector, to be added increases
[0007] Furthermore, in the flotation step, because the ash content to which the oil content is attached also easily attaches to the air bubbles, a part of the ash content is also recovered as froth (unburned carbon) along with the unburned carbon. Therefore, the problem exists that the recovery rate of the ash content in the tail side decreases. Furthermore, because the oil of the collector does not attach selectively to the unburned carbon, the amount of collector becomes insufficient and there is a tendency for the amount of unburned carbon in the tail side to become high.
SUMMARY OF THE INVENTION
[0008] The present invention aims at solving such problems, and the objective is to provide a method for removing the unburned carbon in fly ash in which the recovery rate of the ash content is improved upon, the added amount of oil used as the collector is reduced, and the amount of unburned carbon in the tail side can be decreased when the unburned carbon in the fly ash is removed through using a flotation method which utilizes surface lipophilization (surface modification).
[0009] In order to solve the above-described problems, the present invention is constructed as follows.
[0010] The invention described in Claim 1 is a method of removing unburned carbon from fly ash of a raw material consisting of several steps: making the fly ash into a slurry by adding water; shearing the fly ash made into a slurry with a stirring blade rotating at high speed and adding lipophilicity by generating activation energy to the surface of the unburned carbon with the shearing force; and performing flotation by attaching the unburned carbon attached to the collector to the air bubbles together while attaching the collector to the lipophiliced unburned carbon by adding the collector and the flother to the slurry including the lipophiliced unburned carbon.
[0011] The invention described in Claim 2 is a method for removing unburned carbon in fly ash as in Claim 1 in which the concentration of the fly ash in the slurry is 5 to 40 wt % when the fly ash is made into slurry by adding water.
[0012] The invention described in Claim 3 is a method for removing unburned carbon in fly ash as in Claim 1 in which the stirring force is 10 to 100 kWh/m 3 per unit of slurry when the shear force is applied to the fly ash that is made into slurry.
[0013] The invention described in Claim 4 is a method for removing unburned carbon in fly ash as in Claim 1 in which the residence time of the slurry is 0.1 to 10 minutes when the shear force is added to the fly ash that is made into slurry.
[0014] The invention described in Claim 5 is a method for removing unburned carbon in fly ash as in Claim 1 in which the added amount of collector is 0 to 3.0 wt % to the fly ash when the collector is added to the slurry including the unburned carbon that has been lipophiliced by the activation energy.
[0015] The invention described in Claim 6 is a method for removing unburned carbon in fly ash as in Claim 1 in which the added amount of flother is 20 to 5,000 ppm when the flother is added to the slurry including the unburned carbon that has been lipophiliced by the activation energy.
[0016] According to the present invention, because the fly ash is made into a slurry by adding water and then applying a shearing force to it using a high speed shear mixer for example, excessive activation energy (surface energy) is generated on the surface of the unburned carbon included in the fly ash and the surface is lipophiliced (hydrophobiced) at a higher rate.
[0017] Because the fly ash generated in a coal burning thermal electric power plant is generally combustion ash generated by combusting pulverized coal at high temperature (for example, 1200to 1500° C.), the surface of the unburned carbon included in it is in an oxidized state and the original lipophilicity is lost. However, the lipophilicity (hydrophobicity) can be recovered by applying a high shearing force during the slurry stage.
[0018] After that, when the collector and the flother are added to the slurry including the unburned carbon that has been lipophiliced by the activation energy, the surface of the lipophiliced unburned carbon is brought into close contact with the surface of particles in the collector (oil), and the surface energy decreases. On the one hand, the surface energy decreases as the surface of the activated fly ash adapts to water and disperses in water, and the hydrophilicity increases even more. As a result, the fly ash disperses into water and separates from the unburned carbon in the latter part of the flotation step. On the other hand, because air bubbles are generated by the flother, the unburned carbon separated from the fly ash attaches to the surface of the air bubbles and floats.
[0019] Therefore, according to the present invention, the collector is attached to the unburned carbon of which the surface is lipophiliced by activation by the surface modification. However, because the collector does not attach to the hydrophiliced fly ash, the added amount (the used amount) of the collector (oil) can be reduced compared to the amount in the conventional method. Furthermore, because there is no attachment of the collector to the surface of the fly ash, the recovery rate of the fly ash becomes high and the amount of the unburned carbon in the recovered fly ash becomes small.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 shows a system block diagram to carry out the method for removing the unburned carbon in the fly ash in the present invention.
[0021] FIG. 2 shows a configuration diagram of an apparatus to carry out the method for removing the unburned carbon in the fly ash in the present invention.
[0022] FIG. 3 shows a side view including a part of the cross-section of a high speed shear mixer.
[0023] FIG. 4 shows a sectional view of one example of a flotation unit.
[0024] FIG. 5 shows a plan view of one example of a flotation unit.
[0025] FIG. 6 shows a sectional view of one example of a stirring machine.
[0026] FIG. 7 ( a ) is a state view showing when it is slurry, FIG. 7 ( b ) is a state-view showing when surface upgrading is performed, FIG. 7 ( c ) is a state view showing when the collector is added, and FIG. 7 ( d ) is a state view showing when flotation is performed.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The embodiments of the present invention are explained using figures below.
[0028] As shown in FIG. 1 , the system to carry out the method for removing the unburned carbon in fly ash in the present invention is mainly configured with a slurry adjusting tank 1 in which fly ash a of a raw material is made into a slurry by adding water b, a surface upgrading machine (for example, a high speed shear mixer 10 ) performing surface upgrading of the fly ash made into a slurry, an adjusting tank 30 in which a collector e and a flother f are added to the slurry after surface upgrading, a flotation unit 40 in which the slurry after the collector and the flother are added is stirred and the unburned carbon is floated together with air bubbles, etc.
[0029] As shown in FIG. 2 , the slurry adjusting tank 1 is provided to produce a slurry d with the fly ash a and the water b and is equipped with a stirring blade 2 to stir the slurry d inside. The front part of this slurry adjusting tank 1 is provided with a fly ash tank and a water supplying facility, and the back part has a pump 3 to supply the slurry d to a high speed shear mixer 10 which is a surface upgrading apparatus.
[0030] The high speed shear mixer 10 is provided to modify the surface of the unburned carbon by adding a shearing force (grazing force) to the fly ash that is made into slurry. This high speed shear mixer 10 is, as shown in FIG. 3 , equipped with a lateral type cylindrically-shaped main body 11 , a plurality of annular partitioning walls 13 partitioning the main body 11 into a plurality of rooms 12 in its axial direction, a rotary shaft 14 passing through the main body 11 , a disc 15 provided in the rotary shaft 14 , and a plurality of stirring blades 16 provided radially on both sides of the disc 15 , and the rotary shaft 14 and the stirring blades 16 are made to rotate by a motor 17 and a speed reducer 18 .
[0031] In the adjusting tank 30 , a small amount of the collector e such as kerosene, gas oil, and heavy oil and the flother f such as MIBC (methylisobutylcarbinol) is added to the slurry which is made from the high speed shear mixer 10 and mixed, and as shown in FIG. 2 , the adjusting tank 30 is equipped with a stirring blade 31 for stirring at low speed inside. In the latter part of this adjusting tank 30 , a pump 32 is arranged to supply the slurry d to the flotation unit 40 .
[0032] In the flotation unit 40 , the unburned carbon is floated by attaching to the generated air bubbles, and the slurry d is separated into unburned carbon c and an ash content in which the unburned carbon is removed a′. This flotation unit 40 has a structure shown in FIGS. 4 to 6 , for example. However, other structures (for example, a column flotation) can be used.
[0033] This flotation unit 40 has a plurality of rooms 43 partitioned into partitions 42 in a rectangular tank 41 and is equipped with a stirring machine 44 in each of the rooms 43 . This stirring machine 44 has an external pipe 47 outside of a lateral rotary shaft 45 . This external pipe 47 , as shown in FIG. 6 , has an air introducing pipe 48 in the upper part and has a hood 49 to cover a stirring blade 46 in the lower part.
[0034] Further, this flotation unit 40 has froth-discharge paths 50 in both sides of the tank 41 . This froth-discharge path 50 has an inclined bottom part 51 and a froth gathering path 52 connecting to both of the froth-discharge paths 50 in the valley side. Further, this flotation unit 40 is provided with a froth rake-out machine 54 in the upper part of the side wall (may be referred to as a weir) 53 having the froth-discharge path 50 . This froth rake-out machine 54 is configured with a rotary shaft 56 rotated by a motor 55 and a plurality of water wheels 57 provided in this rotary shaft 56 .
[0035] Further, this flotation unit 40 has a slurry input port 58 on an end face of the upstream side, a tail output port 59 on an end face of the downstream side, and a froth output port 60 in the froth gathering path 52 . Further, it has a communication port 61 in each partition 42 .
[0036] Next, operation of the above-described system is explained by referring to FIGS. 2 to 7 .
[0037] As shown in FIG. 2 , the fly ash a is supplied to the slurry adjusting tank 1 and becomes the slurry d by mixing with the water b. Here, the fly ash concentration in the slurry is adjusted to the range of 5 to 40 wt %, and preferably to the range of 15 to 25 wt %. When the fly ash concentration in the slurry is less than 5 wt %, it is not profitable to industrialize it because the fly ash content is too low. On the other hand, when it exceeds 40 wt %, the slurry concentration becomes high and difficulty occurs in the later steps.
[0038] The slurry d in the slurry adjusting tank 1 is supplied to the high speed shear mixer 10 by the pump 3 and the application of the shearing force is performed by the high speed shear mixer 10 . The addition of the shear force can be performed using the high speed shear mixer 10 in FIG. 3 for example. A shearing force is applied by the stirring blade 16 rotating at high speed in each room 12 partitioned with a partitioning wall 13 , and the slurry d supplied from an input port 19 of the high speed shear mixer 10 is activated. At that time, short passing of the slurry d is prevented by the annular partitioning wall 13 and the shearing force can be applied to the slurry with certainty. The slurry d to which the shearing force is applied, and activated, is discharged from an exit 20 and is supplied to the adjusting tank 30 .
[0039] As described above, the purpose of applying the shearing force to the slurry of the fly ash and activating it is to improve the floating property of the unburned carbon by performing surface modification. This is explained by referring to FIGS. 7( a ) to 7 ( d ).
[0040] The slurry d including the fly ash is, as shown in FIG. 7( a ), only in the state where the fly ash a and the unburned carbon c are mixed individually in the water b. However, when the shearing force is applied to the slurry d and the surface upgrading of the unburned carbon c is performed, as shown in FIG. 7( a ), excessive activation energy (surface energy) is generated on the surface of the unburned carbon c, and its surface is lipophiliced (hydrophobiced) even more. On the other hand, the surface of the fly ash a is hydrophiliced more and becomes adaptable to water.
[0041] When the collector e and the flother f are added to the slurry after the surface upgrading of the unburned carbon c is performed, as shown in FIG. 7( c ), the collector e attaches to the unburned carbon c. Then, when the flotation is performed using the flotation unit, as shown in FIG. 7( d ), the unburned carbon c to which the collector e is attached floats by attaching to air bubbles n.
[0042] Moreover, when the shearing force is applied to the slurry by the high speed shear mixer 10 , a stirring force (stirring force) of 10 to 100 kWh/m 3 per unit slurry amount of the slurry, preferably 30 to 50 kWh/m 3 is applied. When the stirring force per unit slurry amount is less than 10 kWh/m 3 , the surface upgrading of the unburned carbon is insufficient, and when the stirring force per unit slurry amount exceeds 100 kWh/m 3 , there are problems such as an increase in running cost and wear and tear of the surface upgrading machine.
[0043] Further, the residence time of the slurry in the high speed shear mixer 10 is 0.1 to 10 minutes and preferably should be 0.5 to 5 minutes. When the residence time of the slurry is less than 0.1 minute, the surface upgrading of the unburned carbon is insufficient, and when it exceeds 10 minutes, there are problems such as increases in equipment cost and running cost of the surface upgrading machine.
[0044] The slurry d′ in which the shearing force is applied by the high speed shear mixer 10 and is activated, is supplied to the adjusting tank 30 , and in the adjusting tank 30 , the collector e (for example, kerosene, gas oil, and heavy oil) and the flother f (for example, MIBC (methylisobutylcarbinol)) are added to the slurry d′ after the surface upgrading. When the slurry is stirred at low speed with the stirring blade 31 while the collector e and the flother f are added to the slurry including the lipophiliced unburned carbon, the surface of the unburned carbon c lipophiliced by the activation energy is brought into close contact with the surface of the particles of the collector (refer to FIG. 7( c )), and the surface energy decreases. On the other hand, because the surface of the activated fly ash a adapts to water and disperses into water, the surface energy decreases.
[0045] Here, the added amount of the collector is 0 to 3.0 wt % and preferably should be 0.05 to 1.0 wt %. Further, the added amount of the flother is 20 to 5,000 ppm and preferably should be 100 to 1000 ppm. When the added amount of the collector exceeds 3.0 wt %, the added amount of the collector becomes excessive and uneconomical.
[0046] In the case that the added amount of the flother is less than 20 ppm, the added amount of the flother is insufficient and it becomes difficult to generate air bubbles sufficiently. And, when the added amount of the flother exceeds 5,000 ppm, there is the problem that the recovery rate of the fly ash decreases because fly ash is absorbed into the air bubbles.
[0047] Next, the slurry d″ that has been stirred and adjusted in the adjusting tank 30 is supplied to the flotation unit 40 by the pump 3 . The slurry d′ supplied to the flotation unit 40 is stirred with the stirring machine 44 . However, air h is sucked in from the air introducing pipe 48 when the stirring machine 44 rotates and the air bubbles n are generated. At that time, it is possible that air may be blown in involuntarily. For example, there is a method in which the air introducing pipe is provided and in which air is supplied from a blower, etc. When the air bubbles are generated, as shown in FIG. 7( d ), the unburned carbon c is attached to the surface of the air bubbles n through the collector e and floats together with the air bubbles n. The unburned carbon floated together with the air bubbles n is raked out to the outside of the tank by the froth rake-out machine 54 provided on the upper end of the side wall (weir) 53 and flows down to the froth-discharge path 50 .
[0048] The froth (unburned carbon) i in the froth-discharge path 50 flows along the inclined bottom part 51 and is discharged to the outside of the machine through the froth gathering path 52 . Meanwhile, the tail (fly ash) j remaining in the tank 41 is discharged to the outside of the machine from the output port 59 together with water.
[0049] In the above explanation, the method whereby the surface of the unburned carbon is modified by the shearing force of the high speed shear mixer is explained. However, the surface of the unburned carbon may be modified by the shearing force using a machine such as an ejector. Any machine may be used essentially as long as it can modify the surface of the unburned carbon by applying a shearing force to the slurry-state unburned carbon.
EMBODIMENTS
Embodiment 1
[0050] 1000 ml of water and 200 g of fly ash (unburned carbon content, 5.0%) were mixed while being stirred, and were made into slurry. By stirring this slurry at high speed with a high speed shear mixer (high speed shear mixer power: 40 kWh/m 3 ), a shearing force was applied to the slurry, the slurry was activated, and the unburned carbon in the fly ash was lipophiliced (hydrophobiced).
[0051] While the slurry that has been lipophiliced by the activation energy was stirred at low speed, 1.3 ml of kerosene as a collector was added and 200 mg of MIBC (methylisobutylcarbinol) as a flother was added. Next, air bubbles were generated by a flotation operation, the unburned carbon was floated by being attached to the generated air bubbles, and the floated air bubbles were taken out as froth. This flotation step was performed continuously for 5 minutes.
[0052] Next, when the tail remaining in the container was dried and weighed, it was 165 g, and the amount of the unburned carbon in it was 0.4 wt %. As a result, it was found that the recovery rate of the fly ash was 86.5 wt % (=(165×0.996/200×0.95)×100).
[0053] By contrast, in the case when the same amount of kerosene as a collector was added to the slurry before the shearing force was applied with the mixer, as in the conventional method, the recovery rate of the fly ash was 76.5 wt %. Further, the amount of unburned carbon in the recovered fly ash was 1.1 wt %, and it resulted in the amount of the collector being insufficient.
INDUSTRIAL APPLICABILITY
[0054] For example, the present invention could possibly be used in removing the unburned carbon effectively from the fly ash generated in a coal burning thermal electric power plant, etc. | Disclosed is a method for removal of an unburned carbon contained in a fly ash material. The method comprises the steps of adding water to the fly ash to prepare a fly ash slurry; shearing the fly ash slurry using an agitating blade that can rotate at a high speed to generate an active energy on the surface of an unburned carbon by the shearing force, thereby imparting lipophilicity to the unburned carbon; and adding a collecting agent and a foaming agent to the slurry containing the lipophylized unburned carbon to cause the attachment of the collecting agent to the lipophylized unburned carbon, and at the same time, causing the attachment of the unburned carbon having the collecting agent attached thereto an air bubble to separate the unburned carbon by flotation. | 1 |
[0001] This is a continuation-in-part of application Ser. No. 09/274,609, filed Mar. 23, 1999; application Ser. No. 09/452,346, filed Dec. 1, 1999; and application Ser. No. 09/311,126, filed May 13, 1999, which is a continuation-in-part of application Ser. No. 09/153,144, filed Sep. 14, 1998, now U.S. Pat. No. 6,097,147.
FIELD OF INVENTION
[0002] The present invention is directed to organic light emitting devices (OLEDs) comprised of emissive layers that contain an organometallic phosphorescent compound.
BACKGROUND OF THE INVENTION
[0003] Organic light emitting devices (OLEDs) are comprised of several organic layers in which one of the layers is comprised of an organic material that can be made to electroluminesce by applying a voltage across the device, C.W. Tang et al., Appl. Phys. Lett. 1987, 51, 913. Certain OLEDs have been shown to have sufficient brightness, range of color and operating lifetimes for use as a practical alternative technology to LCD-based full color flat-panel displays (S. R. Forrest, P. E. Burrows and M. E. Thompson, Laser Focus World, Feb. 1995). Since many of the thin organic films used in such devices are transparent in the visible spectral region, they allow for the realization of a completely new type of display pixel in which red (R), green (G), and blue (B) emitting OLEDs are placed in a vertically stacked geometry to provide a simple fabrication process, a small R-G-B pixel size, and a large fill factor, International Patent Application No. PCT/US95/15790.
[0004] A transparent OLED (TOLED), which represents a significant step toward realizing high resolution, independently addressable stacked R-G-B pixels, was reported in International Patent Application Ser. No. PCT/US97/02681 in which the TOLED had greater than 71% transparency when turned off and emitted light from both top and bottom device surfaces with high efficiency (approaching 1% quantum efficiency) when the device was turned on. The TOLED used transparent indium tin oxide (ITO) as the hole-injecting electrode and a Mg—Ag—ITO electrode layer for electron-injection. A device was disclosed in which the ITO side of the Mg—Ag—ITO electrode layer was used as a hole-injecting contact for a second, different color-emitting OLED stacked on top of the TOLED. Each layer in the stacked OLED (SOLED) was independently addressable and emitted its own characteristic color. This colored emission could be transmitted through the adjacently stacked, transparent, independently addressable, organic layer or layers, the transparent contacts and the glass substrate, thus allowing the device to emit any color that could be produced by varying the relative output of the red and blue color-emitting layers.
[0005] The PCT/US95/15790 application disclosed an integrated SOLED for which both intensity and color could be independently varied and controlled with external power supplies in a color tunable display device. The PCT/US95/15790 application, thus, illustrates a principle for achieving integrated, full color pixels that provide high image resolution, which is made possible by the compact pixel size. Furthermore, relatively low cost fabrication techniques, as compared with prior art methods, may be utilized for making such devices.
[0006] Because light is generated in organic materials from the decay of molecular excited states or excitons, understanding their properties and interactions is crucial to the design of efficient light emitting devices currently of significant interest due to their potential uses in displays, lasers, and other illumination applications. For example, if the symmetry of an exciton is different from that of the ground state, then the radiative relaxation of the exciton is disallowed and luminescence will be slow and inefficient. Because the ground state is usually anti-symmetric under exchange of spins of electrons comprising the exciton, the decay of a symmetric exciton breaks symmetry. Such excitons are known as triplets, the term reflecting the degeneracy of the state. For every three triplet excitons that are formed by electrical excitation in an OLED, only one symmetric state (or singlet) exciton is created. (M. A. Baldo, D. F. O'Brien, M. E. Thompson and S. R. Forrest, Very high-efficiency green organic light-emitting devices based on electrophosphorescence, Applied Physics Letters, 1999, 75, 4-6.) Luminescence from a symmetry-disallowed process is known as phosphorescence. Characteristically, phosphorescence may persist for up to several seconds after excitation due to the low probability of the transition. In contrast, fluorescence originates in the rapid decay of a singlet exciton. Since this process occurs between states of like symmetry, it may be very efficient.
[0007] Many organic materials exhibit fluorescence from singlet excitons. However, only a very few have been identified which are also capable of efficient room temperature phosphorescence from triplets. Thus, in most fluorescent dyes, the energy contained in the triplet states is wasted. However, if the triplet excited state is perturbed, for example, through spin-orbit coupling (typically introduced by the presence of a heavy metal atom), then efficient phosphoresence is more likely. In this case, the triplet exciton assumes some singlet character and it has a higher probability of radiative decay to the ground state. Indeed, phosphorescent dyes with these properties have demonstrated high efficiency electroluminescence.
[0008] Only a few organic materials have been identified which show efficient room temperature phosphorescence from triplets. In contrast, many fluorescent dyes are known (C. H. Chen, J. Shi, and C. W. Tang, “Recent developments in molecular organic electroluminescent materials,” Macromolecular Symposia, 1997, 125, 1-48; U. Brackmann, Lambdachrome Laser Dyes (Lambda Physik, Gottingen, 1997)) and fluorescent efficiencies in solution approaching 100% are not uncommon. (C. H. Chen, 1997, op. cit.) Fluorescence is also not affected by triplet-triplet annihilation, which degrades phosphorescent emission at high excitation densities. (M. A. Baldo, et al., “High efficiency phosphorescent emission from organic electroluminescent devices,” Nature, 1998, 395, 151-154; M. A. Baldo, M. E. Thompson, and S. R. Forrest, “An analytic model of triplet-triplet annihilation in electrophosphorescent devices,” 1999). Consequently, fluorescent materials are suited to many electroluminescent applications, particularly passive matrix displays.
[0009] To understand the different embodiments of this invention, it is useful to discuss the underlying mechanistic theory of energy transfer. There are two mechanisms commonly discussed for the transfer of energy to an acceptor molecule. In the first mechanism of Dexter transport (D. L. Dexter, “A theory of sensitized luminescence in solids,” J. Chem. Phys., 1953, 21, 836-850), the exciton may hop directly from one molecule to the next. This is a short-range process dependent on the overlap of molecular orbitals of neighboring molecules. It also preserves the symmetry of the donor and acceptor pair (E. Wigner and E. W. Wittmer, Uber die Struktur der zweiatomigen Molekelspektren nach der Quantenmechanik, Zeitschrift fur Physik, 1928, 51, 859-886; M. Klessinger and J. Michl, Excited states and photochemistry of organic molecules (VCH Publishers, New York, 1995)). Thus, the energy transfer of Eq. (1) is not possible via Dexter mechanism. In the second mechanism of Förster transfer (T. Förster, Zwischenmolekulare Energiewanderung and Fluoreszenz, Annalen der Physik, 1948, 2, 55-75; T. Förster, Fluoreszenz organischer Verbindugen (Vandenhoek and Ruprecht, Gottinghen, 1951 ), the energy transfer of Eq. (1) is possible. In Forster transfer, similar to a transmitter and an antenna, dipoles on the donor and acceptor molecules couple and energy may be transferred. Dipoles are generated from allowed transitions in both donor and acceptor molecules. This typically restricts the Forster mechanism to transfers between singlet states.
[0010] Nevertheless, as long as the phosphor can emit light due to some perturbation of the state such as due to spin-orbit coupling introduced by a heavy metal atom, it may participate as the donor in Forster transfer. The efficiency of the process is determined by the luminescent efficiency of the phosphor (F Wilkinson, in Advances in Photochemistry (eds. W. A. Noyes, G. Hammond, and J. N. Pitts), pp. 241-268, John Wiley & Sons, New York, 1964), i.e., if a radiative transition is more probable than a non-radiative decay, then energy transfer will be efficient. Such triplet-singlet transfers were predicted by Förster (T. Forster,“Transfer mechanisms of electronic excitation,” Discussions of the Faraday Society, 1959, 27, 7-17) and confirmed by Ermolaev and Sveshnikova (V. L. Ermolaev and E. B. Sveshnikova, “Inductive-resonance transfer of energy from aromatic molecules in the triplet state,” Doklady Akademii Nauk SSSR, 1963, 149, 1295-1298), who detected the energy transfer using a range of phosphorescent donors and fluorescent acceptors in rigid media at 77K or 90K. Large transfer distances are observed; for example, with triphenylamine as the donor and chrysoidine as the acceptor, the interaction range is 52 Å.
[0011] The remaining condition for Förster transfer is that the absorption spectrum should overlap the emission spectrum of the donor assuming the energy levels between the excited and ground state molecular pair are in resonance. In one example of this application, we use the green phosphor fac tris(2-phenylpyridine) iridium (Ir(ppy) 3 ; M. A. Baldo, et al., Appl. Phys. Lett., 1999, 75, 4-6) and the red fluorescent dye [2-methyl-6-[2-(2,3,6,7-tetrahydro-1H,5H-benzo[ij]quinolizin-9-yl) ethenyl]-4H-pyran-ylidene] propane-dinitrile] (“DCM2”; C. W. Tang, S. A. VanSlyke, and C. H. Chen, “Electroluminescence of doped organic films,” J. Appl. Phys., 1989, 65, 3610-3616). DCM2 absorbs in the green, and, depending on the local polarization field (V. Bulovic, et al., “Bright, saturated, red-to-yellow organic light-emitting devices based on polarization-induced spectral shifts,” Chem. Phys. Lett., 1998, 287, 455-460), it emits at wavelengths between λ=570 nm and λ=650 nm.
[0012] It is possible to implement Forster energy transfer from a triplet state by doping a fluorescent guest into a phosphorescent host material. Unfortunately, such systems are affected by competitive energy transfer mechanisms that degrade the overall efficiency. In particular, the close proximity of the host and guest increase the likelihood of Dexter transfer between the host to the guest triplets. Once excitons reach the guest triplet state, they are effectively lost since these fluorescent dyes typically exhibit extremely inefficient phosphorescence.
[0013] To maximize the transfer of host triplets to fluorescent dye singlets, it is desirable to maximize Dexter transfer into the triplet state of the phosphor while also minimizing transfer into the triplet state of the fluorescent dye. Since the Dexter mechanism transfers energy between neighboring molecules, reducing the concentration of the fluorescent dye decreases the probability of triplet-triplet transfer to the dye. On the other hand, long range Forster transfer to the singlet state is unaffected. In contrast, transfer into the triplet state of the phosphor is necessary to harness host triplets, and may be improved by increasing the concentration of the phosphor.
[0014] Devices whose structure is based upon the use of layers of organic optoelectronic materials generally rely on a common mechanism leading to optical emission. Typically, this mechanism is based upon the radiative recombination of a trapped charge. Specifically, OLEDs are comprised of at least two thin organic layers separating the anode and cathode of the device. The material of one of these layers is specifically chosen based on the material's ability to transport holes, a “hole transporting layer” (HTL), and the material of the other layer is specifically selected according to its ability to transport electrons, an “electron transporting layer” (ETL). With such a construction, the device can be viewed as a diode with a forward bias when the potential applied to the anode is higher than the potential applied to the cathode. Under these bias conditions, the anode injects holes (positive charge carriers) into the hole transporting layer, while the cathode injects electrons into the electron transporting layer. The portion of the luminescent medium adjacent to the anode thus forms a hole injecting and transporting zone while the portion of the luminescent medium adjacent to the cathode forms an electron injecting and transporting zone. The injected holes and electrons each migrate toward the oppositely charged electrode. When an electron and hole localize on the same molecule, a Frenkel exciton is formed. Recombination of this short-lived state may be visualized as an electron dropping from its conduction potential to a valence band, with relaxation occurring, under certain conditions, preferentially via a photoemissive mechanism. Under this view of the mechanism of operation of typical thin-layer organic devices, the electroluminescent layer comprises a luminescence zone receiving mobile charge carriers (electrons and holes) from each electrode.
[0015] As noted above, light emission from OLEDs is typically via fluorescence or phosphorescence. There are issues with the use of phosphorescence. It has been noted that phosphorescent efficiency decreases rapidly at high current densities. It may be that long phosphorescent lifetimes cause saturation of emissive sites, and triplet-triplet annihilation may produce efficiency losses. Another difference between fluorescence and phosphorescence is that energy transfer of triplets from a conductive host to a luminescent guest molecule is typically slower than that of singlets; the long range dipole-dipole coupling (Förster transfer) which dominates energy transfer of singlets is (theoretically) forbidden for triplets by the principle of spin symmetry conservation. Thus, for triplets, energy transfer typically occurs by diffusion of excitons to neighboring molecules (Dexter transfer); significant overlap of donor and acceptor excitonic wavefunctions is critical to energy transfer. Another issue is that triplet diffusion lengths are typically long (e.g., >1400 Å) compared with typical singlet diffusion lengths of about 200 Å. Thus, if phosphorescent devices are to achieve their potential, device structures need to be optimized for triplet properties. In this invention, we exploit the property of long triplet diffusion lengths to improve external quantum efficiency.
[0016] Successful utilization of phosphorescence holds enormous promise for organic electroluminescent devices. For example, an advantage of phosphorescence is that all excitons (formed by the recombination of holes and electrons in an EL), which are (in part) triplet-based in phosphorescent devices, may participate in energy transfer and luminescence in certain electroluminescent materials. In contrast, only a small percentage of excitons in fluorescent devices, which are singlet-based, result in fluorescent luminescence.
[0017] An alternative is to use phosphorescence processes to improve the efficiency of fluorescence processes. Fluorescence is in principle 75% less efficient due to the three times higher number of symmetric excited states.
[0018] Because one typically has at least one electron transporting layer and at least one hole transporting layer, one has layers of different materials, forming a heterostructure. The materials that produce the electroluminescent emission are frequently the same materials that function either as the electron transporting layer or as the hole transporting layer. Such devices in which the electron transporting layer or the hole transporting layer also functions as the emissive layer are referred to as having a single heterostructure. Alternatively, the electroluminescent material may be present in a separate emissive layer between the hole transporting layer and the electron transporting layer in what is referred to as a double heterostructure. The separate emissive layer may contain the emissive molecule doped into a host or the emissive layer may consist essentially of the emissive molecule.
[0019] That is, in addition to emissive materials that are present as the predominant component in the charge carrier layer, that is, either in the hole transporting layer or in the electron transporting layer, and that function both as the charge carrier material as well as the emissive material, the emissive material may be present in relatively low concentrations as a dopant in the charge carrier layer. Whenever a dopant is present, the predominant material in the charge carrier layer may be referred to as a host compound or as a receiving compound. Materials that are present as host and dopant are selected so as to have a high level of energy transfer from the host to the dopant material. In addition, these materials need to be capable of producing acceptable electrical properties for the OLED. Furthermore, such host and dopant materials are preferably capable of being incorporated into the OLED using starting materials that can be readily incorporated into the OLED by using convenient fabrication techniques, in particular, by using vacuum-deposition techniques.
[0020] The exciton blocking layer used in the devices of the present invention (and previously disclosed in U.S. application Ser. No. 09/154,044) substantially blocks the diffusion of excitons, thus substantially keeping the excitons within the emission layer to enhance device efficiency. The material of blocking layer of the present invention is characterized by an energy difference (“band gap”) between its lowest unoccupied molecular orbital (LUMO) and its highest occupied molecular orbital (HOMO). In accordance with the present invention, this band gap substantially prevents the diffusion of excitons through the blocking layer, yet has only a minimal effect on the turn-on voltage of a completed electroluminescent device. The band gap is thus preferably greater than the energy level of excitons produced in an emission layer, such that such excitons are not able to exist in the blocking layer. Specifically, the band gap of the blocking layer is at least as great as the difference in energy between the triplet state and the ground state of the host.
[0021] It is desirable for OLEDs to be fabricated using materials that provide electroluminescent emission in a relatively narrow band centered near selected spectral regions, which correspond to one of the three primary colors, red, green and blue so that they may be used as a colored layer in an OLED or SOLED. It is also desirable that such compounds be capable of being readily deposited as a thin layer using vacuum deposition techniques so that they may be readily incorporated into an OLED that is prepared entirely from vacuum-deposited organic materials.
[0022] Co-pending application U.S. Ser. No. 08/774,087, filed Dec. 23, 1996, now U.S. Pat. No. 6,048,630, is directed to OLEDs containing emitting compounds that produce a saturated red emission.
SUMMARY OF THE INVENTION
[0023] The present invention is directed to organic light emitting devices wherein the emissive layer comprises an emissive molecule, optionally with a host material (wherein the emissive molecule is present as a dopant in said host material), which molecule is adapted to luminesce when a voltage is applied across the heterostructure, wherein the emissive molecule is selected from the group of phosphorescent organometallic complexes. The emissive molecule may be further selected from the group of phosphorescent organometallic platinum, iridium or osmium complexes and may be still further selected from the group of phosphorescent cyclometallated platinum, iridium or osmium complexes. A specific example of the emissive molecule is fac tris(2-phenylpyridine) iridium, denoted (Ir(ppy) 3 ) of formula
[0024] [In this, and later figures herein, we depict the dative bond from nitrogen to metal (here, Ir) as a straight line.]
[0025] The general arrangement of the layers is hole transporting layer, emissive layer, and electron transporting layer. For a hole conducting emissive layer, one may have an exciton blocking layer between the emissive layer and the electron transporting layer. For an electron conducting emissive layer, one may have an exciton blocking layer between the emissive layer and the hole transporting layer. The emissive layer may be equal to the hole transporting layer (in which case the exciton blocking layer is near or at the anode) or to the electron transporting layer (in which case the exciton blocking layer is near or at the cathode).
[0026] The emissive layer may be formed with a host material in which the emissive molecule resides as a guest or the emissive layer may be formed of the emissive molecule itself. In the former case, the host material may be a hole-transporting material selected from the group of substituted tri-aryl amines. The host material may be an electron-transporting material selected from the group of metal quinoxolates, oxadiazoles and triazoles. An example of a host material is 4,4′-N,N′-dicarbazole-biphenyl (CBP), which has the formula:
[0027] The emissive layer may also contain a polarization molecule, present as a dopant in said host material and having a dipole moment, that affects the wavelength of light emitted when said emissive dopant molecule luminesces.
[0028] A layer formed of an electron transporting material is used to transport electrons into the emissive layer comprising the emissive molecule and the (optional) host material. The electron transporting material may be an electron-transporting matrix selected from the group of metal quinoxolates, oxadiazoles and triazoles. An example of an electron transporting material is tris-(8-hydroxyquinoline) aluminum (Alq 3 ).
[0029] A layer formed of a hole transporting material is used to transport holes into the emissive layer comprising the emissive molecule and the (optional) host material. An example of a hole transporting material is 4,4′-bis[N-(1-naphthyl)-N-phenyl-amino] biphenyl [“α-NPD”].
[0030] The use of an exciton blocking layer (“barrier layer”) to confine excitons within the luminescent layer (“luminescent zone”) is greatly preferred. For a hole-transporting host, the blocking layer may be placed between the luminescent layer and the electron transport layer. An example of a material for such a barrier layer is 2,9-dimethyl-4,7-diphenyl-1,10-phenanthroline (also called bathocuproine or BCP), which has the formula:
[0031] For a situation with a blocking layer between a hole-conducting host and the electron transporting layer (as is the case in Example 2 below), one seeks the following characteristics, which are listed in order of relative importance.
[0032] 1. The difference in energy between the LUMO and HOMO of the blocking layer is greater than the difference in energy between the triplet and ground state singlet of the host material.
[0033] 2. Triplets in the host material are not quenched by the blocking layer.
[0034] 3. The ionization potential (IP) of the blocking layer is greater than the ionization potential of the host. (Meaning that holes are held in the host.)
[0035] 4. The energy level of the LUMO of the blocking layer and the energy level of the LUMO of the host are sufficiently close in energy such that there is less than 50% change in the overall conductivity of the device.
[0036] 5. The blocking layer is as thin as possible subject to having a thickness of the layer that is sufficient to effectively block the transport of excitons from the emissive layer into the adjacent layer.
[0037] That is, to block excitons and holes, the ionization potential of the blocking layer should be greater than that of the HTL, while the electron affinity of the blocking layer should be approximately equal to that of the ETL to allow for facile transport of electrons.
[0038] [For a situation in which the emissive (“emitting”) molecule is used without a hole transporting host, the above rules for selection of the blocking layer are modified by replacement of the word “host” by “emitting molecule.”]
[0039] For the complementary situation with a blocking layer between a electron-conducting host and the hole-transporting layer one seeks characteristics (listed in order of importance):
[0040] 1. The difference in energy between the LUMO and HOMO of the blocking layer is greater than the difference in energy between the triplet and ground state singlet of the host material.
[0041] 2. Triplets in the host material are not quenched by the blocking layer.
[0042] 3. The energy of the LUMO of the blocking layer is greater than the energy of the LUMO of the (electron-transporting) host. (Meaning that electrons are held in the host.)
[0043] 4. The ionization potential of the blocking layer and the ionization potential of the host are such that holes are readily injected from the blocker into the host and there is less than a 50% change in the overall conductivity of the device.
[0044] 5. The blocking layer is as thin as possible subject to having a thickness of the layer that is sufficient to effectively block the transport of excitons from the emissive layer into the adjacent layer.
[0045] [For a situation in which the emissive (“emitting”) molecule is used without an electron transporting host, the above rules for selection of the blocking layer are modified by replacement of the word “host” by “emitting molecule.”]
[0046] The present invention covers articles of manufacture comprising OLEDs comprising a new family of phosphorescent materials, which can be used as dopants in OLEDs, and methods of manufacturing the articles. These phosphorescent materials are cyclometallated platinum, iridium or osmium complexes, which provide electroluminiscent emission at a wavelength between 400 nm and 700 nm. The present invention is further directed to OLEDs that are capable of producing an emission that will appear blue, that will appear green, and that will appear red.
[0047] More specifically, OLEDs of the present invention comprise, for example, an emissive layer comprised of platinum (II) complexed with Bis[2-(2-phenyl)pyridinato-N,C2], Bis[2-(2′-thienyl)pyridinato-N,C3], and Bis[benzo(h)quinolinato-N,C]. The compound cis-Bis[2-(2′-thienyl)pyridinato-N,C3] Pt(II) gives a strong orange to yellow emission.
[0048] The invention is further directed to emissive layers wherein the emissive molecule is selected from the group of phosphorescent organometallic complexes, wherein the emissive molecule contains substituents selected from the class of electron donors and electron acceptors. The emissive molecule may be further selected from the group of phosphorescent organometallic platinum, iridium or osmium complexes and may be still further selected from the group of phosphorescent cyclometallated platinum, iridium or osmium complexes, wherein the organic molecule contains substituents selected from the class of electron donors and electron acceptors.
[0049] The invention is further directed to an organic light emitting device comprising a heterostructure for producing luminescence, wherein the emissive layer comprises a host material, an emissive molecule, present as a dopant in said host material, adapted to luminesce when a voltage is applied across the heterostructure, wherein the emissive molecule is selected from the group consisting of cyclometallated platinum, iridium or osmium complexes and wherein there is a polarization molecule, present as a dopant in the host material, which polarization molecule has a dipole moment and which polarization molecule alters the wavelength of the luminescent light emitted by the emissive dopant molecule. The polarization molecule may be an aromatic molecule substituted by electron donors and electron acceptors.
[0050] The present invention is directed to OLEDs, and a method of fabricating OLEDs, in which emission from the device is obtained via a phosphorescent decay process wherein the phosphorescent decay rate is rapid enough to meet the requirements of a display device. More specifically, the present invention is directed to OLEDs comprised of a material that is capable of receiving the energy from an exciton singlet or triplet state and emitting that energy as phosphorescent radiation.
[0051] The OLEDs of the present invention may be used in substantially any type of device which is comprised of an OLED, for example, in OLEDs that are incorporated into a larger display, a vehicle, a computer, a television, a printer, a large area wall, theater or stadium screen, a billboard or a sign.
[0052] The present invention is also directed to complexes of formula L L′L″ M, wherein L, L′, and L″ are distinct bidentate ligands and M is a metal of atomic number greater than 40 which forms an octahedral complex with the three bidentate ligands and is preferably a member of the third row (of the transition series of the periodic table) transition metals, most preferably Ir and Pt. Alternatively, M can be a member of the second row transition metals, or of the main group metals, such as Zr and Sb. Some of such organometallic complexes electroluminesce, with emission coming from the lowest energy ligand or MLCT state. Such electroluminescent compounds can be used in the emitter layer of organic light emitting diodes, for example, as dopants in a host layer of an emitter layer in organic light emitting diodes. This invention is further directed to organometallic complexes of formula L L′L″ M, wherein L, L′, and L″ are the same (represented by L 3 M) or different (represented by L L′L″ M), wherein L, L′, and L″ are bidentate, monoanionic ligands, wherein M is a metal which forms octahedral complexes, is preferably a member of the third row of transition metals, more preferably Ir or Pt, and wherein the coordinating atoms of the ligands comprise sp 2 hybridized carbon and a heteroatom. The invention is further directed to compounds of formula L 2 MX, wherein L and X are distinct bidentate ligands, wherein X is a monoanionic bidentate ligand, wherein L coordinates to M via atoms of L comprising sp 2 hybridized carbon and heteroatoms, and wherein M is a metal forming an octahedral complex, preferably iridium or platinum. It is generally expected that the ligand L participates more in the emission process than does X. The invention is directed to meridianal isomers of L 3 M wherein the heteroatoms (such as nitrogen) of two ligands L are in a trans configuration. In the embodiment in which M is coordinated with an sp 2 hybridized carbon and a heteroatom of the ligand, it is preferred that the ring comprising the metal M, the SP 2 hybridized carbon and the heteroatom contains 5 or 6 atoms. These compounds can serve as dopants in a host layer which functions as a emitter layer in organic light emitting diodes.
[0053] Furthermore, the present invention is directed to the use of complexes of transition metal species M with bidentate ligands L and X in compounds of formula L 2 MX in the emitter layer of organic light emitting diodes. A preferred embodiment is compounds of formula L 2 IrX, wherein L and X are distinct bidentate ligands, as dopants in a host layer functioning as an emitter layer in organic light emitting diodes.
[0054] The present invention is also directed to an improved synthesis of organometallic molecules which function as emitters in light emitting devices. These compounds of this invention can be made according to the reaction:
L 2 M (μ- Cl ) 2 ML 2 +XH−>L 2 MX+HCl
[0055] wherein L 2 M(μ-Cl) 2 ML 2 is a chloride bridged dimer with L a bidentate ligand, and M a metal such as Ir; XH is a Bronsted acid which reacts with bridging chloride and serves to introduce a bidentate ligand X, where XH can be, for example, acetylacetone, 2-picolinic acid, or N-methylsalicyclanilide, and H represents hydrogen. The method involves combining the L 2 M(μ-Cl) 2 ML 2 chloride bridged dimer with the XH entity. The resultant product of the form L 2 MX has approximate octahedral disposition of the bidentate ligands L, L, and X about M.
[0056] The resultant compounds of formula L 2 MX can be used as phosphorescent emitters in organic light emitting devices. For example, the compound wherein L=(2-phenylbenzothiazole), X=acetylacetonate, and M=Ir (the compound abbreviated as BTIr) when used as a dopant in 4,4′-N,N′-dicarbazole-biphenyl (CBP) (at a level 12% by mass) to form an emitter layer in an OLED shows a quantum efficiency of 12%. For reference, the formula for CBP is:
[0057] The synthetic process to make L 2 MX compounds of the present invention may be used advantageously in a situation in which L, by itself, is fluorescent but the resultant L 2 MX is phosphorescent. One specific example of this is where L=coumarin-6.
[0058] The synthetic process of the present invention facilitates the combination of L and X pairs of certain desirable characteristics. For example, the present invention is further directed to the appropriate selection of L and X to allow color tuning of the complex L 2 MX relative to L 3 M. For example, Ir(ppy) 3 and (ppy) 2 Ir(acac) both give strong green emission with a λ max of 510 nm (ppy denotes phenyl pyridine). However, if the X ligand is formed from picolinic acid instead of from acetylacetone, there is a small blue shift of about 15 nm.
[0059] Furthermore, the present invention is also directed to a selection of X such that it has a certain HOMO level relative to the L 3 M complex so that carriers (holes or electrons) might be trapped on X (or on L) without a deterioration of emission quality. In this way, carriers (holes or electrons) which might otherwise contribute to deleterious oxidation or reduction of the phosphor would be impeded. The carrier that is remotely trapped could readily recombine with the opposite carrier either intramolecularly or with the carrier from an adjacent molecule.
[0060] The present invention, and its various embodiments, are discussed in more detail in the examples below. However, the embodiments may operate by different mechanisms. Without limitation and without limiting the scope of the invention, we discuss the different mechanisms by which various embodiments of the invention may operate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] [0061]FIG. 1. Electronic absorbance spectra of Pt(thpy) 2 , Pt(thq) 2 , and Pt(bph)(bpy).
[0062] [0062]FIG. 2. Emission spectra of Pt(thpy) 2 , Pt(thq) 2 , and Pt(bph)(bpy).
[0063] [0063]FIG. 3. Energy transfer from polyvinylcarbazole (PVK) to Pt(thpy) 2 in the solid film.
[0064] [0064]FIG. 4. Characteristics of OLED with Pt(thpy) 2 dopant: (a) I-V characteristic; (b) Light output curve.
[0065] [0065]FIG. 5. Quantum efficiency dependence on applied voltage for OLED with Pt(thpy) 2 dopant.
[0066] [0066]FIG. 6. Characteristics of the OLED device with Pt(thpy) 2 dopant: (a) normalized electroluminescence (EL) spectrum of the device at 22 V (b) CIE diagram based on normalized EL spectrum.
[0067] [0067]FIG. 7. Proposed energy level structure of the electrophosphorescent device of Example 2. The highest occupied molecular orbital (HOMO) energy and the lowest unoccupied molecular orbital (LUMO) energy are shown (see I. G. Hill and A. Kahn, J. Appl. Physics (1999)). Note that the HOMO and LUMO levels for lr(ppy) 3 are not known. The inset shows structural chemical formulae for: (a) Ir(ppy) 3 ; (b) CBP; and (c) BCP.
[0068] [0068]FIG. 8. The external quantum efficiency of OLEDs using Ir(ppy) 3 : CBP luminescent layers. Peak efficiencies are observed for a mass ratio of 6% Ir(ppy) 3 to CBP. The 100% Ir(ppy) 3 device has a slightly different structure than shown in FIG. 7. In it, the Ir(ppy) 3 layer is 300 A thick and there is no BCP blocking layer. The efficiency of a 6% Ir(ppy) 3 : CBP device grown without a BCP layer is also shown.
[0069] [0069]FIG. 9. The power efficiency and luminance of the 6% Ir(ppy) 3 : CBP device. At 100 cd/m 2 , the device requires 4.3 V and its power efficiency is 19 lm/W.
[0070] [0070]FIG. 10. The electroluminescent spectrum of 6% Ir(Ppy) 3 : CBP. Inset: The Commission Internationale de L'Eclairage (CIE) chromaticity coordinates of Ir(ppy) 3 in CBP are shown relative to fluorescent green emitters Alq 3 and poly(p-phenylenevinylene) (PPV).
[0071] [0071]FIG. 11. Expected structure of L 2 IrX complexes along with the structure expected for PPIr. Four examples of X ligands used for these complexes are also shown. The structure shown is for an acac derivative. For the other X type ligands, the O—O ligand would be replaced with an N—O ligand.
[0072] [0072]FIG. 12. Comparison of facial and meridianal isomers of L 3 M.
[0073] [0073]FIG. 13. Molecular formulae of mer- isomers disclosed herewith: mer-Ir(ppy) 3 and mer-Ir(bq) 3 . PPY (or ppy) denotes phenyl pyridyl and BQ (or bq) denotes 7,8-benzoquinoline.
[0074] [0074]FIG. 14. Models of mer-Ir(ppy) 3 (left) and (Ppy) 2 Ir(acac) (right).
[0075] [0075]FIG. 15. (a) Electroluminescent device data (quantum efficiency vs. current density) for 12% by mass “BTIr” in CBP. BTIr stands for bis (2-phenylbenzothiazole) iridium acetylacetonate; (b) Emission spectrum from same device
[0076] [0076]FIG. 16. Representative molecule to trap holes (L 2 IrX complex).
[0077] [0077]FIG. 17. Emission spectrum of Ir(3-MeOppy) 3
[0078] [0078]FIG. 18. Emission spectrum of tpyIrsd.
[0079] [0079]FIG. 19. Proton NMR spectrum of tpyIrsd (=typIrsd).
[0080] [0080]FIG. 20. Emission spectrum of thpyIrsd.
[0081] [0081]FIG. 21. Proton NMR spectrum of thpyIrsd.
[0082] [0082]FIG. 22. Emission spectrum of btIrsd.
[0083] [0083]FIG. 23. Proton NMR spectrum of btIrsd.
[0084] [0084]FIG. 24. Emission spectrum of BQIr.
[0085] [0085]FIG. 25. Proton NMR spectrum of BQIr.
[0086] [0086]FIG. 26. Emission spectrum of BQIrFA.
[0087] [0087]FIG. 27. Emission spectrum of THIr (=thpy; THPIr).
[0088] [0088]FIG. 28. Proton NMR spectrum of THPIr.
[0089] [0089]FIG. 29. Emission spectra of PPIr.
[0090] [0090]FIG. 30. Proton NMR spectrum of PPIr.
[0091] [0091]FIG. 31. Emission spectrum of BTHPIr (=BTPIr).
[0092] [0092]FIG. 32. Emission spectrum of tpyIr.
[0093] [0093]FIG. 33. Crystal structure of tpyIr showing trans arrangement of nitrogen.
[0094] [0094]FIG. 34. Emission spectrum of C6.
[0095] [0095]FIG. 35. Emission spectrum of C6Ir.
[0096] [0096]FIG. 36. Emission spectrum of PZIrP.
[0097] [0097]FIG. 37. Emission spectrum of BONIr.
[0098] [0098]FIG. 38. Proton NMR spectrum of BONIr.
[0099] [0099]FIG. 39. Emission spectrum of BTIr.
[0100] [0100]FIG. 40. Proton NMR spectrum of BTIr.
[0101] [0101]FIG. 41. Emission spectrum of BOIr.
[0102] [0102]FIG. 42. Proton NMR spectrum of BOIr.
[0103] [0103]FIG. 43. Emission spectrum of BTIrQ.
[0104] [0104]FIG. 44. Proton NMR spectrum of BTIrQ.
[0105] [0105]FIG. 45. Emission spectrum of BTIrP.
[0106] [0106]FIG. 46. Emission spectrum of BOIrP.
[0107] [0107]FIG. 47. Emission spectrum of btIr-type complexes with different ligands.
[0108] [0108]FIG. 48. Proton NMR spectrum of mer-Irbq.
[0109] [0109]FIG. 49. Other suitable L and X ligands for L 2 MX compounds. In all of these ligands listed, one can easily substitute S for O and still have a good ligand.
[0110] [0110]FIG. 50. Examples of L L′L″ M compounds. In the listed examples of L L′L″ M and L L′ M X compounds, the compounds would be expected to emit from the lowest energy ligand or the MLCT state, involving the bq or thpy ligands. In the listed example of an L M X X′ compound, emission therefrom is expected from the ppy ligand. The X and X′ ligands will modify the physical properties (for example, a hole trapping group could be added to either ligand).
DETAILED DESCRIPTION OF THE INVENTION
[0111] The present invention is generally directed to emissive molecules, which luminesce when a voltage is applied across a heterostructure of an organic light-emitting device and which molecules are selected from the group of phosphorescent organometallic complexes, and to structures, and correlative molecules of the structures, that optimize the emission of the light-emitting device. The term “organometallic” is as generally understood by one of ordinary skill, as given, for example, in “Inorganic Chemistry” (2nd edition) by Gary L. Miessler and Donald A. Tarr, Prentice-Hall (1998). The invention is further directed to emissive molecules within the emissive layer of an organic light-emitting device which molecules are comprised of phosphorescent cyclometallated platinum, iridium or osmium complexes. On electroluminescence, molecules in this class may produce emission which appears red, blue, or green. Discussions of the appearance of color, including descriptions of CIE charts, may be found in H. Zollinger, Color Chemistry, VCH Publishers, 1991 and H. J. A. Dartnall, J. K. Bowmaker, and J. D. Mollon, Proc. Roy. Soc. B (London), 1983, 220, 115-130.
[0112] The present invention will now be described in detail for specific preferred embodiments of the invention, it being understood that these embodiments are intended only as illustrative examples and the invention is not to be limited thereto.
[0113] Synthesis of the Cyclometallated Platinum Complexes
[0114] We have synthesized a number of different Pt cyclometallated complexes.
[0115] Numerous publications, reviews and books are dedicated to the chemistry of cyclometallated compounds, which also are called intramolecular-coordination compounds. (I.Omae, Organometallic Intramolecular-coordination compounds. N.Y. 1986. G. R. Newkome, W. E. Puckett, V. K. Gupta, G. E. Kiefer, Chem. Rev. 1986,86, 451. A. D. Ryabov, Chem. Rev. 1990, 90, 403). Most of the publications depict mechanistical aspects of the subject and primarily on the cyclometallated compounds with one bi- or tri-dentate ligand bonded to metal by C-M single bond and having cycle closed with one or two other X-M bonds where X may be N, S, P, As, O. Not so much literature was devoted to bis- or tris-cyclometallated complexes, which do not possess any other ligands but C,N type bi-dentate ones. Some of the subject of this invention is in these compounds because they are not only expected to have interesting photochemical properties as most cyclometallated complexes do, but also should exhibit increased stability in comparison with their monocyclometallated analogues. Most of the work on bis-cyclopaladated and bis-cycloplatinated compounds was performed by von Zelewsky et al (For a review see: M.Maestri, V.Balzani, Ch.Deuschel-Comioley, A.von Zelewsky, Adv.Photochem. 1992 17, 1. L.Chassot, A.Von Zelewsky, Helv. Chim.Acta 1983, 66, 243. L.Chassot, E.Muler, A. von Zelewsky, Inorg. Chem. 1984, 23, 4249. S Bonafede, M.Ciano, F.Boletta, V.Balzani, L.Chassot, A. von Zelewsky, J.Phys. Chem. 1986, 90, 3836. L.Chassot, A.von Zelewsky, D.Sandrini, M.Maestri, V.Balzani, J.Am. Chem. Soc. 1986, 108, 6084. Ch.Cornioley-Deuschel, A.von Zelewsky, Inorg. Chem. 1987, 26, 3354. L.Chassot, A.von Zelewsky, Inorg.Chem. 1987, 26, 2814. A.von Zelewsky, A. P. Suckling, H.Stoeckii-Evans, Inorg.Chem. 1993, 32, 4585. A. von Zelewsky, P.Belser, P.Hayoz, R.Dux, X.Hua, A.Suckling, H.Stoeckii-Evans, Coord. Chem.Rev. 1994, 132, 75. P.Jolliet, M.Gianini, A.von Zelewsky, G.Bemardinelli, H.Stoeckii-Evans, Inorg.Chem. 1996, 35, 4883. H.Wiedenhofer, S.Schutzenmeier, A.von Zelewsky, H.Yersin, J.Phys. Chem. 1995, 99, 13385. M. Gianini, A.von Zelewsky, H. Stoeckii-Evans, Inorg. Chem. 1997,36, 6094.) In one of their early works, (M.Maestri, D.Sandrini, V.Balzani, L.Chassot, P.Jolliet, A.von Zelewsky, Chem.Phys.Lett. 1985,122,375) luminescent properties of three bis-cycloplatinated complexes were investigated in detail. The summary of the previously reported results on Pt bis-cyclometallated complexes important for our current research is as follows:
[0116] i. in general, cyclometallated complexes having a 5-membered ring formed between the metal atom and C,X ligand are more stable.
[0117] ii. from the point of view of stability of resulting compounds, complexes not containing anionic ligands are preferred; thus, bis-cyclometallated complexes are preferred to mono-cyclometallated ones.
[0118] iii. a variety of Pt(Pd) cyclometallated complexes were synthesized, homoleptic (containing similar C,X ligands), heteroleptic (containing two different cyclometallating C,X ligands) and complexes with one C,C cyclometallating ligand and one N,N coordinating ligand.
[0119] iv. most bis-cyclometallated complexes show M+ions upon electron impact ionization in their mass spectra; this can be a base for our assumption on their stability upon vacuum deposition.
[0120] v. on the other hand, some of the complexes are found not to be stable in certain solvents; they undergo oxidative addition reactions leading to Pt(IV) or Pd(IV) octahedral complexes.
[0121] vi. optical properties are reported only for some of the complexes; mostly absorption data is presented. Low-energy electron transitions observed in both their absorption and emission spectra are assigned to MLCT transitions.
[0122] vii. reported luminescent properties are summarized in Table 1. Used abbreviations are explained in Scheme 1. Upon transition from bis-cyclometalated complexes with two C,N ligands to the complexes with one C,C and one N,N ligand batochromic shift in emission was observed. (M.Maestri, D.Sandrini, V.Balzani, A.von Zelewsky, C.Deuschel-Cornioley, P.Jolliet, Helv. Chim.Acta 1988, 71, 1053. Table 1: Absorption and emission properties of several cycloplatinated complexes. Reproduced from A.von Zelewsky et. al (Chem. Phys. Lett., 1985, 122, 375 and Helv. Chim. Acta 1988, 17, 1053). Abbreviation explanations are given in Scheme 1.
emission spectra absorption 77K 293K solvent λmax(ε) λmax(τ) λmax(τ) Pt(Phpy) 2 (1) CH 3 CN 402(12800) 491(4.0) — 291(27700) Pt(Thpy) 2 (2) CH 3 CN 418(10500) 570(12.0) 578(2.2) 303(26100) Pt(Bhq) 2 (3) CH 3 CN 421(9200) 492(6.5) — 367(12500) 307(15000) Pt(bph)(bpy)(4)
[0123] [0123]
[0124] We synthesized different bis-cycloplatinated complexes in order to investigate their optical properties in different hosts, both polymeric and molecular, and utilize them as dopants in corresponding hosts for organic light-emitting diodes (OLEDs). Usage of the complexes in molecular hosts in OLEDs prepared in the vacuum deposition process requires several conditions to be satisfied. The complexes should be sublimable and stable at the standard deposition conditions (vacuum˜10 −6 torr). They should show emission properties interesting for OLED applications and be able to accept energy from host materials used, such as Alq 3 or NPD. On the other hand, in order to be useful in OLEDs prepared by wet techniques, the complexes should form true solutions in conventional solvents (e.g., CHCl 3 ) with a wide range of concentrations and exhibit both emission and efficient energy transfer from polymeric hosts (e.g., PVK). All these properties of cycloplatinated complexes were tested. In polymeric hosts we observe efficient luminescence from some of the materials.
[0125] Syntheses proceeded as follows:
[0126] 2-(2-thienyl)pyridine. Synthesis is shown in Scheme 2, and was performed according to procedure close to the published one (T.Kauffmann, A.Mitschker, A.Woltermann, Chem.Ber. 1983, 116, 992). For purification of the product, instead of recommended distillation, zonal sublimation was used (145-145-125° C., 2-3 hours). Light brownish white solid (yield 69%). Mass-spec: m/z: 237(18%), 161 (100%, M + ), 91 (71%). 1 H NMR (250 MHZ, DMSO-d 6 ) δ,ppm: 6.22-6.28 (d. of d., 1H), 6.70-6.80 (d. of d., 1H), 6.86-7.03 (m,3H), 7.60-7.65 (m,1H). 13 C NMR (250 MHZ, DMSO-d 6 ): 118.6, 122.3, 125.2, 128.3, 128.4, 137.1, 144.6, 149.4, 151.9.
[0127] 2-(2-thienyl)quinoline. Synthesis is displayed in Scheme 3, and was made according to published procedure (K. E. Chippendale, B.Iddon, H.Suschitzky, J Chem.Soc. 1949, 90, 1871). Purification was made exactly following the literature as neither sublimation nor column chromatography did not give as good results as recrystallizations from (a) petroleum ether, and (b) EtOH-H 2 O (1:1) mixture. Pale yellow solid, gets more yellow with time (yield 84%). Mass-spec: m/z: 217 (32%), 216 (77%), 215 (83%), 214 (78%), 213 (77%), 212 (79%), 211(100%, M + ), 210 (93%), 209 (46%). 1 H NMR (250 MHZ, DMSO-d 6 ) δ,ppm: 7.18-7.24 (d. of d.,1H), 7.48-7.58 (d. of d. of d.,1H), 7.67-7.78 (m,2H), 7.91-7.97 (m,3H), 8.08-8.11 (d,1H), 8.36-8.39 (d,1H).
[0128] 2-(2′-bromophenyl)pyridine. Synthesis was performed according to literature (D. H. Hey, C. J. M. Stirling, G. H. Williams, J.Chem. Soc. 1955, 3963; R. A. Abramovich, J. G. Saha, J. Chem.Soc. 1964, 2175). It is outlined in Scheme 4. Literature on the subject was dedicated to the study of aromatic substitution in different systems, including pyridine, and study of isomeric ratios in the resulting product. Thus in order to resolve isomer mixtures of different substituted phenylpyridines, not 2-(2′-bromophenyl)pyridine, the authors utilized 8 ft.×¼ in. column packed with ethylene glycol succinate (10%) on Chromosorb W at 155° C. and some certain helium inlet pressure. For resolving the reaction mixture we obtained, we used column chromatography with hexanes:THF (1:1) and haxanes:THF:PrOH-1 (4:4:1) mixtures as eluents on silica gel because this solvent mixture gave best results in TLC (three well resolved spots). Only the first spot in the column gave mass spec major peak corresponding to n-(2′-bromophenyl)pyridines (m/z: 233, 235), in the remaining spots this peak was minor. Mass spec of the first fraction: m/z: 235 (97%), 233 (100%,M + ), 154 (86%), 127 (74%). 1 H NMR of the first fraction (250 MHZ, DMSO-d6) δ, ppm: 7.27-7.51 (m,4H), 7.59-7.96 (m,2H), 8.57-8.78 (m,2H).
[0129] Sublimation of the 1st fraction product after column did not lead to disappearance of the peaks of contaminants in 1 H NMR spectrum, and we do not expect the sublimation to lead to resolving the isomers if present.
[0130] 2-phenylpyridine. Was synthesized by literature procedure (J. C. W. Evans, C. F. H. Allen, Org. Synth. Cell. 1943, 2, 517) and is displayed in Scheme 5. Pale yellow oil darkening in the air (yield 48%). 1 H NMR (250 MHZ, DMSO-d 6 ) of the product after vacuum distillation: δ,ppm: 6.70-6.76 (m,1H), 6.92-7.10 (m,3H), 7.27-7.30 (m,1H), 7.36-7.39 (q,1H), 7.60-7.68 (m,2H), 8.16-8.23 (m,1H)).
[0131] 2,2′-diaminobiphenyl. Was prepared by literature method (R. E. Moore, A. Furst, J. Org. Chem. 1958, 23, 1504) (Scheme 6). Pale pink solid (yield 69%). 1 H NMR (250 MHZ, DMSO-d 6 ) δ,ppm: 5.72-5.80 (t. of d.,2H), 5.87-5.93 (d. of d., 2H), 6.03-6.09 (d. of d.,2H), 6.13-6.23 (t. of d.,2H). Mass spec: m/z: 185 (40%), 184 (100%, M + ), 183 (73%), 168 (69%), 167 (87%), 166 (62%), 139 (27%).
[0132] 2,2′-dibromobiphenyl. (Scheme 6) (A. Uehara, J. C. Bailar, Jr., J.Organomet. Chem. 1982, 239,1).
[0133] 2,2′-dibromo-1, 1′-binaphthyl. Was synthesized according to literature (H.Takaya, S. Akutagawa, R.Noyori, Org.Synth. 1989, 67,20) (Scheme 7).
[0134] trans-Dichloro-bis-(diethyl sulfide) platinum (II). Prepared by a published procedure (G. B. Kauffman, D. O. Cowan, Inorg. Synth. 1953, 6, 211) (Scheme 8). Bright yellow solid (yield 78%).
[0135] cis-Dichloro-bis-(diethyl sulfide) platinum (II). Prepared by a published procedure (G. B. Kauffman, D. O. Cowan, Inorg. Synth. 1953, 6, 211). (Scheme 8). Yellow solid (63%).
[0136] Scheme 8: Syntheses of cis- and trans-Dichloro-bis-(diethyl sulfide) platinum (II).
[0137] cis-Bis[2-(2′-thienyl)pyridinato-N, C 5′ platinum (II). Was synthesized according to literature methods (L. Chassot, A. von Zelewsky, Inorg. Chem. 1993, 32, 4585).
[0138] (Scheme 9). Bright red crystals (yield 39%). Mass spec: m/z: 518 (25%), 517 (20%), 516 (81%), 513 (100%,M + ), 514 (87%), 481 (15%), 354 (23%).
[0139] cis-Bis[2-(2′-thienyl)quinolinato-N, C 3 ) platinum (II). Was prepared following published procedures (P. Jolliet, M. Gianini, A. von Zelewsky, G. Bemardinelli, H. Stoeckii-Evans, Inorg. Chem. 1996, 35, 4883). (Scheme 10 ). Dark red solid (yield 21%).
[0140] Absorption spectra were recorded on AVIV Model 14DS-UV-Vis-IR spectrophotometer and corrected for background due to solvent absorption. Emission spectra were recorded on PTI QuantaMaster Model C-60SE spectrometer with 1527 PMT detector and corrected for detector sensitivity inhomogeneity.
[0141] Vacuum deposition experiments were performed using standard high vacuum system (Kurt J.Lesker vacuum chamber) with vacuum ˜10 −6 torr. Quartz plates (ChemGlass Inc.) or borosilicate glass-IndiumTin Oxide plates (ITO, Delta Technologies,Lmtd.), if used as substrates for deposition, were precleaned according to the published procedure for the later (A. Shoustikov, Y. You, P. E. Burrows, M. E. Thomspon, S. R. Forrest, Synth. Met. 1997, 91, 217).
[0142] Thin film spin coating experiments were done with standard spin coater (Specialty Coating Systems, Inc.) with regulatable speed, acceleration speed, and deceleration speed. Most films were spun coat with 4000 RPM speed and maximum acceleration and deceleration for 40 seconds.
[0143] Optical properties of the Pt cyclometalated complexes:
[0144] Table 1: Absorption and emission properties of several cycloplatinated complexes. Reproduced from A. von Zelewsky et. al (Chem. Phys. Lett., 1985, 122, 375 and Helv. Chim. Acta 1988, 71, 1053). Abbreviation explanations are given in Scheme 1.
emission spectra absorption 77K 293K solvent λmax(ε) λmax(τ) λmax(τ) Pt(Phpy) 2 CH 3 CN 402(12800) 491(4.0) — 291(27700) Pt(Thpy) 2 CH 3 CN 418(10500) 570(12.0) 578(2.2) 303(26100) Pt(Bhq) 2 CH 3 CN 421(9200) 492(6.5) — 367(12500) 307(15000) Pt(bph)(bpy)
[0145] [0145]
[0146] Optical Properties in Solution:
[0147] Absorbance spectra of the complexes Pt(thpY) 2 , Pt(thq) 2 and Pt(bph)(bpy) in solution (CHCl 3 or CH 2 Cl 2 ) were normalized and are presented in FIG. 1. Absorption maximum for Pt(phpy) 2 showed a maximum at ca. 400 nm, but because the complex apparently requires further purification, the spectrum is not presented.
[0148] Normalized emission spectra are shown in FIG. 2. Excitation wavelengths for Pt(thpy) 2 , Pt(thq) 2 and Pt(bph)(bpy) are correspondingly 430 nm, 450 nm, and 449 nm (determined by maximum values in their excitation spectra). Pt(thpy) 2 gives strong orange to yellow emission, while Pt(thq) 2 gives two lines at 500 and 620 nm. The emission form these materials is due to efficient phosphorescence. Pt(bph)(bpy) gives blue emission, centered at 470 nm. The emission observed for Pt(bph)(bpy) is most likely due to fluorescence and not phosphorescence.
[0149] Emission lifetimes and quantum yields in solution:
Pt(thPy) 2 : 3.7 μs (CHCl 3 , deoxygenated for 10 min) 0.27 Pt(thq) 2 : 2.6 μs (CHCl 3 , deoxygenated for 10 min) not measured Pt(bph)(bpy): not in μs region (CH 2 O 2 , deoxygenated not measured for 10 min)
[0150] Optical properties in PS solid matrix:
[0151] Pt(thpy) 2 : Emission maximum is at 580 nm (lifetime 6.5 μs) upon excitation at 400 nm. Based on the increased lifetime for the sample in polystyrene we estimate a quantum efficiency in polystyrene for Pt(thpy) 2 of 0.47. Pt(thq) 2 : Emission maximum at 608 nm (lifetime 7.44 μs) upon excitation at 450 nm.
[0152] Optical properties of the complexes in PVK film:
[0153] These measurements were made for Pt(thpy) 2 only. Polyvinylcarbazole (PVK) was excited at 250 nm and energy transfer from PVK to Pt(thpy) 2 was observed (FIG. 3). The best weight PVK:Pt(thpy) 2 ratio for the energy transfer was found to be ca. 100:6.3.
EXAMPLES OF LIGHT EMITTING DIODES
[0154] Example 1
[0155] ITO/PVK:PBD.Pt(thpy) 2 (100:40:2)/Ag:Mg/Ag
[0156] Pt(thpy) 2 does not appear to be stable toward sublimation. In order to test it in an OLED we have fabricated a polymer blended OLED with Pt(thpy) 2 dopant. The optimal doping level was determined by the photoluminescence study described above. The emission from this device comes exclusively from the Pt(thpy) 2 dopant. Typical current-voltage characteristic and light output curve of the device are shown in FIG. 4. Quantum efficiency dependence on applied voltage is demonstrated in FIG. 5. Thus, at 22 V quantum efficiency is ca. 0.11%. The high voltage required to drive this device is a result of the polymer blend OLED structure and not the dopant. Similar device properties were observed for a polymer blend device made with a coumarin dopant in place of Pt(thpy) 2 . In addition, electroluminescence spectrum and CIE diagram are shown in FIG. 6.
[0157] Example 2
[0158] In this example, we describe OLEDs employing the green, electrophosphorescent materialfac tris(2-phenylpyridine) iridium (Ir(ppy) 3 ). This compound has the following formulaic representation:
[0159] The coincidence of a short triplet lifetime and reasonable photolumine scent efficiency allows Ir(ppy) 3 -based OLEDs to achieve peak quantum and power efficiencies of 8.0% (28 cd/A) and ˜30 lm/W respectively. At an applied bias of 4.3V, the luminance reaches 100cd/m 2 and the quantum and power efficiencies are 7.5% (26 cd/A) and 19 lm/W, respectively.
[0160] Organic layers were deposited by high vacuum (10 −6 Torr) thermal evaporation onto a cleaned glass substrate precoated with transparent, conductive indium tin oxide. A 400A thick layer of 4,4′-bis(N-(1 -naphthyl)-N-phenyl-amino) biphenyl (α-NPD) is use d to transport holes to the luminescent layer consisting of Ir(ppy) 3 in CBP. A 200 A thick layer of the electron transport material tris-(8-hydroxyquinoline) aluminum (Alq 3 ) is used to transport electrons into the Ir(ppy) 3 :CBP layer, and to reduce Ir(ppy) 3 luminescence absorption at the cathode. A shadow mask with 1 mm diameter openings was used to define the cathode consisting of a 1000 A thick layer of 25:1 Mg:Ag, with a 500 A thick Ag cap. As previously (O'Brien, et al., App. Phys. Lett. 1999, 74, 442-444), we found that a thin (60 A) barrier layer of 2,9-dimethyl-4,7-diphenyl-1,10-phenanthroline (bathocuproine, or BCP) inserted between the CBP and the A1q 3 was necess ary to confine excitons within the luminescent zone and hence maintain high efficiencies. In O'Brien et al., Appl. Phys. Lett. 1999, 74, 442-444, it was argued that this layer prevents triplets from diffusing outside of the doped region. It was also suggested that CBP may readily transport holes and that BCP may be required to force exciton formation within the luminescent layer. In either case, the use of BCP clearly serves to trap excitons within the luminescent region. The molecular structural formulae of some of the materials used in the OLEDs, along with a proposed energy level diagram, is shown in FIG. 7.
[0161] [0161]FIG. 8 shows the external quantum efficiencies of several Ir(ppy) 3 -based OLEDs. The doped structures exhibit a slow decrease in quantum efficiency with increasing current. Similar to the results for the Alq 3 :PtOEP system the doped devices achieve a maximum efficiency (˜8%) for mass ratios of Ir(ppy) 3 :CBP of approximately 6-8%. Thus, the energy transfer pathway in Ir(ppy) 3 :CBP is likely to be similar to that in PtOEP:Alq 3 (Baldo, et al., Nature, 1998, 395, 151; O'Brien, 1999, op. cit.) i.e. via short range Dexter transfer of triplets from the host. At low Ir(ppy) 3 concentrations, the lumophores often lie beyond the Dexter transfer radius of an excited Alq 3 molecule, while at high concentrations, aggregate quenching is increased. Note that dipole-dipole (Forster) transfer is forbidden for triplet transfer, and in the PtOEP:Alq 3 system direct charge trapping was not found to be significant.
[0162] Example 3
[0163] In addition to the doped device, we fabricated a heterostructure where the luminescent region was a homogeneous film of Ir(Ppy) 3 . The reduction in efficiency (to ˜0.8% ) of neat Ir(ppy) 3 is reflected in the transient decay, which has a lifetime of only ˜100 ns, and deviates significantly from mono-exponential behavior. A 6% Ir(ppy) 3 :CBP device without a BCP barrier layer is also shown together with a 6% Ir(ppy) 3 :Alq 3 device with a BCP barrier layer. Here, very low quantum efficiencies are observed to increase with current. This behavior suggests a saturation of nonradiative sites as excitons migrate into the Alq 3 , either in the luminescent region or adjacent to the cathode.
[0164] Example 4
[0165] In FIG. 9 we plot luminance and power efficiency as a function of voltage for the device of Example 2. The peak power efficiency is ˜30 lm/W with a quantum efficiency of 8%, (28 cd/A). At 100 cd/m 2 , a power efficiency of 191 m/W with a quantum efficiency of 7.5% (26 cd/A) is obtained at a voltage of 4.3V. The transient response of Ir(ppy) 3 in CBP is a mono-exponential phosphorescent decay of ˜500 ns, compared with a measured lifetime (e.g., King, et al., J. Am. Chem. Soc., 1985, 107, 1431-1432) of 2 μs in degassed toluene at room temperature. These lifetimes are short and indicative of strong spin-orbit coupling, and together with the absence of Ir(ppy) 3 , fluorescence in the transient response, we expect that Ir(ppy) 3 possesses strong intersystem crossing from the singlet to the triplet state. Thus all emission originates from the long lived triplet state. Unfortunately, slow triplet relaxation can form a bottleneck in electrophosphorescence and one principal advantage of Ir(ppy) 3 is that it possesses a short triplet lifetime. The phosphorescent bottleneck is thereby substantially loosened. This results in only a gradual decrease in efficiency with increasing current, leading to a maximum luminance of ˜100,000 cd/m 2 .
[0166] Example 5
[0167] In FIG. 10, the emission spectrum and Commission Internationale de L'Eclairage (CIE) coordinates of Ir(ppy) 3 are shown for the highest efficiency device. The peak wavelength is λ=510 nm and the full width at half maximum is 70 nm. The spectrum and CIE coordinates (x=0.27,y=0.63) are independent of current. Even at very high current densities (˜100 mA/cm 2 ) blue emission from CBP is negligible-an indication of complete energy transfer.
[0168] Other techniques known to one of ordinary skill may be used in conjunction with the present invention. For example, the use of LiF cathodes (Hung, et al., Appl. Phys. Lett., 1997, 70, 152-154), shaped substrates (G. Gu, et al., Optics Letters, 1997, 22, 396-398), and novel hole transport materials that result in a reduction in operating voltage or increased quantum efficiency (B. Kippelen, et al., MRS (San Francisco, Spring, 1999) are also applicable to this work. These methods have yielded power efficiencies of ˜20 lm/W in fluorescent small molecule devices (Kippelen, Id.). The quantum efficiency in these devices (Kido and lizumi, App. Phys. Lett., 1998, 73, 2721) at 100 cd/m 2 is typically ≦4.6% (lower than that of the present invention), and hence green-emitting electrophosphorescent devices with power efficiencies of >40 lm/W can be expected. Purely organic materials (Hoshino and Suzuki, Appl. Phys. Lett., 1996, 69, 224-226) may sometimes possess insufficient spin orbit coupling to show strong phosphorescence at room temperature. While one should not rule out the potential of purely organic phosphors, the preferred compounds may be transition metal complexes with aromatic ligands. The transition metal mixes singlet and triplet states, thereby enhancing intersystem crossing and reducing the lifetime of the triplet excited state.
[0169] The present invention is not limited to the emissive molecule of the examples. One of ordinary skill may modify the organic component of the Ir(ppy) 3 (directly below) to obtain desirable properties.
[0170] One may have alkyl substituents or alteration of the atoms of the aromatic structure.
[0171] These molecules, related to Ir(ppy) 3 , can be formed from commercially available ligands. The R groups can be alkyl or aryl and are preferably in the 3, 4, 7 and/or 8 positions on the ligand (for steric reasons). The compounds should give different color emission and may have different carrier transport rates. Thus, the modifications to the basic Ir(ppy) 3 structure in the three molecules can alter emissive properties in desirable ways.
[0172] Other possible emitters are illustrated below, by way of example.
[0173] This molecule is expected to have a blue-shifted emission compared to Ir(Ppy) 3 . R and R′ can independently be alkyl or aryl.
[0174] Organometallic compounds of osmium may also be used in this invention. Examples include the following.
[0175] These osmium complexes will be octahedral with 6d electrons (isoelectronic with the Ir analogs) and may have good intersystem crossing efficiency. R and R′ are independently selected from the group consisting of alkyl and aryl. They are believed to be unreported in the literature.
[0176] Herein, X can be selected from the group consisting of N or P. R and R′ are independently selected from the group alkyl and aryl.
[0177] The molecule of the hole-transporting layer of Example 2 is depicted below.
[0178] The present invention will work with other hole-transporting molecules known by one of ordinary skill to work in hole transporting layers of OLEDs.
[0179] The molecule used as the host in the emissive layer of Example 2 is depicted below.
[0180] The present invention will work with other molecules known by one of ordinary skill to work as hosts of emissive layers of OLEDs. For example, the host material could be a hole-transporting matrix and could be selected from the group consisting of substituted tri-aryl amines and polyvinylcarbazoles.
[0181] The molecule used as the exciton blocking layer of Example 2 is depicted below. The invention will work with other molecules used for the exciton blocking layer, provided they meet the requirements listed in the summary of the invention.
[0182] Molecules which are suitable as components for an exciton blocking layer are not necessarily the same as molecules which are suitable for a hole blocking layer. For example, the ability of a molecule to function as a hole blocker depends on the applied voltage, the higher the applied voltage, the less the hole blocking ability. The ability to block excitons is roughly independent of the applied voltage.
[0183] This invention is further directed to the synthesis and use of certain organometallic molecules of formula L 2 MX which may be doped into a host phase in an emitter layer of an organic light emitting diode. Optionally, the molecules of formula L 2 MX may be used at elevated concentrations or neat in the emitter layer. This invention is further directed to an organic light emitting device comprising an emitter layer comprising a molecule of the formula L 2 MX wherein L and X are inequivalent, bidentate ligands and M is a metal, preferably selected from the third row of the transition elements of the periodic table, and most preferably Ir or Pt, which forms octahedral complexes, and wherein the emitter layer produces an emission which has a maximum at a certain wavelength λ max . The general chemical formula for these molecules which are doped into the host phase is L 2 MX, wherein M is a transition metal ion which forms octahedral complexes, L is a bidentate ligand, and X is a distinct bidentate ligand. Examples of L are 2-(1-naphthyl)benzoxazole)), (2-phenylbenzoxazole), (2-phenylbenzothiazole), (2-phenylbenzothiazole), (7,8-benzoquinoline), coumarin, (thienylpyridine), phenylpyridine, benzothienylpyridine, 3-methoxy-2-phenylpyridine, thienylpyridine, and tolylpyridine. Examples of X are acetylacetonate (“acac”), hexafluoroacetylacetonate, salicylidene, picolinate, and 8-hydroxyquinolinate. Further examples of L and X are given in FIG. 49 and still further examples of L and X may be found in Comprehensive Coordination Chemistry, Volume 2, G. Wilkinson (editor-in-chief), Pergamon Press, especially in chapter 20.1 (beginning at page 715) by M. Calligaris and L. Randaccio and in chapter 20.4 (beginning at page 793) by R. S. Vagg.
[0184] Synthesis of Molecules of Formula L 2 MX
[0185] The compounds of formula L 2 MX can be made according to the reaction:
L 2 M (μ- Cl ) 2 ML 2 +XH→L 2 MX+HCl
[0186] wherein L 2 M(μ-Cl) 2 ML 2 is a chloride bridged dimer with L a bidentate ligand, and M a metal such as Ir; XH is a Bronsted acid which reacts with bridging chloride and serves to introduce a bidentate ligand X, wherein XH can be, for example, acetylacetone, hexafluoroacetylacetone, 2-picolinic acid, or N-methylsalicyclanilide; and L 2 MX has approximate octahedral disposition of the bidentate ligands L, L, and X about M.
[0187] L 2 Ir(μ-Cl) 2 IrL 2 complexes were prepared from IrCl 3 ·nH 2 O and the appropriate ligand by literature procedures (S. Sprouse, K. A. King, P. J. Spellane, R. J. Watts, J. Am. Chem. Soc., 1984, 106, 6647-6653; for general reference: G. A. Carlson, et al., Inorg. Chem., 1993, 32, 4483; B. Schmid, et al., Inorg. Chem., 1993, 33, 9; F. Garces, et al.; Inorg. Chem., 1988, 27, 3464; M. G. Colombo, et al., Inorg. Chem., 1993, 32, 3088; A. Mamo, et al., Inorg. Chem., 1997, 36, 5947; S. Serroni, et al.; J. Am. Chem. Soc., 1994, 116, 9086; A. P. Wilde, et al., J. Phys. Chem., 1991, 95, 629; J. H. van Diemen, et al., Inorg. Chem., 1992, 31, 3518; M. G. Colombo, et al., Inorg. Chem., 1994, 33, 545), as described below.
[0188] Ir(3-MeOppy) 3 . Ir(acac) 3 (0.57 g, 1.17 mmol) and 3-methoxy-2-phenylpyridine (1.3 g, 7.02 mmol) were mixed in 30 ml of glycerol and heated to 200° C. for 24 hrs under N 2 . The resulting mixture was added to 100 ml of 1 M HCl. The precipitate was collected by filtration and purified by column chromatography using CH 2 Cl 2 as the eluent to yield the product as bright yellow solids (0.35 g, 40%). MS (EI): m/z (relative intensity) 745 (M + , 100), 561 (30), 372 (35). Emission spectrum in FIG. 17.
[0189] tpyIrsd. The chloride bridge dimer (tpyIrCl) 2 (0.07 g, 0.06 mmol), salicylidene (0.022 g, 0.16 mmol) and Na 2 CO 3 (0.02 g, 0.09 mmol) were mixed in 10 ml of 1,2-dichloroethane and 2 ml of ethanol. The mixture was refluxed under N 2 for 6 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the solvent evaporated. The excess salicylidene was removed by gentle heating under vacuum.
[0190] The residual solid was redissolved in CH2Cl 2 and the insoluble inorganic materials were removed by filtration. The filtrate was concentrated and column chromatographed using CH 2 Cl 2 as the eluent to yield the product as bright yellow solids (0.07 g, 85%). MS (EI): m/z (relative intensity) 663 (M + , 75), 529 (100), 332 (35). The emission spectrum is in FIG. 18 and the proton NMR spectrum is in FIG. 19.
[0191] thpyIrsd. The chloride bridge dimer (thpyIrCl) 2 (0.21 g, 0.19 mmol) was treated the same way as (tpyIrCl) 2 . Yield: 0.21 g, 84%. MS (EI): m/z (relative intensity) 647 (M + , 100), 513 (30), 486 (15), 434 (20), 324 (25). The emission spectrum is in FIG. 20 and the proton NMR spectrum is in FIG. 21.
[0192] btIrsd. The chloride bridge dimer (btIrCl) 2 (0.05 g, 0.039 mmol) was treated the same way as (tpyIrCl) 2 . Yield: 0.05 g, 86%. MS (El): m/z (relative intensity) 747 (M + , 100), 613 (100), 476 (30), 374 (25), 286 (32). The emission spectrum is in FIG. 22 and the proton NMR spectrum is in FIG. 23.
[0193] Ir(bq) 2 (acac), BQIr. The chloride bridged dimer (Ir(bq) 2 Cl) 2 (0.091 g, 0.078 mmol), acetylacetone (0.021 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: bright yellow solids (yield 91%). 1 H NMR (360 MHz, acetone-d 6 ), ppm: 8.93 (d,2H), 8.47 (d,2H), 7.78 (m,4H), 7.25 (d,2H), 7.15 (d,2H), 6.87 (d,2H), 6.21 (d,2H), 5.70 (s,1H), 1.63 (s,6H). MS, e/z: 648 (M+,80%), 549 (100%). The emission spectrum is in FIG. 24 and the proton NMR spectrum is in FIG. 25.
[0194] Ir(bq) 2 (Facac), BQIrFA. The chloride bridged dimer (Ir(bq) 2 Cl) 2 (0.091 g, 0.078 mmol), hexafluoroacetylacetone (0.025 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: yellow solids (yield 69%). 1 H NMR (360 MHz, acetone-d 6 ), ppm: 8.99 (d,2H), 8.55 (d,2H), 7.86 (m,4H), 7.30 (d,2H), 7.14 (d,2H), 6.97 (d,2H), 6.13 (d,2H), 5.75 (s,1H). MS, e/z: 684 (M+,59%), 549 (100%). Emission spectrum in FIG. 26.
[0195] Ir(thpy) 2 (acac), THPIr. The chloride bridged dimer (Ir(thpy) 2 Cl) 2 (0.082 g, 0.078 mmol), acetylacetone (0.025 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: yellow-orange solid (yield 80%). 1 H NMR (360 MHz, acetone-d 6 ), ppm: 8.34 (d,2H), 7.79 (m,2H), 7.58 (d,2H), 7.21 (d,2H), 7.15 (d,2H), 6.07 (d,2H), 5.28 (s,1H), 1.70 (s,6H). MS, e/z: 612 (M+,89%), 513 (100%). The emission spectrum is in FIG. 27 (noted “THIr”) and the proton NMR spectrum is in FIG. 28.
[0196] Ir(ppy) 2 (acac), PPIr. The chloride bridged dimer (Ir(ppy) 2 Cl) 2 (0.080 g, 0.078 mmol), acetylacetone (0.025 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: yellow solid (yield 87%). 1 H NMR (360 MHz, acetone-d 6 ), ppm: 8.54 (d,2H), 8.06 (d,2H), 7.92 (m,2H), 7.81 (d,2H), 7.35 (d,2H), 6.78 (m,2H), 6.69 (m,2H), 6.20 (d,2H), 5.12 (s,1H), 1.62 (s,6H). MS, e/z: 600 (M+,75%), 501 (100%). The emission spectrum is in FIG. 29 and the proton NMR spectrum is in FIG. 30.
[0197] Ir(bthpy) 2 (acac), BTPIr. The chloride bridged dimer (Ir(bthpy) 2 Cl) 2 (0.103 g, 0.078 mmol), acetylacetone (0.025 g) and sodium carbonate (0.083 g) were mixed in 10 ml of 2-ethoxyethanol. The mixture was refluxed under N 2 for 10 hrs or until no dimer was revealed by TLC. The reaction was then cooled and the yellow precipitate filtered. The product was purified by flash chromatography using dichloromethane. Product: yellow solid (yield 49%). MS, e/z: 712 (M+,66%), 613 (100%). Emission spectrum is in FIG. 31.
[0198] [Ir(ptpy) 2 Cl] 2 . A solution of IrCl 3 ·xH 2 O (1.506g, 5.030 mmol) and 2-(p-tolyl)pyridine (3.509 g, 20.74 mmol) in 2-ethoxyethanol (30 mL) was refluxed for 25 hours. The yellow-green mixture was cooled to room temperature and 20 mL of 1.0 M HCl was added to precipitate the product. The mixture was filtered and washed with 100 mL of 1.0 M HCl followed by 50 mL of methanol then dried. The product was obtained as a yellow powder (1,850 g, 65%).
[0199] [Ir(ppz) 2 Cl] 2 . A solution of IrCl 3 ·xH 2 O (0.904 g, 3.027 mmol) and 1-phenylpyrazole (1.725 g, 11.96 mmol) in 2-ethoxyethanol (30 mL) was refluxed for 21 hours. The gray-green mixture was cooled to room temperature and 20 mL of 1.0 M HCl was added to precipitate the product. The mixture was filtered and washed with 100 mL of 1.0 M HCl followed by 50 mL of methanol then dried. The product was obtained as a light gray powder (1.133 g, 73%).
[0200] [Ir(C6) 2 Cl] 2 . A solution of IrCl 3 ·xH 2 O (0.075 g, 0.251 mmol) and coumarin C6 [3-(2-benzothiazolyl)-7-(diethyl)coumarin] (Aldrich) (0.350 g, 1.00 mmol) in 2-ethoxyethanol (15 mL) was refluxed for 22 hours. The dark red mixture was cooled to room temperature and 20 mL of 1.0 M HCl was added to precipitate the product. The mixture was filtered and washed with 100 mL of 1.0 M HCl followed by 50 mL of methanol. The product was dissolved in and precipitated with methanol. The solid was filtered and washed with methanol until no green emission was observed in the filtrate. The product was obtained as an orange powder (0.0657 g, 28%).
[0201] Ir(ptpy) 2 (acac) (tpylr). A solution of [Ir(ptpy) 2 Cl] 2 (1.705 g, 1.511 mmol), 2,4-pentanedione (3.013 g, 30.08 mmol) and (1.802 g, 17.04 mmol) in 1,2-dichloroethane (60 mL) was refluxed for 40 hours. The yellow-green mixture was cooled to room temperature and the solvent was removed under reduced pressure. The product was taken up in 50 mL of CH 2 Cl 2 and filtered through Celite. The solvent was removed under reduced pressure to yield orange crystals of the product (1.696 g, 89%). The emission spectrum is given in FIG. 32. The results of an x-ray diffraction study of the structure are given in FIG. 33. One sees that the nitrogen atoms of the tpy (“tolyl pyridyl”) groups are in a trans configuration. For the x-ray study, the number of reflections was 4663 and the R factor was 5.4%.
[0202] Ir(C6) 2 (acac) (C6Ir). Two drops of 2,4-pentanedione and an excess of Na 2 CO 3 was added to solution of [Ir(C6) 2 Cl] 2 in CDCl 3 . The tube was heated for 48 hours at 50° C. and then filtered through a short plug of Celite in a Pasteur pipet. The solvent and excess 2,4-pentanedione were removed under reduced pressure to yield the product as an orange solid. Emission of C6 in FIG. 34 and of C6Ir in FIG. 35.
[0203] Ir(ppz) 2 picolinate (PZIrp). A solution of [Ir(ppz) 2 Cl] 2 (0.0545 g, 0.0530 mmol) and picolinic acid (0.0525 g, 0.426 mmol) in CH 2 Cl 2 (15 mL) was refluxed for 16 hours. The light green mixture was cooled to room temperature and the solvent was removed under reduced pressure. The resultant solid was taken up in 10 mL of methanol and a light green solid precipitated from the solution. The supernatant liquid was decanted off and the solid was dissolved in CH 2 Cl 2 and filtered through a short plug of silica. The solvent was removed under reduced pressure to yield light green crystals of the product (0.0075 g, 12%). Emission in FIG. 36.
[0204] 2-(1-naphthyl)benzoxazole, (BZO-Naph). (11.06 g, 101 mmol) of 2-aminophenol was mixed with (15.867 g, 92.2 mmol) of 1-naphthoic acid in the presence of polyphosphoric acid. The mixture was heated and stirred at 240° C. under N 2 for 8 hrs. The mixture was allowed to cool to 100° C., this was followed by addition of water. The insoluble residue was collected by filtration, washed with water then reslurried in an excess of 10% Na 2 CO 3 . The alkaline slurry was filtered and the product washed thoroughly with water and dried under vacuum. The product was purified by vacuum distillation. BP 140° C. /0.3 mmHg. Yield 4.8 g (21%).
[0205] Tetrakis(2-(1-naphthyl)benzoxazoleC 2 , N′)(μ-dichloro)diiridium. ((Ir 2 (BZO-Naph) 4 Cl) 2 ). Iridium trichloride hydrate (0.388 g) was combined with 2-(1-naphthyl)benzoxazole (1.2 g, 4.88 mmol). The mixture was dissolved in 2-ethoxyethanol (30 mL) then refluxed for 24 hrs. The solution was cooled to room temperature, the resulting orange solid product was collected in a centrifuge tube. The dimer was washed with methanol followed by chloroform through four cycles of centrifuge/redispersion cycles. Yield 0.66 g.
[0206] Bis(2-(1-naphthyl)benzoxazole) acetylacetonate, Ir(BZO-Naph) 2 (acac), (BONIr). The chloride bridged dimer (Ir 2 (BZO-Naph) 4 Cl) 2 (0.66 g, 0.46 mmol), acetylacetone (0.185 g) and sodium carbonate (0.2 g) were mixed in 20 ml of dichloroethane. The mixture was refluxed under N 2 for 60 hrs. The reaction was then cooled and the orange/red precipitate was collected in centrifuge tube. The product was washed with water/methanol (1:1) mixture followed by methanol wash through four cycles of centrifuge/redispersion cycles. The orange/red solid product was purified by sublimation. SP 250° C./2×10 −5 torr, yield 0.57 g (80%). The emission spectrum is in FIG. 37 and the proton NMR spectrum is in FIG. 38.
[0207] Bis(2-phenylbenzothiazole) Iridium acetylacetonate (BTIr). 9.8 mmol (0.98 g, 1.0 mL) of 2,4-pentanedione was added to a room-temperature solution of 2.1 mmol 2-phenylbenzothiazole Iridium chloride dimer (2.7 g) in 120 mL of 2-ethoxyethanol. Approximately 1 g of sodium carbonate was added, and the mixture was heated to reflux under nitrogen in an oil bath for several hours. Reaction mixture was cooled to room temperature, and the orange precipitate was filtered off via vacuum. The filtrate was concentrated and methanol was added to precipitate more product. Successive filtrations and precipitations afforded a 75% yield. The emission spectrum is in FIG. 39 and the proton NMR spectrum is in FIG. 40.
[0208] Bis(2-phenylbenzooxazole) Iridium acac (BOIr). 9.8 mmol (0.98 g, 1.0 mL) of 2,4-pentanedione was added to a room-temperature solution of 2.4 mmol 2-phenylbenzoxazole Iridium chloride dimer (3.0 g) in 120 mL of 2-ethoxyethanol. Approximately 1 g of sodium carbonate was added, and the mixture was heated to reflux under nitrogen in an oil bath overnight (˜16 hrs.). Reaction mixture was cooled to room temperature, and the yellow precipitate was filtered off via vacuum. The filtrate was concentrated and methanol was added to precipitate more product. Successive filtrations and precipitations afforded a 60% yield. The emission spectrum is in FIG. 41 and the proton NMR spectrum is in FIG. 42.
[0209] Bis(2-phenylbenzothiazole) Iridium (8-hydroxyquinolate) (BTIrQ). 4.7 mmol (0.68 g) of 8-hydroxyquinoline was added to a room-temperature solution of 0.14 mmol 2-phenylbenzothiazole Iridium chloride dimer (0.19 g) in 20 mL of 2-ethoxyethanol. Approximately 700 mg of sodium carbonate was added, and the mixture was heated to reflux under nitrogen in an oil bath overnight (23 hrs.).
[0210] Reaction mixture was cooled to room temperature, and the red precipitate was filtered off via vacuum. The filtrate was concentrated and methanol was added to precipitate more product. Successive filtrations and precipitations afforded a 57% yield. The emission spectrum is in FIG. 43 and the proton NMR spectrum is in FIG. 44.
[0211] Bis(2-phenylbenzothiazole) Iridium picolinate (BTIrP). 2.14 mmol (0.26 g) of picolinic acid was added to a room-temperature solution of 0.80 mmol 2-phenylbenzothiazole Iridium chloride dimer (1.0 g) in 60 mL of dichloromethane. The mixture was heated to reflux under nitrogen in an oil bath for 8.5 hours. The reaction mixture was cooled to room temperature, and the yellow precipitate was filtered off via vacuum. The filtrate was concentrated and methanol was added to precipitate more product. Successive filtrations and precipitations yielded about 900 mg of impure product. Emission spectrum is in FIG. 45.
[0212] Bis(2-phenylbenzooxazole) Iridium picolinate (BOIrP). 0.52 mmol (0.064 g) of picolinic acid was added to a room-temperature solution of 0.14 mmol 2-phenylbenzoxazole Iridium chloride dimer (0.18 g) in 20 mL of dichloromethane. The mixture was heated to reflux under nitrogen in an oil bath overnight (17.5 hrs.). Reaction mixture was cooled to room temperature, and the yellow precipitate was filtered off via vacuum. The precipitate was dissolved in dichloromethane and transferred to a vial, and the solvent was removed. Emission spectrum is in FIG. 46.
[0213] Comparative emission spectra for different L′ in btIr complexes are shown in FIG. 47.
[0214] These syntheses just discussed have certain advantages over the prior art.
[0215] Compounds of formula PtL 3 cannot be sublimed without decomposition. Obtaining compounds of formula IrL 3 can be problematic. Some ligands react cleanly with Ir(acac) 3 to give the tris complex, but more than half of the ligands we have studied do not react cleanly in the reaction:
3 L+Ir ( acac ) 3 →L 3 Ir+ ( acac ) H;
[0216] typically 30% yield, L=2-phenylpyridine, benzoquinoline, 2-thienylpyridine. A preferred route to Ir complexes can be through the chloride-bridged dimer L 2 M(μ-Cl) 2 ML 2 via the reaction:
4 L +IrCl 3 ·nH 2 O→L 2 M (μ- Cl ) 2 ML 2 +4 HCl
[0217] Although fewer than 10% of the ligands we have studied failed to give the Ir dimer cleanly and in high yield, the conversion of the dimer into the tris complex IrL 3 is problematic working for only a few ligands. L 2 M(μ-Cl) 2 ML 2 +2Ag + +2L→L 3 Ir+2AgCl.
[0218] We have discovered that a far more fruitful approach to preparing phosphorescent complexes is to use chloride bridged dimers to create emitters. The dimer itself does not emit strongly, presumably because of strong self quenching by the adjacent metal (e.g., iridium) atoms. We have found that the chloride ligands can be replaced by a chelating ligand to give a stable, octahedral metal complex through the chemistry:
L 2 M (μ- Cl ) 2 ML 2 +XH→L 2 MX+HCl
[0219] We have extensively studied the system wherein M=iridium. The resultant iridium complexes emit strongly, in most cases with lifetimes of 1-3 microseconds (“μsec”). Such a lifetime is indicative of phosphorescence (see Charles Kittel, Introduction to Solid State Physics). The transition in these materials is a metal ligand charge transfer (“MLCT”).
[0220] In the discussion that follows below, we analyze data of emission spectra and lifetimes of a number of different complexes, all of which can be characterized as L 2 MX (M=Ir), where L is a cyclometallated (bidentate) ligand and X is a bidentate ligand. In nearly every case, the emission in these complexes is based on an MLCT transition between Ir and the L ligand or a mixture of that transition and an intraligand transition. Specific examples are described below. Based on theoretical and spectroscopic studies, the complexes have an octahedral coordination about the metal (for example, for the nitrogen heterocycles of the L ligand, there is a trans disposition in the Ir octahedron). Specifically, in FIG. 11, we give the structure for L 2 IrX, wherein L=2-phenyl pyridine and X=acac, picolinate (from picolinic acid), salicylanilide, or 8-hydroxyquinolinate.
[0221] A slight variation of the synthetic route to make L 2 IrX allows formation of meridianal isomers of formula L 3 Ir. The L 3 Ir complexes that have been disclosed previously all have a facial disposition of the chelating ligands. Herewith, we disclose the formation and use of meridianal L 3 Ir complexes as phosphors in OLEDs. The two structures are shown in FIG. 12.
[0222] The facial L 3 Ir isomers have been prepared by the reaction of L with Ir(acac) 3 in refluxing glycerol as described in equation 2 (below). A preferred route into L 3 Ir complexes is through the chloride bridged dimer (L 2 Ir(μ-Cl) 2 IrL 2 ), equation 3+4 (below). The product of equation 4 is a facial isomer, identical to the one formed from Ir(acac) 3 . The benefit of the latter prep is a better yield of facial-L 3 Ir. If the third ligand is added to the dimer in the presence of base and acetylacetone (no Ag + ), a good yield of the meridianal isomer is obtained. The meridianal isomer does not convert to the facial one on recrystallization, refluxing in coordinating solvents or on sublimation. Two examples of these meridianal complexes have been formed, mer-Irppy and mer-Irbq (FIG. 13); however, we believe that any ligand that gives a stable facial-L 3 Ir can be made into a meridianal form as well.
3 L+Ir ( acac ) 3 →facial - L 3 Ir+acacH (2)
[0223] typically 30% yield, L=2-phenylpyridine, bezoquinoline, 2-thienylpyridine
4 L +IrCl 3 ·nH 2 O→L 2 Ir (μ- Cl ) 2 IrL 2 +4 HCl (3)
[0224] typically>90% yield, see attached spectra for examples of L, also works well for all ligands that work in equation (2)
L 2 Ir (μ- Cl ) 2 IrL 2 +2 Ag + +2 L→ 2 facial - L 3 Ir+ 2 AgCl (4)
[0225] typically 30% yield, only works well for the same ligands that work well for equation (2)
L 2 Ir (μ- Cl ) 2 IrL 2 +XH+Na 2 CO 3 +L→merdianal - L 3 Ir (5)
[0226] typically>80% yield, XH=acetylacetone
[0227] Surprisingly, the photophysics of the meridianal isomers is different from that of the facial forms. This can be seen in the details of the spectra discussed below, which show a marked red shift and broadening in the meridianal isomer relative to its facial counterpart. The emission lines appear as if a red band has been added to the band characteristic of the facial-L 3 Ir. The structure of the meridianal isomer is similar to those of L 2 IrX complexes, with respect, for example, to the arrangement of the N atoms of the ligands about Ir. Specifically, for L=ppy ligands, the nitrogen of the L ligand is trans in both mer-Ir(ppy) 3 and in (ppy) 2 Ir(acac). Further, one of the L ligands for the mer-L 3 Ir complexes has the same coordination as the X ligand of L 2 IrX complexes. In order to illustrate this point a model of mer-Ir(ppy) 3 is shown next to (ppy) 2 Ir(acac) in FIG. 14. One of the ppy ligands of mer-Ir(ppy) 3 is coordinated to the Ir center in the same geometry as the acac ligand of (ppy) 2 Ir(acac).
[0228] The HOMO and LUMO energies of these L 3 Ir molecules are clearly affected by the choice of isomer. These energies are very important is controlling the current-voltage characteristics and lifetimes of OLEDs prepared with these phosphors. The syntheses for the two isomers depicted in FIG. 13 are as follows.
[0229] Syntheses of Meridianal Isomers
[0230] mer-Irbq: 91 mg (0.078 mmol) of [Ir(bq) 2 Cl] 2 dimer, 35.8 mg (0.2 mmol) of 7,8-benzoquinoline, 0.02 ml of acetylacetone (ca. 0.2 mmol) and 83 mg (0.78 mmol) of sodium carbonate were boiled in 12 ml of 2-ethoxyethanol (used as received) for 14 hours in inert atmosphere. Upon cooling yellow-orange precipitate forms and is isolated by filtration and flash chromatography (silica gel, CH 2 Cl 2 ) (yield 72%). 1H NMR (360 MHz, dichloromethane-d2), ppm: 8.31 (q,1H), 8.18 (q,1H), 8.12 (q, 1H), 8.03(m,2H), 7.82 (m, 3H), 7.59 (m,2H), 7.47 (m,2H), 7.40 (d,1H), 7.17 (m,9H), 6.81 (d,1H), 6.57 (d,1H). MS, e/z: 727 (100%, M+). NMR spectrum in FIG. 48.
[0231] mer-Ir(tpy) 3 : A solution of IrCl 3 ·xH 2 O (0.301 g, 1.01 mmol), 2-(p-tolyl)pyridine (1.027 g, 6.069 mmol), 2,4-pentanedione (0.208 g, 2.08 mmol) and Na 2 CO 3 (0.350 g, 3.30 mmol) in 2-ethoxyethanol (30 mL) was refluxed for 65 hours. The yellow-green mixture was cooled to room temperature and 20 mL of 1.0 M HCl was added to precipitate the product. The mixture was filtered and washed with 100 mL of 1.0 M HCl followed by 50 mL of methanol then dried and the solid was dissolved in CH 2 Cl 2 and filtered through a short plug of silica. The solvent was removed under reduced pressure to yield the product as a yellow-orange powder (0.265 g, 38%).
[0232] This invention is further directed toward the use of the above-noted dopants in a host phase. This host phase may be comprised of molecules comprising a carbazole moiety. Molecules which fall within the scope of the invention are included in the following.
[0233] [A line segment denotes possible substitution at any available carbon atom or atoms of the indicated ring by alkyl or aryl groups.]
[0234] An additional preferred molecule with a carbazole functionality is 4,4′-N,N′-dicarbazole-biphenyl (CBP), which has the formula:
[0235] The light emitting device structure that we chose to use is very similar to the standard vacuum deposited one. As an overview, a hole transporting layer (“HTL”) is first deposited onto the ITO (indium tin oxide) coated glass substrate. For the device yielding 12% quantum efficiency, the HTL consisted of 30 nm (300 Å) of NPD. Onto the NPD a thin film of the organometallic compound doped into a host matrix is deposited to form an emitter layer. In the example, the emitter layer was CBP with 12% by weight bis(2-phenylbenzothiazole) iridium acetylacetonate (termed “BTIr”), and the layer thickness was 30 nm (300 Å). A blocking layer is deposited onto the emitter layer. The blocking layer consisted of bathcuproine (“BCP”), and the thickness was 20 nm (200 Å). An electron transport layer is deposited onto the blocking layer. The electron transport layer consisted of Alq 3 of thickness 20 nm. The device is finished by depositing a Mg-Ag electrode onto the electron transporting layer. This was of thickness 100 nm. All of the depositions were carried out at a vacuum less than 5×10 −5 Torr. The devices were tested in air, without packaging.
[0236] When we apply a voltage between the cathode and the anode, holes are injected from ITO to NPD and transported by the NPD layer, while electrons are injected from MgAg to Alq and transported through Alq and BCP. Then holes and electrons are injected into EML and carrier recombination occurs in CBP, the excited states were formed, energy transfer to BTIr occurs, and finally BTIr molecules are excited and decay radiatively.
[0237] As illustrated in FIG. 15, the quantum efficiency of this device is 12% at a current density of about 0.01 mA/cm 2 . Pertinent terms are as follows: ITO is a transparent conducting phase of indium tin oxide which functions as an anode; ITO is a degenerate semiconductor formed by doping a wide band semiconductor; the carrier concentration of the ITO is in excess of 10 9 /cm 3 ; BCP is an exciton blocking and electron transport layer; Alq 3 is an electron injection layer; other hole transport layer materials could be used, for example, TPD, a hole transport layer, can be used.
[0238] BCP functions as an electron transport layer and as an exciton blocking layer, which layer has a thickness of about 10 nm (100 Å). BCP is 2,9-dimethyl-4,7-diphenyl-1,10-phenanthroline (also called bathocuproine) which has the formula:
[0239] The Alq 3 , which functions as an electron injection/electron transport layer has the following formula:
[0240] In general, the doping level is varied to establish the optimum doping level.
[0241] As noted above, fluorescent materials have certain advantages as emitters in devices. If the L ligand that is used. in making the L 2 MX (for example, M=Ir) complex has a high fluorescent quantum efficiency, it is possible to use the strong spin orbit coupling of the Ir metal to efficiently intersystem cross in and out of the triplet states of the ligands. The concept is that the Ir makes the L ligand an efficient phosphorescent center. Using this approach, it is possible to take any fluorescent dye and make an efficient phosphorescent molecule from it (that is, L fluorescent but L 2 MX (M=Ir) phosphorescent).
[0242] As an example, we prepared a L 2 IrX wherein L=coumarin and X=acac. We refer to this as coumarin-6 [“C6Ir”]. The complex gives intense orange emission, whereas coumarin by itself emits green. Both coumarin and C6Ir spectra are given in the Figures.
[0243] Other fluorescent dyes would be expected to show similar spectral shifts. Since the number of fluorescent dyes that have been developed for dye lasers and other applications is quite large, we expect that this approach would lead to a wide range of phosphorescent materials.
[0244] One needs a fluorescent dye with suitable functionality such that it can be metallated by the metal (for example, iridium) to make a 5- or 6-membered metallocycle. All of the L ligands we have studied to date have sp 2 hybridized carbons and heterocyclic N atoms in the ligands, such that one can form a five membered ring on reacting with Ir.
[0245] Potential degradation reactions, involving holes or electrons, can occur in the emitter layer. The resultant oxidation or reduction can alter the emitter, and degrade performance. In order to get the maximum efficiency for phosphor doped OLEDs, it is important to control the holes or electrons which lead to undesirable oxidation or reduction reactions. One way to do this is to trap carriers (holes or electrons) at the phosphorescent dopant. It may be beneficial to trap the carrier at a position remote from the atoms or ligands responsible for the phosphorescence. The carrier that is thus remotely trapped could readily recombine with the opposite carrier either intramolecularly or with the carrier from an adjacent molecule.
[0246] An example of a phosphor designed to trap holes is shown in FIG. 16. The diarylamine group on the salicylanlide group is expected to have a HOMO level 200-300 mV above that of the Ir complex (based on electrochemical measurements), leading to the holes being trapped exclusively at the amine groups. Holes will be readily trapped at the amine, but the emission from this molecule will come from MLCT and intraligand transitions from the Ir(phenylpyridine) system. An electron trapped on this molecule will most likely be in one of the pyridyl ligands. Intramolecular recombination will lead to the formation of an exciton, largely in the Ir(phenylpyridine) system. Since the trapping site is on the X ligand, which is typically not involved extensively in the luminescent process, the presence of the trapping site will not greatly affect the emission energy for the complex. Related molecules can be designed in which electron carriers are trapped remoted to the L 2 Ir system.
[0247] As found in the IrL 3 system, the emission color is strongly affected by the L ligand. This is consistent with the emission involving either MLCT or intraligand transitions. In all of the cases that we have been able to make both the tris complex (i.e., IrL 3 ) and the L 2 IrX complex, the emission spectra are very similar. For example Ir(ppy) 3 and (ppy) 2 Ir(acac) (acronym=PPIr) give strong green emission with a λ max of 510 nm. A similar trend is seen in comparing Ir(BQ) 3 and Ir(thpy) 3 to their L 2 Ir(acac) derivatives, i.e., in some cases, no significant shift in emission between the two complexes.
[0248] However, in other cases, the choice of X ligand affects both the energy of emission and efficiency. Acac and salicylanilide L 2 IrX complexes give very similar spectra. The picolinic acid derivatives that we have prepared thus far show a small blue shift (15 nm) in their emission spectra relative to the acac and salicylanilide complexes of the same ligands. This can be seen in the spectra for BTIr, BTIrsd and BTIrpic. In all three of these complexes we expect that the emission becomes principally form MLCT and Intra-L transitions and the picolinic acid ligands are changing the energies of the metal orbitals and thus affecting the MLCT bands.
[0249] If an X ligand is used whose triplet levels fall lower in energy than the “L 2 Ir” framework, emission from the X ligand can be observed. This is the case for the BTIRQ complex. In this complex the emission intensity is very weak and centered at 650 nm. This was surprising since the emission for the BT ligand based systems are all near 550 nm. The emission in this case is almost completely from Q based transitions. The phosphorescence spectra for heavy metal quinolates (e.g., IrQ 3 or PtQ 2 ) are centered at 650 nm. The complexes themselves emit with very low efficiency, <0.01. Both the energy and efficiency of the L 2 IrQ material is consistent “X” based emission. If the emission from the X ligand or the “IrX” system were efficient this could have been a good red emitter. It is important to note that while all of the examples listed here are strong “L” emitters, this does not preclude a good phosphor from being formed from “X” based emission.
[0250] The wrong choice of X ligand can also severally quench the emission from L 2 IrX complexes. Both hexafluoro-acac and diphenyl-acac complexes give either very weak emission of no emission at all when used as the X ligand in L 2 IrX complexes. The reasons why these ligands quench emission so strong are not at all clear, one of these ligands is more electron withdrawing than acac and the other more electron donating. We give the spectrum for BQIrFA in the Figures. The emission spectrum for this complex is slightly shifted from BQIr, as expected for the much stronger electron withdrawing nature of the hexafluoroacac ligand. The emission intensity from BQIrFA is at least 2 orders of magnitude weaker than BQIr. We have not explored the complexes of these ligands due to this severe quenching problem.
[0251] CBP was used in the device described herein. The invention will work with other hole-transporting molecules known by one of ordinary skill to work in hole transporting layers of OLEDs. Specifically, the invention will work with other molecules comprising a carbazole functionality, or an analogous aryl amine functionality.
[0252] The OLED of the present invention may be used in substantially any type of device which is comprised of an OLED, for example, in OLEDs that are incorporated into a larger display, a vehicle, a computer, a television, a printer, a large area wall, theater or stadium screen, a billboard or a sign. | Organic light emitting devices are described wherein the emissive layer comprises a host material containing an emissive molecule, which molecule is adapted to luminesce when a voltage is applied across the heterostructure, and the emissive molecule is selected from the group of phosphorescent organometallic complexes, including cyclometallated platinum, iridium and osmium complexes. The organic light emitting devices optionally contain an exciton blocking layer. Furthermore, improved electroluminescent efficiency in organic light emitting devices is obtained with an emitter layer comprising organometallic complexes of transition metals of formula L 2 MX, wherein L and X are distinct bidentate ligands. Compounds of this formula can be synthesized more facilely than in previous approaches and synthetic options allow insertion of fluorescent molecules into a phosphorescent complex, ligands to fine tune the color of emission, and ligands to trap carriers. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Application No. PCT/EP02/11502, filed 15 Oct. 2002 and published as WO03/035414 in the French language on May 1, 2003, and which claims priority to French National Application NO.: 01/13624 filed 18 Oct. 2001.
BACKGROUND OF THE INVENTION
[0002] The object of the invention is a method of estimating the temperature of the air in the internal cavity of a tire whilst running and the application of this method to the detection of an abnormal operating of a tire and a running-flat system.
[0003] It is known that temperature is an important parameter for the operating of rubber objects because of the appreciable variations in the physical and mechanical properties of these objects according to this temperature. With regard to tires, the temperature of the air in the internal cavity defined by the wheel and the tire is an important indicator of the operating conditions of the tire. It is in addition not always very easy to measure this temperature whilst running and a requirement exists to be able to estimate it reliably.
SUMMARY OF THE INVENTION
[0004] The object of the invention is a method of estimating the temperature of the air in the internal cavity of a tire in which:
prior to normal operation, a series of running tests are carried out on the tire provided with a means of measuring the temperature of the air in the cavity at given speeds V and external temperatures T amb , the tire supporting a given load and the cavity being at a given internal relative pressure, and an adjustment is made to a function giving the temperature of the internal air T ai according to the parameters of speed and external temperature:
T ai =F ( V,T amb );
in normal operation, the tire equipping a vehicle under the above conditions of load and relative pressure in the cavity, the temperature of the internal air in the cavity is estimated according to the speed of the vehicle and the temperature external to the vehicle.
[0007] By way of preferential example, the internal temperature T ai can be given by:
T ai , n = T SS - ( T SS - T ai , n - 1 ) exp ( 4 τ ( t n - t n - 1 ) )
with: T ai,n , internal temperature estimated at time t n ; T ai,n-1 , internal temperature estimated at time t n-1 ; T SS , internal temperature at thermal equilibrium under the given test conditions; τ, adjustment coefficient; and
T SS =( a+bT amb ) V (c+T amb d)+ T amb
where a, b, c and d are adjustment coefficients.
[0008] It is advantageous to carry out the running tests under conditions such that the relative pressure in the cavity corresponds, when cold, to the normal relative pressure of the tire.
[0009] Such estimation could in particular be useful in the case of the operating of systems for running flat. In this case, it is advantageous to carry out the running tests under conditions of running flat, that is to say with a substantially zero relative pressure in the tire cavity.
[0010] The above method of estimating the temperature of the air in the internal cavity of a tire when running may have many applications. Amongst these the detection of abnormal operating of a tire under running conditions, normal or running flat, is particularly advantageous.
[0011] It is known that the reduction in relative pressure of a tire may be abrupt, for example following a burst, or very slow, for example after a puncture, but in all cases there is a risk of accident through loss of control of the vehicle steering. So-called “running-flat” devices have been conceived, which generally comprise an annular safety support mounted inside the tire in order to limit the sagging of the latter and possibly to prevent the phenomenon of unwedging, that is to say the movement of a tire bead towards the inside of the rim, which causes the tire to come off the rim.
[0012] Such a device is described, for example, in the patents WO 94/13498 and EP 0 796 747 (Michelin et Cie).
[0013] Tires have also been conceived whose structure, in particular of the sidewalls, is strongly reinforced to enable them to run at low relative pressure or at zero relative pressure. One example of such tires, known as “self-supporting”, is given in the patent U.S. Pat. No. 6,026,878.
[0014] Paradoxically, these modern running-flat devices are so effective that the driver does not easily perceive the drop in relative pressure of one of the tires on his vehicle. These systems must therefore comprise apparatus for measuring the relative pressure of the tires, whose essential function is to warm the driver as soon as the relative pressure in a tire drops below a predetermined threshold.
[0015] These systems for running flat, based on the use of means of supporting the tire tread in the event of deflation of the cover disposed in or outside the tire currently allow running, according to the tire manufacturers, under running-flat conditions at limited speed (around 80 km/hour at a maximum) and for a distance which is also limited (around 200 km).
[0016] These range values are values determined under very severe conditions in order to guarantee the safety of the users when running flat. It may however be useful to supplement these average values by informing the driver of a vehicle of abnormal operating of a running-flat system.
[0017] The object of the invention is a method of detecting abnormal operating of a running-flat system equipping a vehicle, the system comprising, for each wheel, a tire forming with the wheel a cavity, a means of detecting the internal temperature of the cavity, a means of estimating this internal temperature of the cavity and means for generating and transmitting an alarm. This method is such that, in normal operation:
the internal temperature T n in the cavity is measured periodically; the internal temperature T ai is estimated periodically; the measured temperature and the estimated temperature are compared; and an alarm is triggered when the result of this comparison is higher than a given threshold.
[0022] According to a simple embodiment, the internal temperature is measured according to the speed V of the vehicle and the temperature T amb external to the vehicle:
T ai =F ( V,T amb )
[0023] The function F is preferably determined from a series of running-flat tests on the tire at given speeds V and external temperatures T amb , the tire supporting a load equal to its normal maximum load and the cavity being substantially at zero relative pressure.
[0024] This series of tests therefore takes place under the most severe conditions expected for the tire with regard to the load and relative pressure within the cavity of the tire. For this purpose, the inflation valve can for example be removed.
[0025] An example of the function F may be:
T ai , n = T SS - ( T SS - T ai , n - 1 ) exp ( 4 τ ( t n - t n - 1 ) )
with: T ai,n , internal temperature estimated at time t n ; T ai,n-1 , internal temperature estimated at time t n-1 ; T SS , internal temperature at thermal equilibrium under the given test conditions; τ, adjustment coefficient; and
T SS =( a+bT amb ) V (c+T amb d) T amb
where a, b, c and d are adjustment coefficients.
[0026] The estimation of the internal temperature may in addition use the value of the load Q supported by the tire. The tests for determining the corresponding function F then include this load Q as an additional parameter for the test. This substantially improves the accuracy of the estimation of the temperature of the internal air in the tire cavity.
[0027] It is also possible to use in addition the value of the relative inflation pressure P of the tire. The tests for determining the function F then also include this parameter P.
[0028] According to the method according to the invention, an alarm can be triggered as soon as the estimated temperature T ai exceeds the measured temperature T n by a given threshold. This threshold can be around 10 degrees Celsius.
[0029] The method according to the invention makes it possible to warn the driver as soon as the running-flat system used is not operating under the conditions provided for by the tire manufacturer. This may for example occur when the vehicle is very overloaded or when, for any reason, the quantity of lubricant present in the cavity for facilitating the flat running is not correct, or when, following a repair for example, the internal surface of the tire has its properties modified by a repair solution etc.
[0030] This method also makes it possible to warn the driver at the end of the normal service life of the running-flat system. Under these circumstances, at the end of the service life, a marked increase in the temperature of the internal air in the cavity is often observed. This heating becomes significant and can be interpreted unambiguously by monitoring the measured and estimated temperatures. The fact that the measured temperature substantially exceeds the estimated temperature, under stable running conditions, can be interpreted as a degradation in the operating of the running-flat system, information which must then be transmitted to the driver of the vehicle without delay.
[0031] The system preferably also comprises a warning device for the deflation of the cavity and the method of detecting abnormal operating according to the invention is triggered as from the time that this warning device has detected a predetermined deflation threshold.
[0032] The tire is preferably provided with structural reinforcement means. These can be a safety support externally disposed radially relative to the wheel rim and intended to support the tire tread in the event of relative inflation pressure.
[0033] They can also be inserted in the tire structure.
[0034] Another object of the invention is a device for detecting abnormal operating of a running-flat system intended to equip a vehicle, the system comprising, for each wheel, a tire forming a cavity with the said wheel and comprising:
a means of measuring the internal temperature in the cavity, a means of estimating the internal temperature, a means of comparison between the measured internal temperature and the estimated internal temperature, and means for generating an alarm and transmitting it to the driver.
[0039] This device is adapted for generating an alarm in normal operation when the result of the said comparison satisfies a given relationship.
[0040] Another object of the invention is a similar method applied to a tire intended to equip a vehicle. In this application, as before, it is possible to estimate the internal temperature according to the speed of the vehicle and the temperature external to the vehicle.
[0041] Likewise, prior to normal operation, the function F is determined from a series of running tests on the tire at given speeds V and external temperatures T amb , the tire supporting a load corresponding to the normal maximum load and the cavity being, when cold, at an internal relative pressure corresponding to the normal relative pressure.
[0042] This method thus has the advantage of indicating abnormal operating related to excessive heating of the internal cavity of the tire and the prior tests are indeed carried out at recommended normal inflation relative pressures rather than at pressures close to zero relative pressures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] The methods and devices according to the invention will now be described further, taking as an example the application to the detection of abnormal operating of a running-flat system, with the help of the accompanying drawing, in which:
[0044] FIG. 1 is a side view of a safety support;
[0045] FIG. 2 is an axial section of the support in FIG. 1 mounted on a wheel rim and in abutment against a tire;
[0046] FIG. 3 is a section AA as indicated in FIG. 1 of a safety support;
[0047] FIG. 4 presents the installation of a warning device on a wheel;
[0048] FIG. 5 presents a diagram for the installation of a device according to the invention in a vehicle;
[0049] FIG. 6 presents the change in internal temperature of a PAX system when running flat;
[0050] FIG. 7 presents the changes in internal temperature of a PAX system during analytical tests under various conditions;
[0051] FIG. 8 presents a comparison between measured and estimated internal temperature during a test of a PAX system when running flat;
[0052] FIG. 9 presents a comparison between the changes in measured and estimated internal temperatures during analytical running;
[0053] FIG. 10 presents a comparison between the changes in measured and estimated internal temperatures during analytical running similar to that in FIG. 4 with a smaller quantity of lubrication gel;
[0054] FIG. 11 is similar to FIG. 9 during analytical running with an even smaller quantity of lubrication gel; and
[0055] FIG. 12 presents a simplified diagram of an example of the method of detecting abnormal operating of a running-flat system.
DETAILED DESCRIPTION
[0056] All the tests described below were carried out on a Renault “Scenic” vehicle equipped with a “PAX” running-flat system from Michelin comprising a rubber safety support.
[0057] FIGS. 1 to 4 illustrate the PAX running-flat system. This system comprises a tire 1 ( FIG. 2 ), a wheel 2 ( FIGS. 2 and 4 ), a safety support 3 FIGS. 1, 2 and 3 ) and a device for warning of the deflation of the internal cavity defined by the tire and wheel with, for each wheel, a wheel module 4 disposed in the internal cavity 5 of the tire ( FIG. 4 );
[0058] The tire 1 comprises two beads 11 , two sidewalls 12 , and a tread 13 . This tire 1 is described in particular in the patent application WO 00/41902. The size used in the tests is 195-620R420 Spaicity. The tire 1 is adapted to be mounted on a wheel 2 with a disc 21 ( FIG. 4 ) and a rim 22 ( FIG. 2 ). The rim 22 comprises two seats 23 , a mounting groove 24 and a support surface 25 for the safety support. The wheel 2 used in the test is illustrated in FIG. 4 . The rim of this wheel has a support surface 25 for the safety support 3 with a circumferential lightening groove 26 as presented in the patent application WO 00/5083. As illustrated by FIGS. 2 and 4 , the wheel module 4 is placed in the mounting groove 24 and fixed by a rigid band 41 surrounding this mounting groove 24 . The wheel module used is a SmarTire Generation I. This module includes a pressure sensor and a temperature sensor. It is this module which was used in all the tests for measuring the internal temperature in the cavity 5 .
[0059] FIG. 1 presents a side view of the safety support 3 of the PAX system. This support comprises essentially three parts: a base 31 , annular in shape overall, a top 32 , substantially annular, with, on its radially external wall (optionally), longitudinal grooves 33 and an annular body 34 for connection between the base 31 and the top 32 . FIG. 3 presents a particular embodiment of the annular body 34 as used in the tests. FIG. 3 is a section AA as presented in FIG. 1 . The annular body 34 is circumferentially continuous. It comprises partitions 35 extending on each side of the support with a substantially circumferentially oriented central part 36 . The partitions 35 are inclined at an angle α relative to the circumferential direction. This angle is close to 80 degrees. The partitions are thus close to an axial orientation. The partitions 35 are connected together in an alternating fashion by circumferentially oriented connections 37 . Such a safety support is described in the patent application WO 00/76791 (the embodiment in FIG. 5 of this application). The characteristics of the safety supports used are: 115-420(45); 115 is the width of the support, 420 the nominal diameter of the corresponding tire and rim and 45 the height of the support; all these dimensions are in millimeters. These supports are essentially produced from rubber material.
[0060] FIG. 2 illustrates the operating of the PAX system during running flat. When the pressure of the air in the internal cavity decreases greatly and approaches atmospheric pressure, the tread comes into abutment against the radially external wall of the safety support and it is this safety support which will progressively support an increasing proportion of the load applied to the wheel. It is then said that the running is “flat running”. When the pressure in the internal cavity becomes identical to atmospheric pressure, it is said that the “relative pressure” in the internal cavity is zero.
[0061] This figure illustrates clearly that, in running-flat condition, friction is observed between the tire tread and the top of the safety support. This friction is liable to cause significant heating. To control this heating, a lubrication gel is usually included in the internal cavity of the tire. This lubrication gel can be disposed on the surface of the top of the safety support or in adapted reservoirs such as the one disclosed by the application WO 01/28789.
[0062] FIG. 5 presents a scheme for installing the device according to the invention in a vehicle 6 . The vehicle 6 comprises four tires 1 . The vehicle is equipped with a tire deflation warning device. This warning device comprises a wheel module 4 disposed in each tire/wheel assembly on the vehicle, a central unit 41 disposed in the chassis of the vehicle 6 and a display 42 disposed in the vehicle cabin. The wheel modules are disposed in the tire/wheel assemblies of the vehicle so as to be in contact with the internal cavity 5 of the tires (see FIGS. 2 and 4 ). These modules comprise in particular pressure and temperature sensors. The wheel modules 4 and the central unit 41 are equipped with data transmission means such as radio transceivers and their associated antennae. These radio transceivers permit the transfer of the data measured by the temperature and pressure sensors included in the wheel modules 4 to the central unit 41 . The central unit 41 comprises means of processing the data received, such as a microcomputer. This computer is programmed to identify the origin of the radio signals transmitted by the wheel modules, to store the pressure and temperature values received, to process them, to generate alarms if necessary and to transmit them to the display 42 so that they are brought to the knowledge of the driver of the vehicle. In the case of the device according to the invention, the central unit is also connected to the vehicle odometer and to an external temperature sensor disposed on the vehicle chassis. It thus regularly receives the values of the vehicle speed V and temperature T external to the vehicle.
[0063] FIG. 6 presents a conventional change in the temperature of the air in the internal cavity of the tire or “internal temperature” during a running-flat test on the test run under very severe conditions. The graph presents the change in the temperature T n as a function of the duration of the test t. After high initial heating, around 80 degrees Celsius, the temperature stabilizes. At the end of the test, a strong rise in the temperature is once again noted, which testifies to irreversible damage to the safety support. The support is then no longer in a state to fulfill its functions.
[0064] In order to be able to empirically determine the temperature of the internal air in the cavity of the tire under running-flat conditions, a series of analytical tests were carried out on the test run at variable applied speeds V, external temperatures T amb and loads Q. FIG. 7 illustrates the results obtained. On the X-axis, the graph presents the duration of the test and on the Y-axis the measured difference between the internal temperature in the cavity and the external temperature: T n −T amb .
[0065] The tests were carried out until the thermal stabilization temperature T SS of the internal air was reached and were then stopped. High heating is therefore observed as illustrated in FIG. 6 , and then a stabilized temperature phase followed by a decrease. All the results obtained at a maximum applied load Q can be modeled thus:
T SS =( a+bT amb ) V (c+T amb d) +T amb
with: T SS internal temperature at thermal equilibrium under the given test conditions, T amb , temperature outside the tire, V, running speed and a, b, c and d adjustment coefficients.
[0066] For the PAX system tested, the values of the coefficients are as follows:
[0000] a=11.9734° C.hr/km, b=−0.03152 hr/km, c=0.4852 and d≈0.
[0000] (hr is the abbreviation of hour, km of kilometer, ° C. of degrees Celsius).
[0067] It is thus possible to estimate the temperature of the internal air during transient heating and cooling phases by means of the equation:
T ai , n = T SS - ( T SS - T ai , n - 1 ) exp ( 4 τ ( t n - t n - 1 ) )
with: T ai,n , estimated internal temperature at time t n ; T ai,n-1 estimated internal temperature at time t n-1 ; τ, adjustment coefficient.
[0068] The coefficient τ characterizes principally the time necessary for obtaining thermal equilibrium and has the value:
τ=40 min when T SS >T ai,n
τ=130 min when T SS <T ai,n
(min being the abbreviation of minute).
[0069] It should be noted that thermal equilibrium takes appreciably longer to achieve during cooling than during heating.
[0070] FIG. 8 presents the changes in the estimated and measured temperatures during running-flat tests of long duration. On the X-axis is the distance traveled, on the Y-axis the temperatures T n (measured) and T ai,n (estimated). The total length traveled by the vehicle is around 750 km. It should be noted that the estimated temperatures are practically routinely substantially higher than the measured temperatures. This is related principally to the fact that the tests taken into account for establishing the empirical model are tests carried out at the maximum load Q for the tire in question, whilst the running tests were carried out at variable loads. Another reason may also be the inaccuracy of the temperature measurement sensor.
[0071] It is of course possible to improve the accuracy of the estimation of the internal temperature by taking account of the actual load applied to the tire during analytical tests, but also during running-flat tests.
[0072] The simplified model does however have a very important application in terms of operating safety; it makes it possible to check at all times that the operating of the running-flat system, here the PAX system, is normal.
[0073] FIG. 12 presents a simplified diagram of the method of detecting abnormal operating of a running-flat system. As soon as the vehicle is started, the deflation warning device periodically measures, for each tire, the relative pressure and the temperature of the internal air in this cavity. The central unit receives and processes the data received and triggers appropriate alarms to the driver. As soon as, for one of the tires, the relative pressure becomes lower than a given threshold, for example 0.7 bar, this means that, for this tire, the tread is beginning to come into contact with the safety support, and these are then running-flat conditions. The central unit then initiates the method of detecting abnormal operating of this running-flat system. For this purpose, it periodically receives the values of internal temperature T n , vehicle speed V and external temperature T amb . Periodically, the central unit 41 calculates an estimate of the internal temperature T ai,n and compares this estimate to the measured value T n :
T n −T ai,n
[0074] If the result of the comparison is greater than 10 degrees Celsius, the central unit generates an alarm and transmits it to the display 42 so that it is brought to the knowledge of the driver of the vehicle.
[0075] When such a difference is recorded, it is necessary to warn the driver of the vehicle that the running-flat system is no longer operating normally and that it is necessary for him to reduce his speed very substantially, or even to stop quickly.
[0076] A concrete example of an application of this method of detecting abnormal operating of the running-flat system is now described with the help of the three FIGS. 9 to 11 .
[0077] FIG. 9 presents the change in the internal temperature when running under normal operating conditions of a PAX system, that is to say with in particular 25 grams of silicone lubricant introduced into the internal cavity before the test. It can be seen as before that the estimated temperature is substantially greater than the measured temperature.
[0078] FIG. 10 presents the result of a similar test in which the quantity of lubrication gel inside the cavity has been reduced to 15 grams instead of 25. In this case it can be seen that, at the end of 3000 seconds, the measured temperature exhibits significant heating and an alarm is very rapidly triggered.
[0079] FIG. 11 is a test similar to the two previous ones in which the quantity of lubrication gel is reduced further to 7.5 grams instead of 25 and 15. In this case, it can be seen that the measured temperature is always greater than the estimated temperature and the alert threshold is passed after 200 seconds of test.
[0080] These results fully show the advantage of the method of detecting abnormal operating of a running-flat system according to the invention. It is in fact necessary, for normal safety reasons, to be able to detect such an abnormal operating as soon as possible. Such an abnormal operating may be related to an overloading of the tire, to a very significant puncture hole, which could reduce the quantity of lubrication gel present in the internal cavity of the cover, or to an excessively long duration of flat running, not following the recommendations of the manufacturers of the system. This detection method is of course limited to the detection of abnormal operating which give rise to a substantial increase in the friction conditions between the safety support and the tire tread and thus a substantial increase in the internal temperature of the internal air.
[0081] The invention has been described in terms of preferred principles, embodiments, and structures for the purposes of description and illustration. Those skilled in the art will understand that substitutions may be made and equivalents found without departing, from the scope of the invention as defined by the appended claims. | A method of estimating the temperature of the air in the internal cavity of a tire in which:
prior to normal operation, a series of running tests are carried out on the tire provided with a means of measuring the internal air temperature at given speeds V and external temperatures T amb , the tire supporting a given load and the cavity being at a given internal relative pressure, and an adjustment is made to a function giving the temperature of the internal air T ai according to the parameters of speed and external temperature; and in normal operation, the tire equipping a vehicle under the above conditions of load and relative pressure, the internal air temperature is estimated according to the speed of the vehicle and the temperature external to the vehicle. The method ia applied to the detection of abnormal operating in particular of a running-flat system. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a sliding member having a sliding surface composed of a resin composition, which sliding member excellent in friction properties, particularly excellent in cavitation resistance.
In the case of a sliding member used in a site in which the pressure fluctuation is severe as in a shock absorber, a diesel engine or the like, it has been considered that the use of a composition excellent in cavitation resistance makes it possible to protect the sliding member from being eroded by cavitation. Sliding members improved in cavitation resistance are disclosed in Japanese Patent Application Kokai No. 58-28,016 (JP-A 58(1983)-28,016), which describes a multilayer sliding member in which a composition composed of 0.1 to 50% by volume, based on the volume of the composition, of a tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer resin (referred to hereinafter as PFA) and the balance which is substantially a polytetrafluoroethylene (referred to hereinafter as PTFE) is coated on the surface of a metal layer backed with a backing metal.
However, the above multilayer sliding member is not satisfactory in friction properties. In particular, not only the friction coefficient thereof at the time of driving is not sufficiently small, but also, when it is used as a bearing for a rotating shaft, the starting friction coefficient thereof at the time of starting is not sufficiently small and when it is used as a reciprocating sliding member such as shock absorber or the like, the friction coefficient thereof where the reciprocating motion is turned at both ends of the motion is also not sufficiently small. Therefore, a further improvement of said friction coefficient has been desired.
The present inventors have found by trial and error that the friction properties are improved by increasing the molecular weight of PTFE to 5,000,000 or more, whereas the molecular weight of the conventional PTFE was about 3,000,000.
SUMMARY OF THE INVENTION
An object of this invention is to provide a sliding member which is excellent in friction properties as well as cavitation resistance.
Another object of this invention is to provide a sliding member having a sliding surface composed of a resin composition comprising a PTFE having a molecular weight of at least 5,000,000.
A further object of this invention is to provide a multilayer sliding member excellent in friction properties in which a low friction resin composition comprising a PTFE having a molecular weight of at least 5,000,000 is coated on the surface of a metal layer backed with a backing metal.
Other objects and advantages of this invention will become apparent from the following description.
According to this invention, there is provided a sliding member having a sliding surface composed of a resin composition comprising a tetrafluoroethyleneperfluoroalkyl vinyl ether copolymer resin and a polytetrafluoroethylene having a molecular weight of 5,000,000 to 15,000,000, wherein the proportion of the tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer resin is 1 to 50% by volume based on the volume of the resin composition.
This invention also provides a multilayer sliding member in which the above resin composition is coated on the surface of a metal layer backed with a backing metal.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a graph showing the relation between the proportion (% by volume) of PFA in the resin composition of which the sliding surface of a sliding member is composed and the resistance value of the sliding member in a reciprocating sliding test.
FIG. 2 is a graph showing the relation between the proportion (% by volume) of graphite in the resin composition and the resistance value of a sliding member in the reciprocating sliding test.
FIG. 3 is a graph showing the relation between the molecular weight of PTFE in the resin composition and the resistance value of a sliding member in the reciprocating sliding test.
DETAILED DESCRIPTION OF THE INVENTION
The sliding member of this invention has a sliding surface composed of a resin composition which comprises a PFA and a PTFE having a molecular weight of 5,000,000 to 15,000,000, the proportion of the PFA being 1 to 50% by volume, based on the volume of the resin composition.
The PFA is superior in bonding strength to PTFE to other fluoroplastics and when the proportion of PFA is less than 1% by volume, the addition effect thereof is insignificant and the desired friction properties and cavitation resistance are not obtained. On the other hand, when the proportion of PFA is more than 50% by volume, PFA becomes the main constituent and the desired friction properties are deteriorated though the cavitation resistance is enhanced. Therefore, it is necessary that the proportion of PFA should be 1 to 50% by volume based on the volume of the resin composition.
The PTFE has a molecular weight of 5,000,000 to 15,000,000. When the molecular weight is less than 5,000,000 or more than 15,000,000, the enhancement of friction properties is not desired. In particular, a PTFE having a molecular weight of 6,000,000 to 10,000,000 is preferred because the friction properties become excellent. In this invention, the friction properties are further improved by adding to the above resin composition 0.5 to 10% by volume of a solid lubricant based on the volume of the resin composition.
The solid lubricant includes carbon type solid lubricants such as graphite, graphite fluoride, carbon and the like; metal lubricants each consisting of a metal such as Pb, Sn, Cu, Zn or the like or an alloy thereof; metal fluorides such as PbF 2 , AlF 3 , CaF 2 and the like. The carbon type solid lubricants are preferable and graphite per se is particularly preferable.
When the amount of the solid lubricant is less than 0.5% by volume, no addition effect thereof is obtained. When the amount is more than 10% by volume, the friction properties are rather gradually deteriorated as the amount increases. Hence, it is necessary that the amount of the solid lubricant should be 0.5 to 10% by volume. In particular, an amount of the solid lubricant of 0.5 to 7.5% by volume is desirable because the friction properties are better. When the sliding member is used in a lubricating oil and exfoliated graphite is added as the solid lubricant to the resin composition, the excellent oil-retainability thereof further enhances the friction properties. It is preferable that the exfoliated graphite has a larger oil-absorption; however, when the oilabsorption is more than 150 ml/100 g, the particle size of the graphite becomes too large, and hence, the dispersibility of the graphite becomes low. Therefore, the oil-absorption of the graphite is preferably 80 ml to 150 ml per 100 g of the graphite.
The sliding member of this invention has a sliding surface composed of the above-mentioned resin composition, and may be composed of the resin composition alone or may be prepared by coating the resin composition on the surface of a metal layer backed with a backing metal. When the resin composition is coated on the surface of the metal layer backed with a backing metal, a multilayer sliding member is obtained which is suitable to, for example, a shock absorber. In the case of the multilayer sliding member, it is possible to form a porous metal layer on the surface of a backing metal and impregnate and coat the porous surface with the resin composition to form the multilayer sliding member. In this sliding member, as the backing metal, copper-plated steel is mainly used. However, the steel may be replaced by another metal and the copper-plating may be replaced by a copper-alloy-plating or another metal-plating. An unplated metal may also be used as the backing metal. The porous metal layer may be composed of a copper alloy such as bronze or the like or another metal or alloy and can be formed by sintering a copper alloy powder or another metal or alloy powder on the backing metal.
As explained above, according to this invention, there can be obtained a sliding member excellent in cavitation resistance and friction properties from the resin composition. According to this invention, a multilayer sliding member excellent in cavitation resistance and friction properties can also be obtained by coating the resin composition on the surface of a metal layer backed with a backing metal.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Examples of this invention are compared with Comparative Examples to explain this invention in more detail hereinafter. For knowing the effect of this invention, test pieces for Examples and Comparative Examples were prepared and subjected to a cavitation test, a friction test and a reciprocating sliding test. The test samples for Examples and Comparative Examples were prepared by spreading a lead-bronze powder in a thickness of 0.3 mm on a copper-plated steel backing having a thickness of 1.7 mm, sintering the powder to form a porous lead-bronze layer, coating a sliding resin composition on the surface of the porous lead-bronze layer, pressing the resulting assembly between rolls to impregnate and coat the porous lead-bronze layer with the resin composition, baking the resulting assembly at a temperature of 350 to 400° C. in a reducing atmosphere and then passing the assembly between rolls to make the thickness uniform.
In the above sliding resin composition, there were used AD1 (a trade name of Asahi Glass Co., Ltd. for a PTFE having a molecular weight of 3,000,000); AD950 (a trade name of Asahi Glass Co., Ltd. for a PTFE having a molecular weight of 6,000,000); AD660 (a trade name of Asahi Glass Co., Ltd. for a PTFE having a molecular weight of 7,000,000); and AD936 (a trade name of Asahi Glass Co., Ltd. for a PTFE having a molecular weight of 15,000,000) as the PTFE.
As the PFA, there were used PFA340J (a trade name of Mitsui-DuPont Co., Ltd.). This PFA had a low melt viscosity and was excellent in bonding strength to PTFE.
As the graphite, three kinds of graphite manufactured by Nippon Kokuen Kabushiki Kaisha were used, namely exfoliated graphite having an oil-absorption of 150 ml/100 g (referred to hereinafter as Graphite A), exfoliated graphite having an oil-absorption of 80 ml/100 g (referred to hereinafter as Graphite B) and natural graphite having an oil-absorption of 50 ml/100 g (referred to hereinafter as Graphite C) were used to prepare three types of test samples.
First of all, the test samples for Comparative Examples 1 to 8 and Examples 1 to 6 shown in Table 1 were subjected to a cavitation test. The cavitation test was conducted under the test conditions shown in Table 2 and the samples were weighed before and after the test. From the weight difference, the reduced volume (cm 3 ) was calculated. The results obtained are shown in Table 3.
TABLE 1______________________________________ PTFE (% by vol.) PFA Molecular weight (×10.sup.4) (% by vol.) 300 600 700 1500______________________________________Comp. Ex. 1 100Comp. Ex. 2 1 99Comp. Ex. 3 5 95Comp. Ex. 4 20 80Comp. Ex. 5 50 50Comp. Ex. 6 60 40Comp. Ex. 7 100Comp. Ex. 8 60 40Example 1 1 99Example 2 5 95Example 3 20 80Example 4 50 50Example 5 20 80Example 6 20 80______________________________________
TABLE 2______________________________________Cavitation test conditions______________________________________Tester used Exclusive tester for cavitationSize of sample Longitudinal Length 40 × Lateral Length 40 × Thickness 2.0 (mm)Resonant frequency 19 (KHz)Output 600 (W)Test liquid WaterTest temperature Room temperatureGap between horn and 1 (mm)test sampleAmplitude of horn 45 to 50 (μm)Test time 5 (min)______________________________________
TABLE 3______________________________________ Friction Resistance Reduced vol. coefficient value ×10.sup.-3 (cm.sup.3) ×10.sup.-2 (N)______________________________________Comp. Ex. 1 8.5 10 or more 124Comp. Ex. 2 3.9 2.2 91Comp. Ex. 3 3.7 2.0 84Comp. Ex. 4 2.8 1.6 80Comp. Ex. 5 1.5 2.1 86Comp. Ex. 6 1.2 4.3 93Comp. Ex. 7 8.1 10 or more 103Comp. Ex. 8 1.4 3.9 85Example 1 3.7 1.8 79Example 2 3.5 1.5 69Example 3 2.9 1.1 62Example 4 1.7 1.8 71Example 5 2.7 1.1 64Example 6 3.0 1.3 67______________________________________
As shown in Comparative Examples 1 to 8 and Examples 1 to 4, there is a tendency that the reduced volume decreases as the volume % of the PFA increases. In Comparative Examples 2 to 6 in which the molecular 5 weight of PTFE is 3,000,000 and Examples 1 to 4 and Comparative Example 8 in which the molecular weight of PTFE is 7,000,000, there is no remarkable differences in reduced volume due to the difference in the molecular weight of PTFE when the Examples and Comparative Examples 10 in which the PFA volume % is the same are compared. Similarly, there is no remarkable differences in reduced volume due to the difference in the molecular weight of PTFE when Comparative Example 4 and Examples 3, 5 and 6 in which the amount of PFA added was 20% by volume are compared. From this fact, it is seen that the difference in molecular weight of PTFE little affects the cavitation resistance.
Subsequently, the above test samples were subjected to a friction test under the conditions shown in Table 4 to determine the friction coefficients of the samples. The results obtained are shown in Table 3.
TABLE 4______________________________________Friction test conditions______________________________________Tester used Thrust washer type friction testerSize of sample Longitudinal Length 40 × Lateral Length 40 × Thickness 2.0 (mm)Load 10 (MPa)Peripheral speed 0.5 (m/sec)Test time 4 (hrs)Lubricanting oil Oil for shock absorber______________________________________
As shown in Comparative Examples 1 to 8 and Examples 1 to 4, the friction coefficient was greatly lowered by adding 1% by volume of PFA, and the smallest friction coefficient was obtained when 20% by volume of PFA was added. In Comparative Examples 6 and 8 in which the amount of PFA added is 60% by volume, the friction coefficients were 4.3×10 -2 and 3.9×10 -2 , respectively, which means that when the amount of PFA added exceeds 50% by volume, the friction coefficient is increased again. Similarly, the comparison of Comparative Example 4 and Examples 3, 5 and 6 in which the amount of PFA added was 20% by volume indicates that the friction coefficient in Examples 3 and 5 is 1.1×10 -2 , namely the smallest, and the friction coefficient in Example 6 in which the molecular weight of PTFE was 15,000,000 is rather slightly increased.
Subsequently, a reciprocating sliding test was conducted under the conditions shown in Table 5, and the results obtained are shown as resistance value (N) in Table 3 and FIG. 1.
TABLE 5______________________________________Reciprocating sliding test conditions______________________________________Tester used Reciprocating sliding testerSample size 41 mm in inner diameter × 20 mm in width × 2.0 mm in thicknessLoad 1,000 (N)Peripheral speed 0.01 (m/sec)Lubricanting oil Oil for shock absorber______________________________________
As shown in Comparative Examples 1 to 8 and Examples 1 to 4, the resistance value is greatly lowered by the addition of PFA, and in Comparative Example 4 and Example 3 in which the amount of PFA added was 20% by volume, the resistance value (N) is the smallest, respectively. In Comparative Examples 6 and 8 in which the amount of PFA added was 60% by volume, the resistance values (N) are 93 and 85, respectively. This means that when the amount of PFA added exceeds 50% by volume, the resistance value increases again. In Comparative Examples 2 to 6 in which the molecular weight of PTFE was 3,000,000 and Examples 1 to 4 and Comparative Example 8 in which the molecular weight of PTFE was 7,000,000, the cases in which the amount of PFA added was the same are compared with each other, it is clear that when the molecular weight of PTFE is 7,000,000, the resistance value is smaller than the other and the friction properties are better than the other. Similarly, the comparison of Comparative Example 4 and Examples 3, 5 and 6 in which the amount of PFA added was 20% by volume indicates that when the molecular weight of PTFE is 7,000,000, the resistance value is the smallest and when the molecular weight of PTFE becomes 15,000,000, the resistance value rather slightly increases.
For investigating the effect of addition of a solid lubricant, samples in Examples 7 to 18 and Comparative Examples 9 and 10 in which a composition consisting of 20% by volume of PFA, the graphite in the amount shown in Table 6 and the balance of PTFE having a molecular weight of 7,000,000 was used were prepared. In this case, samples in which as the graphite, Graphite A (oil-absorption: 150 ml/100 g) and Graphite C (oil-absorption: 50 ml/100 g) were used were subjected to a friction test and a sliding test. The results obtained are shown in Table 6 and FIG. 2.
TABLE 6______________________________________ Graphite Friction Resistance (vol. %) coefficient value A C ×10.sup.-2 (N)______________________________________Comp. Ex. 9 15 2.8 68Comp. Ex. 10 15 2.5 62Example 7 0.5 1.8 61Example 8 1 1.3 59Example 9 2.5 1.0 58Example 10 5 1.2 55Example 11 7.5 1.4 57Example 12 10 1.7 61Example 13 0.5 1.5 47Example 14 1 1.1 45Example 15 2.5 0.8 42Example 16 5 1.1 44Example 17 7.5 1.2 48Example 18 10 1.5 50______________________________________ Note: The composition contained 20% by volume of PFA and the balance of PTFE having a molecular weight of 7,000,000.
From the above results, it is clear that when the graphite is added, the friction coefficient and resistance value becomes small. In particular, it can be seen that when the graphite is added in an amount of 0.5 to 10% by volume, the friction coefficient and resistance value become small, and when the graphite is added in an amount exceeding 10% by volume, the friction coefficient and resistance value are increased and the friction properties are damaged. Also, Graphite A having a large oil-absorption indicates smaller friction coefficient and resistance value than Graphite C having a smaller oil-absorption.
Moreover, in order to know the effect of the oil-absorption of graphite, a composition consisting of 20% by volume of PFA, 2.5% by volume of Graphite A, B or C and 77.5% by volume of PTFE having a molecular weight of 3,000,000; 6,000,000; 7,000,000; or 15,000,000 was prepared as shown as Examples 19 to 27 and Comparative Examples 11 to 13 in Table 7 and subjected to a reciprocating sliding test under the conditions shown in Table 5 to obtain the results shown in Table 7 and FIG. 3.
TABLE 7______________________________________ Molecular Resistance weight of Kind of value PTFE (×10.sup.4) graphite (N)______________________________________Comp. Ex. 11 300 A 62Comp. Ex. 12 300 B 67Comp. #x. 13 300 C 71Example 19 600 A 44Example 20 600 B 49Example 21 600 C 59Example 22 700 A 42Example 23 700 B 47Example 24 700 C 58Example 25 1500 A 49Example 26 1500 B 54Example 27 1500 C 60______________________________________ Note: The composition contained 20% by vol. of PFA, 2.5% by vol. of graphite an 77.5% by vol. of PTFE having a molecular weight of 7,000,000.
From the results shown in Table 7, it can be seen that by adding an exfoliated graphite having a large oil-absorption, the resistance value becomes lower and the friction properties are excellent. | A sliding member excellent in cavitation resistance and friction properties which has a sliding surface composed of a resin composition comprising a tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer resin and a polytetrafluoroethylene having a molecular weight of 5,000,000 to 15,000,000 and optionally a solid lubricant, wherein the proportion of the tetrafluoro-ethylene-perfluoroalkyl vinyl ether copolymer resin is 1 to 50% by volume based on the volume of the resin composition and the proportion of the solid lubricant is 0.5 to 10% by volume based on the volume of the resin composition. The addition of the solid lubricant results in an enhancement of friction properties and the use of an exfoliated graphite as the solid lubricant brings about a further enhancement of friction properties. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cutting board designed to facilitate slicing by providing a safe and efficient bracing mechanism for bread and other food product while incorporating a cutting surface for other common food preparation tasks.
2. Description of the Prior Art
The use of sharp cutting instruments to slice food product has proven to be a hazardous task that has led to many unfortunate injuries, ranging from cuts to the loss of fingers. Generally, these injuries occur because the victims were using their free hand to support the food product, placing that hand in a dangerous position. The solution to this problem is to provide a means for supporting food that will allow the user to keep his hands out of harms way. The device should provide a bracing mechanism that can allow easy control of the force applied in bracing. Bread is a food item that is commonly sliced and the force must be moderated so as to prevent smashing. Many of the devices in the prior art do not provide the capability to make a subtle variation in the bracing force and are restrictive in their use because of their design. The bracing mechanism provided in the present invention can be varied for use with food items of almost any size and delicacy.
While there are numerous devices that exist in the prior art that provide some form of support for slicing food, they ignore the fact that slicing is only one of many food preparation tasks that are required. A cutting surface is required for other jobs such as dicing and chopping. With all of the inventions in the prior art it is necessary to store, find and clean separate units. The present invention combines a bracing mechanism with a cutting surface for other food preparation needs. Unlike previous inventions, this is accomplished with a minimum number of parts so as to make cleaning and maintenance simple. A cook can alternate easily between slicing and dicing, for example, without the need to switch back and forth between tools. Anyone who has performed the task of preparing large amounts of food can understand the importance of this kind of efficiency.
U.S. Pat. No. 5,577,430 to Glen K. Gunderson discloses a device that is designed to assist in the slicing of bread. The design incorporates a slot that guides the pathway of a knife in a vertical path. In addition it provides a surface against which the bread can be placed so as to keep it in one place during the cutting. The position of this surface is variable according to the thickness desired by the user. The device does not provide a means of support on the other side of the bread thus requiring the user to hold that end with his hand. This increases the risk of injury for the user particularly for narrow breads such as bagels. While this design provides a means for adjusting the thickness of a particular slice, it does not enable the user to fully support the food product while keeping their hands out of harms way. The Gunderson '430 Patent also does not provide an incorporated flat cutting surface that can be used for additional food preparation tasks.
U.S. Pat. Nos. 5,611,266 and 5,724,877 to Milo M. Kensrue discloses a device for holding food product while the user slices it. This invention incorporates a flat stationary surface that contacts one side of the food product while the opposite side is supported by a brace that is held against said opposite side by one of two mechanisms. One mechanism uses a spring to provide the support for said brace, while the other uses a variable screw clamp. Neither of these mechanisms allow for the ease and sensitive control that is provided by the combination cutting board and slicing brace. The present invention incorporates a sliding base for the brace support, which allows the user to directly apply the appropriate force. The Kensrue '877 patent also provides no cutting surface for other food preparation.
U.S. Pat. No. 4,125,046 to Norma J. Kroh and George Spector provides aspects that are similar to the present invention for bracing food product during the slicing process. However, the overall design is awkward because it requires separate pieces to store and clean and it incorporates an enclosed frame that would limit the size of food product sliced. The Kroh '046 patent also fails to disclose a cutting surface for additional tasks.
U.S. Pat. No. 4,085,642 to Thomas F. Buckingham provides a sliding support for its bracing mechanism as does the present invention, but the design of this sliding mechanism is distinctly different. The sliding support in the present invention is designed so that it can be incorporated into a cutting surface. The result is an efficient design that combines both a cutting board and a bracing device for slicing. The Buckingham '642 patent employs a rail mechanism that could not be incorporated into a flat cutting surface.
U.S. Pat. No. 389,380 to Simon Yin-Chung Liu, Cheng Yue-Chun, and Kwai Chung is a design patent that discloses a wrack for slicing. While this device is designed for assistance in the slicing of food product, its sole purpose is to provide a means for guiding the cutting instrument during the slicing process. It provides support on only one side and therefore would require the user to use her hand to support the other side. It also does not provide for a means for incorporating a cutting surface such as the cutting board in the present invention.
Therefore a need exists for a novel and enhanced tool for bracing food product during the slicing process while providing a cutting surface for other food preparation procedures. Combining these tasks in a single unit would increase efficiency and minimize the use of storage space. In addition, the design should maximize the safety of the user. In this respect, the combination cutting board and slicing brace according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in doing so provides an apparatus primarily developed for the purpose of slicing food safely and providing a cutting surface.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of devices for assisting in the slicing process now present in the prior art, the present invention provides an improved combination of security and utility, and overcomes the abovementioned disadvantages and drawbacks of the prior art. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved combination cutting board and slicing brace which has all of the advantages of the prior art mentioned heretofore and many novel features that result in a combination cutting board and slicing brace which is not anticipated, rendered obvious, suggested, or even implied by the prior art, either alone or in combination thereof.
In furtherance of this objective, the combination cutting board and slicing brace comprises a cutting board that has a groove in its upper surface. Sliding within said groove is an arm that is shaped so as to create a flat upper surface that combines with the upper surface of said cutting board to create a solid cutting surface. Said arm is also configured to enable the user to grasp the arm for sliding to a desired location. Connected to one end of said arm is a first jaw for clamping food products. Connected to the upper surface of said cutting board is a second jaw positioned opposite of said first jaw so as to clamp the opposite side of food product clamped by said first jaw.
There has been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated.
The arm in said present invention may in addition comprise a cavity that opens on the surface of the end attached to said first jaw and extends to a inner wall inside of said arm. One end of a coil spring is attached to this inner wall. The other end of the coil spring is attached to a beam shaped to slide within said cavity. The beam will be sufficiently long so as to extend out of said cavity when the coil spring is fully extended and provide an upper surface for which to rest food product that is level with the lower edge of the surface of said first jaw.
An additional aspect of the combination cutting board and slicing brace is that the above-described jaws will comprise a shape wherein the top surface is angled upward from the upper edge contiguous with the surface contacting the food product so as to guide the blade of a knife towards the upper surface of the food product. Another feature of the jaws will be pyramidal shaped spikes that are connected to the clamping surface so as to secure the food product being sliced.
Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of presently preferred, but nonetheless illustrative, embodiments of the present invention when taken in conjunction with the accompanying drawings. In this respect, before explaining the current embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
It is therefore an object of the present invention to provide a new and improved combination cutting board and slicing brace that has all of the advantages of the prior art and none of the disadvantages.
It is another object of the present invention to provide a new and improved combination cutting board and slicing brace that may be easily and efficiently manufactured and marketed.
An even further object of the present invention is to provide a new and improved combination cutting board and slicing brace that has a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such combination cutting board and slicing braces economically available to the buying public.
Still another object of the present invention is to provide a new combination cutting board and slicing brace that provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
These together with other objects of the invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
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 top perspective view of the preferred embodiment of the combination cutting board and slicing brace of the present invention.
FIG. 2 is a top side view of the combination cutting board and slicing brace of the present invention illustrating the sliding motion of a clamping jaw.
FIG. 3 is a sectional view of the combination cutting board and slicing brace of the present invention.
FIG. 4 is an alternate top perspective view of the combination cutting board and slicing brace of the present invention comprising a protective slicing guide.
FIG. 5 is a right side sectional view of the combination cutting board and slicing brace comprising a protective slicing guide.
The same reference numerals refer to the same parts throughout the various figures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, and particularly to FIGS. 1-5, a preferred embodiment of the combination cutting board and slicing brace of the present invention is shown and generally designated by the reference numeral 10 .
In FIG. 1 is a cutting board 12 comprising a rectangular shape, a front surface and a rear surface. Said cutting board 12 further comprises an upper surface shaped to form a groove 16 extending from said front surface to a point near said rear surface. Attached to the cutting board is a brace 14 . A stationary rectangular jaw 24 is shown connected to the upper surface of said cutting board 12 at a point adjacent to said rear surface. Said stationary jaw 24 comprises a clamping surface orthogonal to the axis of said groove 16 and facing said front surface of said cutting board 12 . Attached to said clamping surface is multiple spikes 22 comprising a pyramidal shape. In addition FIG. 1 displays a rectangular shaped sliding arm 18 that fits snuggly within said groove 16 and wherein said arm 18 comprises an upper surface that forms a solid plane in connection with said upper surface of said cutting board 12 . Said arm 18 comprises a front end and a rear end. Said arm 18 also comprises a hole 34 near said front end wherein said hole 34 is shaped to enable the user to grasp said arm 18 by passing their fingers through said hole 34 . This will allow the user to apply force in order to slide said arm 18 to the desired position. Connected to said upper surface of said arm 18 is a sliding rectangular jaw 20 adjacent to said rear end of said arm 18 . Said sliding rectangular jaw 20 comprises a clamping surface orthogonal to the axis of said groove 16 and facing said rear surface of said cutting board 12 .
The materials that can be used for the abovementioned parts are numerous and should not be narrowed by the following suggestions. Said cutting board 12 could be easily and cheaply made using wood or a hard plastic. These materials suit the needs of being easily shaped into the desired form while having a surface hard enough to withstand constant impact from the blade of sharp instruments. Materials should not be chosen that would be so hard that they would rapidly dull said instruments. For decorative or storage reasons, said cutting board 12 may comprise shapes other then rectangular.
Said stationary 24 and sliding jaws 20 can consist of the same material used for the cutting board 12 or an alternate material. Again wood and hard plastic would be inexpensive material that could be easily shaped to the desired form. Metal also might be suited for this purpose. In addition, composites of these materials would be appropriate. The shape could be easily adjusted for decorative reasons or to add additional features such as a whet stone for sharpening. The upper surface can be used for decorative patterns or for personalization by inscribing the users initials. The spikes attached to said jaws can de made of materials such as metal, wood, and plastic. They could also have shapes other then pyramidal such as conical. An embodiment can be envisioned comprising detachable clamping surfaces that would comprise different spikes or a flat surface depending on the food product being sliced.
Said arm 18 can be made of the same material chosen to create the aforementioned cutting board 12 if a homogenous surface is desired. Alternate materials can also be used to provide variety in cutting surfaces if necessary. The hole 34 for grasping could be easily replaced by a knob or an external handle that could be made from wood, metal, or plastic. The design could be altered so that the upper surface could offer other uses such as a sharpening tool or a grater.
In FIG. 2 a top side view of said combination cutting board and slicing brace 10 is shown that demonstrates the sliding motion of said arm 18 . In the figure, said arm is rectangular and comprises a front end and a rear end. Said arm further comprises a hole 34 located near the front end shaped to allow the passing through of the user's fingers for grasping. The top surface of said sliding jaw 20 is shown in two positions. The first position depicted is of the sliding jaw 20 slid to a fully closed position. The second position depicted is of the sliding jaw 20 after it has been retracted. The outlined image depicted on the left demonstrates the position of the front end of said arm 18 when said sliding jaw 20 is retracted. Also depicted is the top surface of said stationary jaw 24 with a demonstration of the kind of decorative additions that could be made. Attached to the clamping surface of both jaws are multiple pyramidal spikes 22 . All of the variations suggested above would apply here as well, as would the possible materials.
In FIG. 3 a sectional view of said combination cutting board and slicing brace 10 is shown. This view faces towards the front of said cutting board 12 . Said clamping surface of said sliding jaw 20 is shown with a rectangular shape and attached to the surface is multiple pyramidal spikes 22 . Said spikes 22 are depicted in three rows, equally spaced, and with said spikes on the inner row positioned at the mid-point of the spikes of the first and second rows. This juxtaposition increases the gripping capability of said jaws, 20 and 24 . As suggested earlier, the shape of said spikes 22 can be varied according to purpose. It should also be noted that the pattern of said spikes 22 could also be rearranged according to the particular food product being sliced. The combination cutting board and slicing brace can also have an alternate design whereby the surface of said jaws, 20 and 24 , can be slidably removed to allow for cleaning and variation in surfaces.
Also shown in FIG. 3 is a sectional view of said cutting board 12 facing towards said front surface and illustrates in the outer hashed area a long rectangular shape formed between the upper and lower surface of said cutting board. A view of the aforementioned groove 16 is depicted at the top center of said cutting board 10 by an outlined area. The outer edge is shown having a rectangular shape with rounded sides. The top of this rectangular shape is shown to connect with the upper surface of said cutting board 12 . It should be noted that this is only one suggestion for the shape of said groove 16 . An oval could be used as well or the sides could be flat if deemed appropriate. The white area within the outlined groove 16 depicts a sectional view of said arm 18 and comprises a shape that mirrors the rounded rectangular shape of said outline so as to allow said arm 18 to slide within said groove 16 . Said arm 18 further comprises a cavity 26 , the outline of which is shown within said white area. Depicted within said outline of said cavity 26 is a hatched sectional view of a beam 32 . Said beam 32 has a rectangular shape with curved ends and slides within said cavity 26 . Said beam 32 could be made of several materials such as wood, plastic or metal.
FIG. 4 is an alternate design of the combination cutting board and slicing brace 10 that includes a safety feature not depicted in FIG. 1 . In this figure the top edges of said jaws, 20 and 24 , are slanted towards said clamping surfaces. This slant will act to guide the blade of a cutting instrument towards the area between said jaws so that it cannot slip outwards and injure the user. The slant could be substituted with a curved surface and can be covered with many alternate materials such as plastic and metal. The surface can be marked for decorative purposes as demonstrated by the initials “GOA” depicted in FIG. 5 .
In FIG. 5 a sectional view of the combination cutting board and slicing brace 10 is shown facing towards the left side. This view is shown at the mid point of the cutting board 12 so that it passes down the center axis of said groove. At the left is depicted said front end of said arm 18 , which extends beyond said front surface of said cutting board 12 . The outer edge of said arm 18 is shown comprising a rectangular shape. Also depicted by a white rectangle is a hole 34 located near said front end. Said hole 34 is shaped to allow the passing of fingers for grasping and opens to the upper and lower surfaces of said arm 18 .
The rear end of said arm 18 is shown comprising an opening that leads to a cavity 26 that extends within the majority of said beams length and terminates at an inner wall 28 . Attached to said inner wall is a coil spring 30 . Said spring 30 could be made of metal or plastic and could be replaced by other retracting mechanisms such as helical or air springs. Said spring 30 comprises a front end and a rear end wherein said front end is connected to said inner wall 28 and said rear end is attached to said front end of said beam 32 . Said beam 32 is depicted by a rectangular shape that is connected to said coil spring 30 at said front end of said beam 32 and extends to contact the lower portion of said clamping surface of said stationary jaw 24 . The position of said sliding arm 18 is shown when said coil spring 30 is fully extended. The User can grasp said arm 18 using said hole 34 and push said arm 18 towards said rear surface of said cutting board 10 . Due to this force said coil spring 30 will compress and said front end of said beam 32 will move closer to said inner wall 28 . Concurrently said clamping surface of said sliding jaw 20 will move closer to said clamping surface of said stationary jaw 24 so as to grasp food product such as the bagel shown in FIG. 5 . Due to the expanding force of said coil spring 30 , said rear end of said beam 32 will remain in contact with the lower portion of said clamping surface of said stationary jaw 24 and provide a platform upon which the food will rest. This design is an added feature that will position the food product on a plane level with the top surface of said cutting board 12 . However the design could be modified to allow said beam 32 to be removed if this would not be desirable. The surface of said beam 32 could be modified to contain depressions that would receive various shapes of food. Said beam 32 could be made of materials such as wood or plastic that could match the materials used for the cutting board 12 . Such materials should be easily shaped so as to form the desired sliding shape.
FIG. 5 also depicts a sectional view of said sliding jaw 20 comprising a rectangular surface that further comprises said alternate safety feature. Said feature comprises a slanting upper surface that angles downward toward said clamping surface of said sliding jaw 20 and acts as a guide for cutting instruments towards the food and away from the user. Attached to said clamping surface of said sliding jaw 20 is said spikes 22 for gripping food. Said sliding jaw 20 comprises a lower surface that is connected to the upper surface of said cutting board 12 .
FIG. 5 further depicts a stationary jaw 24 comprising a rectangular shape and also comprising said alternate safety feature. In this embodiment, said safety feature comprises a slant in the upper surface of said jaw 24 that angles downward toward said clamping surface of said stationary jaw 24 . Said slant acts to guide a cutting instrument away from the user. Attached to said clamping surface of said stationary jaw 24 is said spikes 22 for gripping food. Said clamping surface of said stationary jaw 24 is shown as flat. This shape could be varied to conform to particular food items if that would enhance the gripping quality of the brace portion of the present invention. Said stationary jaw 24 comprises a lower surface that is connected to the upper surface of said cutting board and is adjacent to said rear end of said cutting board.
While a preferred embodiment of the combination cutting board and slicing brace 10 has been described in detail, it should be apparent that modifications and variations thereto are possible, all of which fall within the true spirit and scope of the invention. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function, and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. For example, any suitable flexible material may be used instead of the fabrics that have been described. And although the slicing of food product has been described, there are slight variations, such as shape and size that would make the invention appropriate for other items.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | The combination cutting board and slicing brace is a device designed to satisfy two needs that coexist in the food preparation process. One of these needs is a device designed to safely hold food product while it is being sliced. The other of these needs is a surface for additional types of cutting such as chopping or dicing. The present invention consists of a unique structure that does not exist in the prior art and addresses the structural and utilitarian deficiencies of these earlier designs. None of the designs in the prior art provide this unique combination of uses. The structure of the present invention also incorporates a uniquely designed sliding arm that can be incorporated within said cutting surface while controlling the bracing device, thus producing a streamlined homogenous unit that can be stored and cleaned easily. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to an arrangement for measuring or determining the quiescent current of an integrated monolithic digital circuit, which arrangement comprises a current sensor for measuring (sensing) the quiescent current, which is provided with a first connection terminal for coupling to a supply terminal of the integrated monolithic circuit and with a second connection terminal for coupling to a supply.
The invention further relates to an integrated monolithic digital circuit provided with such a current measuring arrangement.
The invention moreover relates to a testing apparatus provided with such an arrangement.
An arrangement for measuring a quiescent current of an integrated monolithic digital circuit is known from the article "Built-In-Current Testing-Feasibility Study", W. Maly and P. Nigh, Proceeding ICCAD 1988, pp. 340-343, IEEE. In this publication, testing of digital VLSI circuits by means of a current sensor incorporated in the integrated monolithic circuit is described. The current sensor has a non-linear characteristic, more particularly the current sensor is a bipolar transistor having an exponential I-U characteristic, is. The current sensor is included between the monolithic circuit and the supply of the monolithic circuit and serves to measure abnormal quiescent currents which are due, for example, to shortcircuits and/or floating gate electrodes of, for example, MOS-FET's in the VLSI circuit. The measurements are made dynamically, that is to say that test vectors are supplied at inputs of the VLSI circuit and the quiescent current is measured in rest periods between switching operations. If the VLSI circuit operates satisfactorily, the quiescent current can be orders of magnitude smaller as compared with an unsatisfactory operation. A quiescent current measurement can therefore give an indication about a satisfactory or an unsatisfactory operation of the VLSI circuit. The voltage across the current sensor is compared with a reference voltage in quiescent current periods. If the voltage is larger than a predetermined value, the VLSI circuit is very likely to be defective. Because of the exponential characteristic of the transistor, it is possible to discriminate between a comparatively large current during switching of transistors in the VLSI circuit and the comparatively small quiescent currents. In the prior arrangement, a bipolar current sensor is used in a MOS environment, which may give rise to problems with respect to integration in the same integrated monolithic digital circuit. Further, a satisfactorily operating VLSI circuit, in which a current sensor is included, will operate more slowly than a VLSI circuit without a current sensor.
SUMMARY OF THE INVENTION
The invention has, inter alia, for its object to provide an arrangement of the kind mentioned in the opening paragraph by means of which a rapid quiescent current measurement can be carried out and with a high resolution.
An arrangement for measuring a quiescent current of an integrated monolithic digital circuit according to the invention is characterized in that the arrangement comprises voltage stabilization means for stabilizing a voltage at the first connection terminal and signal processing means coupled to the voltage stabilization means for signal processing of the quiescent current Due to the fact that also with large current variations the voltage across the current sensor remains substantially constant, on the one hand a high resolution will be attained when measuring the quiescent current and on the other hand the operation of the integrated monolithic circuit will not be adversely affected with peak currents during switching.
An embodiment of an arrangement according to the invention is characterized in that the voltage stabilization means comprise a differential amplifier, of which a first input is coupled to the first connection terminal, a second input is coupled to the second connection terminal or to a connection terminal for connection to a reference voltage source, and an output is coupled to a gate electrode of the transistor. In the case in which the second input is coupled to the second connection terminal, with a predetermined offset voltage (for example 100 mV) of the differential amplifier, the voltage drop across the transistor will then be low and because of the feedback loop the voltage drop will vary only comparatively slightly, even with comparatively large current variations. In the case in which the second input is coupled to a connection terminal for connection to a reference voltage source, for integrated monolithic circuits to which a higher external supply voltage is supplied than an internal supply voltage as operating voltage ("voltage down conversion"), functions of the current measurement, voltage stabilization and step down of the external supply voltage will be combined. If the predetermined offset voltage is substantially 0 V, the voltage at the first connection terminal, and hence the operating voltage of the integrated monolithic circuit, will be substantially equal to the voltage of the reference voltage source.
An embodiment of an arrangement according to the invention is characterized in that the output of the differential amplifier is coupled to the gate electrode via a modification circuit for modifying the operation of the current sensor outside of a quiescent current measurement period or outside a quiescent current measurement of the integrated monolithic circuit. As a result, if the current measuring arrangement is integrated in the integrated monolithic circuit, in normal conditions the operation will be substantially the same as the operation without a current sensor integrated monolithic circuit.
An embodiment of an arrangement according to the invention is characterized in that the signal processing means comprise a first transistor, which constitutes with the current sensor a current mirror configuration, which is designed to supply via an output electrode of the first transistor a current which is a mirror image of the quiescent current. As a result, a measured quiescent current is obtained on which further operations can be carried out without the operation of the integrated monolithic circuit being substantially adversely affected, which could be the case, for example, if an ohmic load were to be coupled to the first connection terminal for obtaining a measuring voltage derived from the quiescent current.
A further embodiment of an arrangement according to the invention is characterized in that the signal processing means comprise a differential amplifier, which is coupled via a first input to the first connection terminal, via a second input to the output electrode of the first transistor and via an output to a gate electrode of a second transistor, which second transistor is coupled via a first output electrode to the output electrode of the first transistor, while a second output electrode of the second transistor serves to supply a further processed quiescent current. The differential amplifier of the voltage stabilization means is adjusted so that the voltage drop across the current sensor is very low. The supply voltage of the integrated monolithic circuit is then very stable and substantially equal to the external supply voltage. The differential amplifier of the signal processing means and the second transistor ensure that the first transistor, like the current sensor transistor, operates in the linear range (triode range). As a result, a current equal (with equal geometric dimensions of the current sensor transistor and the first transistor) or a current proportional (with different geometric dimensions) to that flowing through the current sensor transistor will flow through the first transistor. The second transistor supplies a measured current for further processing.
An embodiment of an arrangement according to the invention is characterized in that the signal processing means further comprise transistors, which constitute with the current sensor a current mirror configuration, while for obtaining different processed quiescent currents the transistors of the signal processing means have different geometric dimensions. As a result, different currents proportional to the quiescent current are obtained for further processing.
An integrated monolithic digital circuit according to the invention, which comprises at least one subcircuit, is characterized in that the integrated monolithic circuit comprises at least one measuring arrangement, or at least a part thereof, for measuring the quiescent current of subcircuits, of combinations of subcircuits, or of all subcircuits. If the integrated monolithic circuit comprises the current sensor, the voltage stabilization means and the signal processing means, the measured quiescent current can be passed to a connection pin of the integrated monolithic circuit for further processing at the printed circuit board level or by means of a testing apparatus for integrated monolithic digital circuits. If the comparison means are also integrated on the integrated monolithic circuit (everything "on-chip"), before a next switching peak the digitized value of the processed quiescent current may be introduced, for example, into a flip-flop. For an integrated monolithic circuit comprising several subcircuits, the digitized values of the quiescent currents obtained can be further processed in "on-chip" or "off-chip" testing apparatuses, which use, for example, techniques such as "scan-test", "self-test" and "boundary scan". With respect to the lastmentioned techniques, reference may be made to the relevant literature.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention now will be described more fully with reference to the accompanying drawing, in which:
FIG. 1A is a diagrammatic representation of an arrangement according to the invention,
FIG. 1B a current through an integrated monolithic digital circuit as a function of time when supplying a given test vector at inputs thereof,
FIG. 2 shows an embodiment of signal processing means and comparison means in an arrangement according to the invention,
FIG. 3 shows an embodiment which provides multiplication of a measured current,
FIG. 4A shows a current measurement according to the invention to measure a metastable condition in a digital circuit,
FIG. 4B shows a current of such a circuit,
FIG. 4C shows a voltage at an output terminal of such a digital circuit,
FIG. 5 shows a current measurement according to the invention to obtain information about the stability of outputs of combinatorial digital subcircuits,
FIG. 6 shows a testing apparatus provided with an arrangement according to the invention,
FIG. 7A shows an embodiment of the current measuring circuit with an embodiment of the modification circuit,
FIG. 7B shows another embodiment of the modification circuit,
FIGS. 8A and 8B show configurations of IC's including a current measuring arrangement according to the invention,
FIG. 9 shows the coupling of the current measuring arrangement with a scan chain in an IC, and
FIG. 10 shows the coupling of the current measuring circuit according to the invention with a self-test circuit in an IC.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1A shows diagrammatically an arrangement 1 according to the invention which is coupled to an integrated monolithic digital circuit 2, of which a quiescent current I DD is measured. The arrangement 1 comprises a transistor Ts as the current sensor for measuring or sensing the quiescent current. The transistor Ts is connected in series with the integrated monolithic circuit 2 between a first supply line V DD and a second supply line V SS . According to the invention, the voltage at a first connection terminal kl1 is stabilized, i.e. kept constant with the aid of voltage stabilization (regulator) means, in the example shown with the aid of a fed-back differential amplifier A1. The current sensor Ts is connected via a second connection terminal k12 to the supply line V DD . The current sensor Ts and the differential amplifier A1 constitute a current measuring circuit CMS according to the invention. The differential amplifier A1 is connected via a first input I1(+) to the first connection terminal kl1, via a second input I2(-) to the supply line V DD (via a reference source V ref to the supply line V SS ) and through an output O1 directly or via a modification circuit M to a gate electrode gs of the current sensor Ts. The modification circuit M may be an amplifier or a filter and may have additional inputs to render the transistor Ts completely conducting outside the measurement of the quiescent current. If the input I2 is connected to the supply line V DD , with an offset of the differential amplifier A1 of, for example, 100 mV, the voltage drop across the sensor Ts will be about 100 mV. By means of the fed-back differential amplifier A1, the voltage at the terminal kl1 is stabilized. If the input I2 is connected via the reference voltage source V ref to the supply line V SS , with an offset of substantially 0 V, the voltage at the terminal kl1 will be stabilized on substantially V ref . The current measuring circuit CMS may be integrated with the integrated monolithic circuit, may be provided on a printed circuit board with the integrated monolithic circuit, may be incorporated in a testing apparatus for integrated monolithic circuits or may be present in an interface module as part of such a testing apparatus. In connection with the speed and with other testing methods "on-chip", such as, for example, "scan test", it is advantageous to integrate the current measuring circuit with the integrated monolithic circuit. The arrangement 1 further comprises signal processing means SPC for processing the quiescent current I DD . The signal processing means SPC comprise the first transistor T1, which constitutes with the transistor Ts a current mirror configuration. Via an output electrode d1, a current is supplied, which is a mirror image of the quiescent current I DD . Further, the arrangement 1 comprises comparison means COM for comparing the processed quiescent current I O with a reference current I ref . At an output O2 of the comparison means COM, an indication appears as to whether or not the reference current is exceeded by the current I O . The indication may be digital; a logic "1" may then indicate, for example, that the current I o exceeds the reference current.
FIG. IB shows the current I DD through an integrated monolithic digital circuit 2 as a function of the time t when supplying a given test vector at the inputs In thereof. t1, t2, t3 and t4 denote a few time instants. At the instants t1 and t3, switching takes place in the integrated monolithic circuit 2. Between t1 and t2 and between t3 and t4, switching results in current peaks p1 and p2. Between t2 and t3 and after t4, the integrated monolithic digital circuit 2 is in the rest condition. In a CMOS circuit, for example, a current peak has a value of the order of 10 mA and a quiescent current in the situation in which the CMOS circuit is not defective of the order of pA/nA. If there is a defect, such as, for example, a shortcircuit, the quiescent current may increase, for example, to an order of nA/mA. The measured current in the rest condition is I O . If I O >I ref , this may indicate a defect in the CMOS circuit. The threshold value I ref is adjustable.
It should be noted the current measuring circuit can be simplified further by omitting the differential amplifier A1 and by then connecting the gate electrode gs to the terminal kl1, but due to low loop amplification a satisfactory stabilization of the voltage at the terminal kl1 is then not attained. It should further be noted that with different geometric dimensions of the transistors Ts and Tl, current amplification can be obtained.
FIG. 2 shows an embodiment of a signal processing means SPC and comparison means COM in an arrangement according to the invention. Symbols corresponding to FIG. 1A are indicated in the same manner. The signal processing means further comprise a differential amplifier A2, which is connected via a first input I3(+) to the first connection terminal kl1, via a second input I4(-) to the output electrode d1 of the first transistor T1, and via an output 03 to a gate electrode g2 of a second transistor T2. The transistor T2 is connected by means of a first output electrode s2 to the output electrode dI of the first transistor T1. A second output electrode d2 serves to supply a current I O to the comparison means COM. The comparison means COM comprise a current mirror configuration constituted by transistors T3 and T4 and having a first input I5 for receipt of the processed quiescent current I O , a second input I6 for the supply of a reference current I ref and a digital output 04. If the current I O is smaller than I ref , the output 04 assumes a first value ("0") and if I O >I ref , the output 04 assumes a second value ("1").
FIG. 3 shows a circuit which provides a multiplication of a measured quiescent current. The signal processing means SPC comprise n transistors T1, . . . , T1n and supply n output currents I 01 , . . . , I 0n . The transistors T1, . . . , T1n may have increasing chip surfaces so that currents increasing in value may be obtained for further processing. The currents I 01 , . . . , I 0n may be supplied to analog or digital comparison means. For I O1 an analogous situation is shown; I O1 is converted by a resistor R into a voltage U, which is supplied to an analog voltage comparator (not shown), for example, of the kind included in a testing apparatus for testing an integrated monolithic digital circuit.
FIG. 4A shows a current measurement according to the invention for measuring a metastable condition in a digital circuit. A metastable condition, i.e. an undefined output value "0" and "1" may occur, for example, due to timing errors and occurs, for example, in flip-flops. A flip-flop as an integrated monolithic circuit 1 and an arrangement 2 according to the invention are shown. The flip-flop 1 has a data input D, a clock input C and an output Q. The arrangement 2 has a control input S and an output O. In a CMOS flip-flop, a comparatively high current (>1mA) can be measured, which occurs due to a metastable condition. The output signal 0 can be used to delay the operation of circuits to be controlled by the flip-flop until the metastable condition has passed.
In FIG. 4B, I DD is shown and in FIG. 4C U Q , i.e. the voltage at the output Q of the flip-flop in a metastable condition is shown. It can be seen that a comparatively large current I DD occurs during a metastable condition m. The normal starting situations for the flip-flops are indicated by "0" and "1".
In FIG. 5 a current measurement according to the invention is shown for obtaining information about the stability of outputs of combinatorial digital subcircuits. The arrangement 1 has additional inputs and outputs in the form of "handshake" signals H. The integrated monolithic digital circuit 2 has inputs I1, . . . , In and outputs 01, . . . , On. In the said circuits, it is difficult to detect when a stable condition is attained. By means of an arrangement according to the invention, an indication can be obtained whether an operation is carried out by the circuit 2. The quiescent current arrangement 1 is then integrated with a so-called "handshake" system, which is required to couple such a circuit 2 to similar circuits. The arrangement 1 is set to the "ready for use" condition when a "handshake" signal is received and waits until a peak current has decreased to a quiescent current. The arrangement 1 then supplies a "handshake" signal to a similar circuit to indicate that data can be transferred. Delays are then no longer required between cascaded circuits, as a result of which in principle circuits operating at a higher speed can be obtained.
FIG. 6 shows a testing apparatus TD provided with an arrangement 1 according to the invention. The arrangement 1 may also be constructed as an interface for the testing apparatus TD. An apparatus commercially available for testing VLSI circuits is, for example, a "Sentry 50" tester of Schlumberger. The arrangement according to the invention can be entirely or partly incorporated therein.
FIG. 7A shows an embodiment of the current measuring circuit CMS with an embodiment of the modification circuit M. The operational amplifier A1 (see FIG. 1A) is constituted by the transistors T5, T6, T7, T8, T9 and T10 and the modification circuit is constituted by the transistor TM. The remaining reference symbols correspond to those in FIG. 1. In the embodiment shown, the stability is also guaranteed outside of the quiescent current measurement when considerably larger currents flow because in the configuration chosen, A1 then has a low amplification.
FIG. 7B shows another embodiment of the modification circuit M, which is coupled to the output 01 of the amplifier A1 in FIG. 1 and to the input gs of the current sensor Ts. The modification circuit M comprises an inverter T11, T12 coupled to the transistor TM. A clock signal C1 is supplied to an input I 3 of the inverter from, for example, the clock generator of the circuit 2, the "Device Under Test" (DUT). Since the inverter has a fixed delay, the phase of the clock signal should be such that the modification circuit M switches more rapidly than the DUT.
FIGS. 8A and 8B show configurations of integrated circuits (IC's) including a current measuring arrangement according to the invention. The IC has, besides the pins usually present, an additional pin Pe in the configuration shown in FIG. 8A. If the IC includes circuits drawing large currents, which remain outside the I DDQ measurement, because of the fact that the circuits drawing large currents are already supplied via an additional pin, i.e. the additional pin for I DDQ measurement, the terminal kl1 is then floating and V DD is supplied to kl2. FIG. 8B shows such a configuration.
FIG. 9 shows the coupling of the current measuring arrangement according to the invention with a scan chain in an IC. A scan chain, which is well known, is constituted by a number of flip-flops . . . , FFn-1, FFn in an IC during testing of the IC. The flip-flops in the IC are joined to form a shift register by means of multiplexers . . . , Mn-1, Mn during testing. Data are supplied to a multiplexer at the beginning of a scan chain at an input SI and are clocked in into the shift register thus formed. At the end of the scan chain, test data become available again at an output pin SO of the IC. An I DDQ monitor MON according to the invention can be coupled to the scan chain, for example, via an additional multiplexer, at a predetermined point in the scan chain. The scan chain is switched on by a control signal Tst. Since a pin was already necessary for the scan test, no additional pin is required for the I DDQ measurement. The I DDQ monitor MON can also be multiplexed with the output of the scan chain. In the scan test mode, that is to say when the signal Tst has a first value, the output of the scan chain is passed to an IC pin, while in the normal mode, that is to say when the signal Tst has a second value, the output of the I DDQ monitor is passed to the IC pin. Per IC, several I DDQ monitors can be present, which can all be coupled to the scan chain.
For testing printed circuit boards (PCB's), an integrated circuit can be formed comprising an I DDQ monitor according to the invention and a so-called boundary scan controller, which is well known per se. The I DDQ monitor then measures the current through a supply line, which is connected to a number of IC's to be measured. The result of the current measurement can then be stored in a register in the boundary scan controller.
FIG. 10 shows the coupling of the current measuring arrangement MON according to the invention with a self-test circuit ST in an integrated circuit IC. The monitor MON measures the quiescent current I DDQ of the logic circuit LC. The self-test circuit ST is connected not only to outputs 01, 02, . . . On of the logic circuit LC, but also to the output OM of the monitor. If a self-test circuit is present in the IC, in this manner an additional pin for the I DDQ monitor is not required. The self-test circuit is, for example, a so-called "linear feedback shift register", which is well known in the field of testing.
It should be noted that the number of applications is not limited to the applications described. For example, when providing (parts of) the arrangement (in multiple) on a printed circuit board, the current measurement may be used for "connectivity checking", i.e. detecting interrupted print tracks or shortcircuits between print tracks. The arrangement according to the invention may also be included in a "boundary scan chain". Besides the MOS technique, the arrangement may also be constructed in another technique, such as, for example, a bipolar technique.
It should further be noted that with integration of the I DDQ monitor in an IC having circuits whose I DDQ is measured, the I DDQ monitor typically occupies about 1% of the "active area". In such a case, the monitor is arranged at an unused area at the periphery of the IC. In general no additional processing steps are required for also integrating the I DDQ monitor. | An arrangement for measuring the quiescent current of a digital IC includes a current sensor connected in series with the IC and the voltage supply, a voltage stabilization circuit for stabilizing the voltage across the IC and a signal processing circuit coupled thereto for processing the measured quiescent current. The quiescent current is measured when no flip-flops are switched in the IC. By means of the arrangement, it is possible to measure rapidly and accurately whether the quiescent current assumes an abnormal value, which indicates that the IC contains defects. The signal processing circuit may include a current mirror which is coupled to a current comparator circuit supplying a digital output signal for determining the existence of a defect. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a division of U.S. patent application Ser. No. 11/586,742, filed Oct. 24, 2006 (hereby incorporated by reference), which claims priority of the filing date of Provisional Application Ser. No. 60/729,765, filed Oct. 24, 2005, the entire contents of which are incorporated by reference.
RIGHTS OF THE GOVERNMENT
The invention described herein may be manufactured and used by or for the Government of the United States for all governmental purposes without the payment of any royalty.
BACKGROUND OF THE INVENTION
The invention relates to detection devices and methods, and particularly pertains to the detection and classification of biological particles including bacterial endospores, various species of vegetative bacteria, various harmless background particles etc. This will be accomplished by comparing information extracted from excitation-emission graphs for unknown samples from the environment with information from such graphs obtained from experiments with known samples including but not limited to comparing information from excitation-emission graphs taken from a normal strain graphs taken from a normal strain dipicolonic acid (DPA +) of Bacillus subtilis spores and from spores of a mutant strain (DPA−) derived from the same DPA + strain, excitation-emission graphs of the pure chemicals such as CaDPA, DPA and tryptophan which may be components of biological particles. CaDPA and DPA are usually found in bacterial endospores. Further information from excitation-emission graphs taken for various species of vegetative bacteria and for spores from different species of bacteria will also be utilized as well as excitation-emission graphs from various background materials expected to be found at times in aerosols or dust.
When released into the environment, endospores can survive extreme heat, lack of water and exposure to many toxic chemicals and radiation. Most of the water present in the cell cytoplasm is eliminated during spore formation. Such endospores do not generally carry out metabolic reactions. A significantly large amount of the organic acid dipicolonic acid (found in the spore core), is accompanied by a large number of calcium ions. Calcium ions (Ca.sup.++) are combined with the dipicolinic acid as seen below.
The calcium-dipicolinic acid complex represents about ten percent of the dry weight of the endospore. As would be understood, such endospores can readily become airborne. If present in an area of human occupancy, such as an office building, home or the like, certain endospores can be life threatening when present through inadvertence, accident or deliberately introduced by bioterrorists.
While various types of detection methods for certain deadly endospores such as Bacillus anthracis (anthrax) are known, current methods generally consist of collecting specimens from office buildings, homes or outdoor locations and delivering them to various instruments which at present take from one to several hours or more to complete the analysis. Thus, those unfortunate enough to be exposed to deadly endospores (such as anthrax) or alternatively with other pathogenic bacteria may have the delivery of medical countermeasures significantly delayed so as to exacerbate their condition. Further, rapid early classification such as provided by the present invention can be a trigger to determine where to deliver samples for further interrogation by more time-consuming methods.
Therefore, in view of the need for a speedy and continuous method of detecting anthrax and other pathogenic bacteria, which may be, for example, airborne in public buildings, the present invention was conceived and one of its objectives is to provide a device and method whereby the presence of bacillus anthracis or the presence of other classes of bacteria can be easily and inexpensively be indicated as likely.
It is an objective of the invention to provide a device for detecting biological particles when their presence is suspected; for indicating when bacterial endospores are present; and for providing preliminary classification of other bacteria (e.g. Gram positive or Gram negative) when vegetative bacteria are present.
It is another objective of the present invention to provide a device and Method for indicating when bacterial endospores are present; and for providing preliminary classification of other bacteria (e.g. Gram positive or Gram negative) when vegetative bacteria are present which is easy to operate and requires little specialized training.
It is yet another objective of the present invention to provide a method for indicating when bacterial endospores are present and for providing preliminary classification of other bacteria (e.g. Gram positive or Gram negative) when vegetative bacteria are present, both of which are relatively inexpensive to operate continuously for twenty-four hours a day. The invention may optionally comprise triggering an alarm when a suspected biological threat is present. The suspected biological threat may include one or more types of bacterial endospores or vegetative bacteria. Various other objectives and advantages of the present invention will become apparent to those skilled in the art as a more detailed description is set forth below.
SUMMARY OF THE INVENTION
The aforesaid and other objectives are realized by providing a method of screening materials suspected of containing unknown particles including particles down to submicron size. The method comprises providing information contained in at least one or numerous (previously obtained two-dimensional excitation-emission (EEM) type) graphs as would be obtained with a fluorometer, collecting a portion of a sample in powder or liquid suspension form, providing distilled water or other fluids to the sample, delivering a portion of the sample to a cuvette or alternatively a non-fluorescent surface for obtaining EEM graphs of the sample, removing fluids from the sample, generating EEM graphs from the nonirradiated sample, irradiating the sample with Ultraviolet (UV) light (e.g. light of wavelengths between 200 nm and 400 nm), generating an EEM graph after the irradiation, comparing the information from these EEM graphs with each other and with the information contained in previously obtained two-dimensional EEM graphs, removing the sample from the device and preparing the device for a subsequent sample, and determining if the particles in the sample are of biological origin, if they are bacterial endospores, if they are vegetative bacteria, and if they are vegetative bacteria, what large class of bacteria they belong to (e.g., Gram positive or Gram negative).
Further to the present invention, it may be determined with the EEM information whether endospores of Bacillus or Clostridia or other genera are present in the sample by comparison of the information from their EEM graphs with those of the stored graphs.
Further to the present invention, it may be determined whether EEM information indicating vegetative bacterial cells are present in the sample and further classifying vegetative bacterial cells made from the EEM information. (e.g., Gram negative from Gram positive).
The objectives of the present invention are further realized with a screening system comprising means for collecting and concentrating a sample, a chamber for washing the sample, non-UV absorbing cuvette for UV irradiation of the sample and/or a nonfluorescent filter on which the sample may be deposited for fluorescent spectrometry with emission measured at a convenient angle, a means for moving the sample (small water and pressure or vacuum source), an ultraviolet light source, an excitation light source or excitation spectrometer, a means of restricting excitation light to desired wavelengths (Excitation spectrometer or broadband light source with filter wheel), an emission spectrometer, a digital or analog medium having stored in it the information from one, several or numerous EEM graphs, a computer, a heating tube for heating the sample (The option of heating may be provided for the purpose of providing additional classification information from EEM graphs taken before and after heating), an aerosol collector concentrator, and a vacuum device or other means of collecting samples from a surface.
The system further includes the option of a screening kit comprising a UV light source, an excitation light source (broadband with filter wheel or excitation spectrometer), an emission spectrometer, a digital medium having stored in it the information from one, several, or numerous EEM graphs, and a computer with appropriate software for comparing the sample EEM graph with information from the stored graphs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an EEM graph for Bacillus subtilis spores dried on g-filter. No irradiation. Vertical axis is excitation wavelength, nm. Horizontal axis is emission wavelength, nm. Linear plot.
FIG. 2 is an EEM graph for Bacillus subtilis spores dried on g-filter after 20 minutes UV irradiation. Linear graph, same axes as FIG. 1 . Apparent brightness on graph amplified by factor 1.66.
FIG. 3 is an EEM graph for Bacillus subtilis spores dried on g-filter. No irradiation. Vertical axis is excitation wavelength, nm. Same experiment as FIG. 1 except Horizontal axis is now (emission wavelength)/(excitation wavelength). Nonlinear graph
FIG. 4 is an EEM graph for Bacillus subtilis spores dried on g-filter after 20 minutes UV irradiation. Nonlinear graph, Em/Ex wavelengths ratio, horizontal axis. Apparent graph brightness amplified by factor 1.66.
FIG. 5 is an EEM graph for Escherichia coli cells dried on g-filter. No UV irradiation. Linear plot (i.e. axes same as FIG. 1 .)
FIG. 6 is EEM graph for Escherichia coli cells dried on g-filter. UV irradiation for 30 minutes. Linear plot (i.e. axes same as FIG. 1 ). Apparent brightness of graph amplified by factor 7.5 from FIG. 5 .
FIG. 7 is an EEM graph for Escherichia coli cells dried on g-filter. No UV irradiation. Nonlinear plot (i.e., data same as FIG. 5 )
FIG. 8 is an EEM graph for Escherichia coli cells dried on g-filter. UV irradiation for 30 minutes. Nonlinear plot (i.e., data same as FIG. 6 ). Graph brightness amplified by factor 7.5.
FIG. 9 is an EEM graph for Escherichia coli cells in suspension in 0.03% NaCl solution. No UV. Linear plot.
FIG. 10 is an EEM graph of luminescence from suspension of E. coli cells after 30 minutes of UV. Linear plot. Same cells and concentration as FIG. 9 but apparent graph brightness amplified by a factor of six in this graph (e.g., Tryp fluorescence appears saturated on scale of graph).
FIG. 11 is a Difference EEM spectrum plotted on scale of FIG. 10 . Data for FIG. 9 is subtracted from data for FIG. 10 to remove tryptophan area and eliminate Raman peaks and distortion due to these peaks. Apparent graph brightness amplified by factor of 10 from FIG. 9 .
FIG. 12 is a Nonlinear difference EEM graph of same data and scale as FIG. 11 . Absence of a peak in the CaDPA region is notable. Apparent graph brightness amplified by factor of 10 from FIG. 9 .
FIG. 13 is a Diagram of steps in typical device incorporating many of the components used in the invention.
DETAILED DESCRIPTION OF THE INVENTION
The findings in references (1) B. V. Bronk, L. Reinisch, S. Sarasanandarajah, B. Setlow, and P. Setlow, Studies relating the fluorescence of CaDPA and DPA to the fluorescence of bacillus spores“ AFRL-HE-WP-TR-2005-0055, 2 May 2005; (2) S. Sarasanandarajah, J. Kunnil, E. Chacko, B. V. Bronk and L. Reinisch, ”Reversible changes in fluorescence of bacterial endospores found in aerosols due to hydration/drying” in press J. Aerosol Science (2005); (3) B. V. Bronk, L. Reinisch, and P. Setlow, “The role of DPA in the fluorescence of Bacillus spores”, in CBIAC Report CB-193503, “6 th Joint Conference on Standoff Detection for Chemical and Biological Defense” (October 2004), report may be ordered from CBIAC, P.O. Box 196, Aberdeen Proving Ground, Edgewood Area, Gunpowder, Md. 21010-0196, tel: 410-676-9030; and (4) S. Sarasanandarajah, J. Kunnil, B. V. Bronk and L. Reinisch, “Two dimensional multiwavelength fluorescence spectra of dipicolinic acid and calcium dipicolinate”, Appl. Optics, Vol 44, 1182-1187 (2005) indicate that the presence of bacterial endospores is easily detected and differentiated from other unknown micron-sized particles by the changes in the fluorescence Excitation-Emission patterns (EEM displayed on a 2-dimensional contour plot) after the particles are irradiated in the UV as compared to the before irradiation EEM. The source of this irradiation may be either the predominant spectral line from mercury in a germicidal lamp or broadband UV as from a Xenon lamp. The characteristic effect which is seen to the particles EEM pattern occurs in all the following cases:
when the particles are irradiated dry then examined in a fluorometer for EEM dry irradiated dry then examined in a fluorometer wet. irradiated wet then dried and examined in a fluorometer for EEM irradiated either wet or dry and examined in a fluorometer for EEM in a water or alcohol suspension.
The particles to be examined may be present in the form of an aerosol, dry or wet; a powder found on surfaces; or inside liquid droplets or damp spots found on surfaces which contain micron-sized particles (i.e. particles in the size range ˜0.5 micrometers to ˜10 or more micrometers); or as micron-sized particles suspended in a liquid.
Endospores (i.e. spores from Bacilli or Clostridia) may be easily distinguished in this manner from vegetative bacteria. Both spores and vegetative bacteria may be distinguished by these means from ambient background such as outdoor and indoor dust, pollen, diesel fuel, smoke and other interferrants. Further there is some differential classification indicated between different classes of bacteria.
The description refers to the EEM (i.e., Excitation-Emission) graphs shown in the Figures. EEM graphs are shown for both before and after UV irradiation. The irradiation used for the graphs of the Figures is from a mercury bulb emitting primarily at ˜254 nm. The dose or amount of irradiation is indicated as minutes of exposure with the intensity measured at the microorganisms approximately equal to 0.85 mW/cm 2 . For example, irradiation for 20-30 minutes at an intensity of 0.85 mW/cm 2 as depicted, for example, in FIGS. 2 , 4 , 6 , 8 , and 10 results in a UV dose of about 1 to 1.5 Joules/cm 2 (1.02 to 1.53 Joules/cm 2 ). The UV irradiation may optionally be provided by a broadband UV light such as from a Xenon lamp. The UV dose from a broadband light source is about 100 Joules/cm 2 .
FIG. 1 shows the EEM graph for Bacillus subtilis spores dried onto a gold particle filter (reference 8: Schiza, M. V., Perkins, D. L., Ryan, J. P., Setlow, B., Setlow, P., Bronk, B. V., Wong, D. M., and Myrick, M. L., “Improved dispersion of bacterial endospores for quantitative infrared sampling on gold coated porous alumina membranes”, Applied Spectroscopy, vol. 59, 1068-1074 (2005)) hereafter referred to as a g-filter. In this experiment the spores were not yet irradiated. All luminescence is referred to as fluorescence although some may be from phosphorescence. The predominant fluorescence is from tryptophan with the peak at excitation near 280 nm. There is a very faint peak for excitation near 370 nm. This peak becomes much stronger after UV irradiation. On all graphs the contours are equally spaced, with the highest luminescence appearing the most white and the least luminescent, the darkest gray or black.
FIG. 2 shows the EEM graph for the same dried spores after 20 minutes UV irradiation from a germicidal lamp. Two new peaks have shown up. One for excitation near 300 nm, and the other for excitation near 340 nm. The peak for excitation near 370 nm has become much stronger. Although it is not apparent from these graphs (scale of the two graphs is not equal), the tryptophan peak for 280 nm excitation has become weaker due to bleaching of the tryptophan molecules. All graphs have their vertical axis as Excitation wavelength in nanometers (nm). All graphs labeled “linear” have their horizontal axis as Emission wavelength.
FIGS. 3 and 4 show graphs corresponding to FIG. 1 and FIG. 2 respectively except that the horizontal axis is now the non-dimensional ratio (emission wavelength)/(excitation wavelength). These plots are called “nonlinear”. All the graphs labeled nonlinear have this horizontal axis. The purpose of including the nonlinear versions of the same data is for easier comparison with the graphs in publications which are plotted this way.
FIG. 5 shows the EEM graph for Escherichia coli cells grown in LB broth, washed once in PBS buffer and then re-suspended in 0.9% saline and dried onto a g-filter with no UV exposure. The very predominant peak is due to tryptophan (peak excitation near 280 nm) and is very similar in shape to an EEM graph for pure tryptophan (not shown). There is a very much fainter luminescent spot at around 360 nm excitation.
FIG. 6 shows the EEM graph for the same cells and prep, but with the following treatment. A drop of water was put on top to wet the spot of cells, 30 minutes UV irradiation was then applied to the spot on the filter. A luminescent spectrum was then taken after the water dried. The scale has been adjusted to make all emissions appear about 7.5 times brighter on the gray scale in FIG. 6 than for FIG. 5 . The tryptophan peak is saturated on this scale. This was done to bring out an apparent change of shape observed for the dimmer spot at about 360 nm excitation.
FIGS. 7 & 8 show the same data as FIGS. 5 & 6 respectively, but with the horizontal axis as Emission/Excitation for comparison with published graphs.
Comparing FIGS. 2 & 4 with FIGS. 6 and 8 , it is see that the new luminescence or change for the E. coli cells after UV irradiation is quite distinguishable from the new luminescence for B. subtilis spores. In particular, the new luminescence for the E. coli cells is much fainter compared to their tryptophan fluorescence than is the case for endospores. Further, the shape is different, and the peak near 300 nm excitation attributable to CaDPA is missing from the E.coli graphs. This is also the case for E. coli fluorescence for cells in suspension (see below).
In the experiment for FIGS. 9 and 10 , the E. coli cells from the same preparation as for FIG. 5 , but suspension was diluted with filtered deionized water to 0.03% NaCl concentration. FIG. 9 shows the EEM linear graph for the unirradiated suspension. Only the tryptophan peak is visible. The shape of the graph indicates that the luminescent region is almost solely attributable to a single chemical. There is a diagonal streak on the graph from lower left to upper right which is due to the water Raman peak. FIG. 10 shows the linear EEM graph for the same suspension after a UV irradiation of 30 minutes. The brightness contours were enhanced by a factor of six making the tryptophan portion appear to saturate the brightness scale. There is additional fluorescence emission at blue wavelengths for excitations near 350 nm. The apparent distortion from smooth contours in FIG. 10 is due to the proximity of bright Raman peaks near the much dimmer E. coli fluorescence in this region. A better representation of the contours of this fluorescence in FIG. 11 may be seen when the plotted contours of a difference EEM graph are shown. This graphs the remainder after FIG. 9 subtracted from the data of FIG. 10 , and then plotted on the scale of FIG. 10 . This eliminates the tryptophan fluorescence region, and the Raman peaks as well as the distortion in the plotting routine caused by the latter. In FIG. 12 the non-linear version of FIG. 11 is plotted. It is notable that the fluorescence of the CaDPA region (refs. 1, 3, and 4) which is prominent in spore fluorescence is much diminished or absent. This makes these vegetative cells easily distinguishable using this method.
The experiments shown here demonstrate that the methods/devices described below can be used to do preliminary classification of unknown particles (e.g., discriminate between several classes of micron-sized particles).
Enabling Methods and Embodiment of Devices Using the Method:
Basically each device will consist of means for exposing the sample to UV irradiation; an excitation-emission fluorometer; means for handling the sample (e.g., adding water if desired); means for transporting a small sample to an observation surface or cuvette; and a computer to record results. The device may optionally be coupled to an alarm that is triggered when a suspected biological threat is detected.
Components, some of which will be used in each of the example devices are listed below. (Not all components will be used in each device). Commercial versions of all the items on the list below exist, but these may need to be redesigned for this application.
Possible Components:
(1) Excitation Source: A source such as a Xenon lamp with strong emission into the UV as well as in the visible. Light at least in the region 250 nm to 550 nm must be available.
(2) UV irradiation source: This may be the same source as (1) but also may be provided by a one or several high intensity mercury lamps (e.g. a germicidal bulb is an inexpensive version) emitting strongly at 254 nm.
(3) Treatment tube for irradiation. This would be a quartz glass tube to allow UV at wavelengths below 300 nm to pass thru to the interior and to hold a liquid suspension. This tube may also act as cuvette if it is desirable to obtain the particle EEM in suspension.
(4) A small excitation spectrometer .
(5) An optical filter wheel and means for changing the band pass center wavelength. This would be used in place of (4) for a simpler less expensive device. The band pass positions may consist of several interference filters or may have continuously changing band pass for a large part of the range.
(6) A small water and pressure or vacuum source for the case when sample is to be immersed and moved in water.
(7) A non-fluorescent tape (e.g. sticky tape) and dispenser which can catch and move the sample in device where sample is not to be wet.
(8) An aerosol collector.
(9) An aerosol concentrator.
10) Emission spectrometer.
(11) A non-fluorescent particle filter to collect particles from water and to provide a surface for taking EEM spectra. An example of such a filter is the gold-coated alumina filter described in reference 8. Its fluorescence has been found to be negligible in unpublished experiments relating to this disclosure.
(12) Vacuum pickup used in place of (8) when it is desirable to collect sample from suspected surfaces and spaces and deposit on filter.
(13) Laptop computer
(14) A means of moving and storing examined particle filter for additional, more time consuming identification (e.g. polymerase chain reaction)
(15) Heating tube. Heat transmitting tube surrounded by resistance heaters.
(16) Rapid Excitation-Emission Fluorometer. This fluorometer combines and replaces (1), (4), and (5) in such a way that the excitation light is spectrally dispersed and each color is directed to a different part of the sample spot. Each individual spot can be contained in a sample less than 1 cm across. The total fluorescence from each fluorescing spot is input to a different position corresponding to excitation wavelength on the slit of an imaging spectrograph. The output is an EEM graph taken in seconds or less.
(17) An input to the emission spectrograph from 90 degree scattering for a selected wavelength, which is attenuated to be comparable to maximum expected fluorescence. This can be directed to a particular position on the imaging spectrograph if properly attenuated.
Situation 1
The main microorganisms to be detected are bacterial spores or vegetative bacteria (eg, powders visible on a surface or from an aerosol suspected in a room or outdoors) then irradiation dry and fluorescence dry may be used.
1 st Embodiment
This is the simplest method, to be used to detect spores where there is a visible powder. Instead of an integrated device there would be a kit. The kit would simply consist of a UV light source (2) to irradiate the suspected surface; an excitation light source [component (1) and (5)], and an emission spectrometer [component (11)] to examine emitted light from the suspected surface and a computer with software to compare the EEM graph to a “type-graph” for bacterial spores or other bacterial particles.
Situation 2
The microorganisms are either present in the air as an aerosol, or are deposited on surfaces at a very low concentration.
This is a more sophisticated version of the first embodiment to be used in Situation 2.
2 nd Embodiment
An aerosol collector/concentrator [a. components (8) and (9)] or a vacuum pickup, [b. component (12)] would be used continuously. The choice of a. or b. depends on whether an aerosol (a.) or surface dust (b.) is being examined. The concentrator delivers the aerosol sample every 10 minutes into ˜5 ml of water which further concentrates the sample into a small spot by being pulled through a non-fluorescent filter [component (11)], leaving all particles greater than the pore size (<1 micrometer) and discarding the liquid. An EEM spectrum is taken on the filter using components (4) and (10). Sample is irradiated [component (2)] on the filter [component (11)], and an EEM spectrum is taken after irradiation with the EEM graphs stored in the computer memory for comparison later.
Small (<100 lbs weight) commercially available versions of these devices [components (8) and (9) combined] typically can concentrate the aerosol from ˜400 liters of air per minute into ˜5 or 10 ml of water in one minute. We have found ˜10 6 to 10 8 organisms in a 10 mm spot on a filter gives a recognizable EEM pattern. Thus if the air contains 1000 organisms/liter as would be typically expected in a deliberate attack, a 10 minute sample on a nonfluorescent particle filter [component (11)] would be adequate.
3 rd Embodiment
The diagram for this version is shown in FIG. 13 . It is typical of the various devices described. Collection and concentration are as in the second embodiment in an aerosol collector concentrator which concentrates particles in desired size range from a large volume of air (e.g., several hundred liters; see A in FIG. 13 ) into a small volume of water (e.g. a few ml; see B in FIG. 13 ). Next the suspended sample is moved to a non-fluorescent filter (F in FIG. 13 ; component (11)) using component (6) and washed with additional water passing through the sample and filter. EEM spectrum is taken of dried sample on non-fluorescent filter using excitation source, (component (4) not shown) and emission spectrometer (component (10) and spectrometer in FIG. 13 ). The sample is transferred to small volume of clean water from the filter, and moved into quartz cuvette (C in Fig.; component (3)) for UV irradiation or it may be irradiated on the filter; it is subsequently moved back to filter for a second spectrum. Data defining both EEM spectra are transferred (I and I′ in FIG. 13 ) are transferred to computer (H in FIG. 13 , component (13)) for comparison with each other and stored type spectrum. This procedure is typical of the several procedures described in this disclosure. After EEM graphs are examined, particles are washed off filter and transferred out of device to a second filter for storage for further tests (e.g., Polymerase Chain Reaction) or for discarding.
A variation of the third embodiment would take EEM spectra while particles are suspended in water in the quartz tube (C in FIG. 13 )
4 th Embodiment
Collection and concentration are as in the second embodiment. The particles in suspension are
a. heated in component (15) b. EEM spectrum taken in component (3) c. UV irradiated in component (3)
The order of application of treatments a., b. and c. will be determined by the treatment which provides maximum differentiation for the classes chosen. EEM graphs are taken with treated sample in cuvette and compared with type graph. with a computer algorithm.
5 th Embodiment
This is a variation of the fourth embodiment in which heating and irradiation are in component (15) and (3) but spectra for EEM graphs are taken of particles on a low fluorescence filter as in FIGS. 1 through 12 .
6 th Embodiment
This is a variation of the other methods in which an attenuated signal (in addition to the EEM spectra) is recorded at a convenient angle from the excitation signal at one or more wavelengths as in component (17). This signal is generally an increasing function of the size of the particles. Its ratio to the tryptophan signal is an additional characteristic of the type of microorganism which will facilitate classification of unknown particles. | A method and device for detecting, differentiating from background and providing partial identification (i.e., classification) for biological particles found in aerosols or surface dust. The method is based on the phenomenon that luminescent excitation-emission (EEM) graphs of microorganisms obtained before and after perturbation by irradiation with ultraviolet light show characteristic patterns which differ according to the type of particle. For example, Bacillus endospores may be distinguished from vegetative bacteria, and gram positive vegetative bacteria may be distinguished from gram negative bacteria, and all these may be distinguished from many types of background particles, e.g. house dust, road dust, and pollen. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the invention
The present invention relates to an improved intermediate transfer device which transfers toner on a photoconductor first to an intermediate transfer belt and then onto a paper, and to an improved toner transfer device (hereinafter called the "1st toner transfer device) which transfers the toner on the photoconductor to the intermediate transfer belt in the intermediate transfer device.
2. Description of the prior art
In recent image forming apparatuses for full color image forming, toner images of yellow, magenta, and cyan are separately formed on a photoconductor, and the thus formed toner images are transferred onto an intermediate transfer belt in such a way that one toner image is superimposed on top of the other, the transferred image being further transferred onto copy paper. Once the colored toner images are superimposed one on top of the other on the intermediate transfer belt, the transfer to the copy paper can be accomplished in a single operation, so this method can prevent copy paper from being damaged.
In the conventional 1st transfer device, toner transfer from the photoconductor to the intermediate transfer belt has been accomplished using a transfer charger which generates corona. However, the transfer charger that utilizes corona discharge for transfer of toner has had the following difficulties in terms of toner transfer.
(1) Transfer area is limited, and uneven transfer may be caused because of unevenness in the potential on the reverse surface of the intermediate transfer belt. (Refer to FIG. 9)
(2) When a low-resistivity (10 8 Ω cm or lower) intermediate transfer belt is used, the transfer belt becomes charged because of the corona, and good quality transfer cannot be obtained for the 2nd transfer (transfer of the toner on the intermediate transfer belt to the copy paper). Therefore, in the conventional 1st transfer device, it has been necessary to restrict the resistivity of the intermediate transfer belt, or to provide a device which removes the charge from the intermediate transfer device prior to the 2nd transfer.
(3) Insufficient pressure between the photoconductor and the intermediate transfer belt has resulted in uneven superposing of the three color image layers, missing portions of the three color image layers, and other defects, that affect the copy quality.
SUMMARY OF THE INVENTION
The toner transfer device of this invention, which overcomes the above-discussed and numerous other disadvantages and deficiencies of the prior art, is a toner transfer device which transfers toner on a photo-conductor to an intermediate transfer belt applied on a plurality of rollers, wherein at least part of the surface of said photoconductor moves in an arc while being pressed against said intermediate transfer belt, said toner transfer device comprising: a pair of transfer rollers disposed along said intermediate transfer belt between two of said rollers in such a manner that said part of the surface of said photoconductor which moves in an arc is positioned between said transfer rollers, at least part of each transfer roller being located outside each of two tangents, one of said tangents touching said photoconductor and one of said two rollers, the other tangent touching said photoconductor and the other roller, thereby allowing a certain length of said intermediate transfer belt between said two transfer rollers to be pressed against said part of the surface of said photoconductor moving in an arc; and a means for applying voltage to said transfer rollers, the voltage polarity being opposite to that of the toner.
In a preferred embodiment, each of said transfer rollers is so located that said intermediate transfer belt is not caught between the transfer roller and said photoconductor.
In a preferred embodiment, each of said transfer rollers is so located as to position said intermediate transfer belt approximately 0.5 to 1.5 mm outwardly from each of said tangent.
In a preferred embodiment, each of said transfer rollers is located approximately 10 to 15 mm away from the point at which each of said tangents touches said photoconductor.
In a preferred embodiment, the two transfer rollers function as idlers that are driven by the rotation of said intermediate transfer belt.
In a preferred embodiment, the voltage applied to said transfer rollers is within the range of 400 to 1000V of the opposite polarity to that of the toner.
The intermediate transfer device of this invention is an intermediate transfer device which transfers toner on a photoconductor to an intermediate transfer belt before said toner is transferred onto paper, wherein the intermediate transfer belt being formed of a dielectric having a resistivity of approximately 10 7 to 10 11 Ω cm.
Thus, the invention described herein makes possible the objectives of (1) providing a first toner transfer device which is capable of accomplishing transfer of sufficiently good quality without restricting the resistivity of an intermediate transfer belt and (2) providing an intermediate transfer device having an intermediate transfer belt capable of producing copy image of excellent quality.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention may be better understood and its numerous objects and advantages will become apparent to those skilled in the art by reference to the accompanying drawings as follows:
FIG. 1 is a diagram showing the construction of an intermediate transfer device of this invention.
FIG. 2 is a perspective view of a 1st toner transfer device of this invention.
FIG. 3 is a plan view of a backup roller.
FIG. 4A is a front view of a supporting section of a 2nd transfer roller, and FIG. 4B is a side view thereof.
FIG. 5 is a graph showing the pressure distribution in the axial direction when pressure is applied between the backup roller and the 2nd transfer roller in the device of this invention.
FIG. 6 is a graph showing the pressure distribution in the axial direction when pressure is applied between the backup roller and the 2nd transfer roller in a conventional device.
FIG. 7 is a sectional front elevation showing a copying apparatus having the intermediate transfer device with the first toner transfer device of this invention.
FIG. 8 is a graph showing the potential on the reverse surface of the intermediate transfer belt of this invention.
FIG. 9 is a graph showing the potential on the rear surface of the intermediate transfer belt in a conventional device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 7 is a schematic diagram showing the front view of a full-color copying machine having the intermediate transfer device with the first toner transfer device.
A document table 1 formed of transparent glass is provided on the top surface of the copying machine. On the document table 1, a document A to be copied is placed with its document side facing down. Disposed under the document table 1 is an optical device including a light source 2a, mirrors 2b to 2f, a lens 2g, and a filter 2h. The optical device scans the document A on the document table 1, and directs the reflected light onto a belt-like photoconductor belt 3. The filter 2h is used to separate the light reflected from the document into three primary colors, red, green, and blue, and to selectively transmit any one of these colors.
The photoconductor belt 3 is provided with a photoconductive layer, the resistivity of which decreases when illuminated with light. The photoconductor belt 3 is stretched with a driving roller 3a on one end and an idler roller 3b at the other end. The driving force is transmitted from a motor not shown to the driving roller 3a for rotation in the direction shown by arrow D in FIG. 7. In the vicinity of the idler roller 3b are disposed a cleaning device 36, a discharge lamp 37 and a charge corona 31 in the order of the direction of rotation of the photoconductor belt 3. A blank lamp 32 and developer units 33 to 35 are disposed above the photoconductor belt 3 and an intermediate transfer device 4 is disposed in the vicinity of the driving roller 3a. Yellow toner is contained in the developer unit 33, magenta toner in the developer unit 34, and cyan toner in the developer unit 35.
In the above construction, toner images are formed on the photoconductor belt 3 in approximately the same manner as in a conventional electrophotographic image forming apparatus. The light reflected from the document is projected onto the photoconductor belt 3 charged by the charge corona 31 to form an electrostatic latent image thereon, and the latent image on the photoconductor belt 3 is developed by the developer units 33 to 35. The toner images formed on the photoconductor belt 3 are transferred first to the intermediate transfer device 4 and then to copy paper. For image forming operations by the developer units 33 to 35, the developer unit which contains the toner of the complementary color, of the color of the light reflected from the document and transmitted through the filter 2h is put into operation. For example, when blue light is transmitted, the developer unit 33 containing yellow toner is put into operation to form a yellow toner image.
The intermediate transfer device 4 comprises an intermediate transfer belt 5 applied on a driving roller 5a, an idler roller 5b, and a backup roller 5c, a 1st toner transfer device 6, a 2nd toner transfer device 7, a separator plate 8, and a cleaning device 9.
The toner images formed on the photoconductor belt 3 are transferred by means of the 1st toner transfer device 6 onto the intermediate transfer belt 5, and the thus transferred images are further transferred to the copy paper which is fed from a paper cassette 9a or 9b installed in the upstream side of the copy paper transporting direction of the copying machine. The yellow, magenta, and cyan images formed on the photoconductor belt 3 are transferred to the intermediate transfer belt 5, one being superimposed one on the other, and then, the thus formed full color image is transferred onto the copy paper. The full color image transferred onto the copy paper is fixed to the copy paper in a fixing device 10 before being discharged out of the copying machine.
The following detailed description deals with the construction of the intermediate transfer device 4. FIG. 1 is a diagram showing the construction of the intermediate transfer device.
The intermediate transfer belt 5 is formed from a sheet-like dielectric material such as polycarbonate the resistivity of which is adjusted with carbon black dispersed therein. According to the experiments conducted by the inventors, it is desirable that the resistivity of the intermediate transfer belt 5 be within the range of 10 7 to 10 11 Ω cm. If the resistivity is set at a higher level, the toner adhesion will become too strong, resulting in transfer failure for the second transfer (toner transfer from the intermediate transfer belt 5 to the copy paper). To prevent the transfer failure, a device will have to be provided to remove the charge after the 1st transfer (toner transfer from the photoconductor belt 3 to the intermediate transfer belt 5). Conversely, if the resistivity is set at a lower level, sufficient electric field cannot be created necessary for the 2nd transfer, also resulting in transfer failure. To prevent this, transfer power of a large capacity will have to be provided. In a conventional transfer corona unit, when the resistivity of the intermediate transfer belt is about 10 7 Ω cm, the toner cannot be separated from the intermediate transfer belt at the time of the 2nd transfer. On the other hand, in the unit using the transfer rollers hereinafter described, if the resistivity is lower than that, sufficient toner separation can be achieved at the time of the 2nd transfer. However, as previously stated, the resistivity should be set preferably within the range of 10 7 to 10 11 Ω cm.
The intermediate transfer belt 5 is applied on the driving roller 5a, the idler roller 5b, and the backup roller 5c, as previously mentioned. The driving roller 5a is a roller of 50 mm in diameter having a surface layer, formed for example of conductive rubber, and is coupled to and driven by a main motor (not shown). The idler roller 5b is a roller of approximately 42 mm in diameter, formed for example of aluminum, while the backup roller 5c is a roller of approximately 25 mm in diameter having a surface layer of insulating rubber. The idler roller 5b is urged in the direction to stretch the intermediate transfer belt by means of a urging mechanism (not shown). Against the intermediate transfer belt 5 thus applied on the rollers, the photoconductor belt 3 is pressed at the portion between the driving roller 5a and the idler roller 5b. Actually, the driving roller 3a on which the photoconductor belt 3 is applied is pressed against the intermediate transfer belt 5, so that tension is applied to the intermediate transfer belt 5 by the driving roller 5a, the idler roller 5b, the backup roller 5c, and the driving roller 3a of the photoconductor belt 3. The 1st toner transfer device 6 is disposed where the intermediate transfer belt 5 is pressed against the photoconductor belt 3. FIG. 2 is an external view of the 1st toner transfer device.
The 1st toner transfer device is formed of metal such as stainless steel, and comprises two 1st transfer rollers 6a and 6b having a diameter, for example, of approximately 8 mm. The 1st transfer rollers 6a and 6b are supported on a supporting member 61 in a freely rotatable manner, and press contact the inner surface of the intermediate transfer belt 5. Therefore, the 1st transfer rollers 6a and 6b are easily rotatable with the rotation of the intermediate transfer belt 5. The numeral 62 indicates a connector for applying voltage to the 1st transfer rollers 6a and 6b. The connector 62 applies to the 1st transfer rollers 6a and 6b a charge of opposite polarity (+in this case) to that of the toner. The position where the 1st transfer rollers 6a and 6b are pressed against the intermediate transfer belt is set in the following manner.
A tangent which touches both the rollers 3a and 5a is in contact with the driving roller 3a at a point P2. Similarly, a tangent which touches both the rollers 3a and 5b is in contact with the driving roller 3a at a point P1. The 1st transfer rollers 6a and 6b are positioned approximately 10 to 15 mm (distance d) away from the points P1 and P2 toward the rollers 5a and 5b, respectively, and are also located in such a manner that they position the intermediate transfer belt 5 away from the above-mentioned tangents toward the driving roller 3a (i.e., outwardly from the tangents) by approximately 0.5 to 1.5 mm (distance p). Thus, the intermediate transfer belt 5 is not caught between the driving roller 3a of the photoconductor belt 3 and the 1st transfer roller 6a or between the driving roller 3a and the 1st transfer roller 6b, while the 1 st transfer rollers 6a and 6b lightly press the intermediate transfer belt 5 toward the photoconductor belt 3, thereby assuring smooth 1st transfer.
The 2nd toner transfer device 7 comprises a 2nd transfer roller 7a. The 2nd transfer roller 7a is supported in a vertically movable manner by means of a moving mechanism such as shown in FIGS. 4A and 4B. When the 2nd transfer roller 7a is moved upward, the 2nd transfer roller 7a is pressed against the backup roller 5c with the intermediate transfer belt 5 interposed therebetween. The 2nd transfer roller 7a is moved upward when copy paper is fed between the intermediate transfer belt 5 and the 2nd transfer roller 7a. The copy paper is pressed between the intermediate transfer belt 5 and the 2nd transfer roller 7a to transfer toner onto the copy paper. The following describes in detail the moving mechanism of the 2nd transfer roller with reference to FIGS. 4A and 4B. FIG. 4A is a front view of a supporting section of the 2nd transfer roller, and FIG. 4B a right side view thereof. The 2nd transfer roller 7a is rotatably supported in support plates 71 and 71 provided at axial ends thereof. Provided at the upstream side of the copy paper transporting direction of the 2nd transfer roller 7a is a shaft 72 about which each support plate 71 rotates in the direction shown by arrows B and C in FIG. 4A. A cam 73 is provided at the upstream side of the copy paper transporting direction of the shaft 72, and further at the same side thereof, a pair of springs 74, each of which is engaged with each one of two support plates 71, is provided. Each support plate 71 is made to swing in the direction shown by arrow B or C when the cam rotates. When each support plate 71 is made to swing in the direction shown by arrow B, the 2nd transfer roller 7a is pressed against the backup roller 5c. Each support plate 71 is urged upward (in the direction shown by arrow B) by means of each spring 74 to press the 2nd transfer roller 7a against the backup roller 5c. Each spring 74 is engaged with each support plate 71 at the furthest position from the shaft 72. Therefore, upward urging force is obtained in the most effective manner, and it is possible to provide sufficient urging force at each of the axial ends of the 2nd transfer roller 7a.
In FIG. 4A, the numeral 74' indicates the spring position previously employed. In contrast with this position, by thus disposing the springs 74 at the furthest position from the shaft 72, the maximum urging force can be provided at the support plates 71, respectively. For example, when the spring was installed at the position 74', difference on the pressure of the 2nd transfer roller 7a against the backup roller 5c was noted between the axial ends of the 2nd transfer roller 7a even when the lateral positional deviation of the 2nd transfer roller 7a was 0.4 mm. On the other hand, when the spring is installed at the position 74, it has been found that even when the lateral positional deviation of the 2nd transfer roller 7a is 0.8 mm, the positional deviation is absorbed and almost uniform pressure is provided at each axial end of the 2nd transfer roller 7a.
A back plate roller 7c is disposed on the inner surface of the intermediate transfer belt and in the vicinity of the backup roller 5c. The back plate roller 7c is formed of metal such as stainless steel. The back plate roller 7c is grounded, and serves as a counter electrode for the 2nd transfer roller 7a. The back plate roller 7c is disposed at a distance l=10 to 18 mm away from a point P3 shown in FIG. 1 where the 2nd transfer roller 7a is pressed against the backup roller 5c toward the idler roller 5b (upstream in the rotating direction of the intermediate transfer belt 5). The back plate roller 7c is so disposed as to lightly contact the inner surface of the intermediate transfer belt 5 in a rotatable manner. When toner is transferred from the intermediate transfer belt 5 to the copy paper, an electric field is created between the 2nd transfer roller 7a and the back plate roller 7c to cause the toner of the polarity opposite to that of the applied voltage to be attracted toward the 2nd transfer roller 7a and transferred onto the copy paper. At this time, the back plate roller 7c is rotated by the rotation of the intermediate transfer belt 5. Therefore, there is no possibility that the inner surface of the intermediate transfer belt 5 is chafed against the backup roller 5c or that dust chafed off the intermediate transfer belt 5 is fused onto the back plate roller to create problems such as transfer failure.
The core of the backup roller 5c is made of relatively hard material such as steel to prevent distortion under pressure, and the surface layer is formed from insulating material having a resistivity of, for example, of 10 12 to 10 14 Ω cm. Specifically, silicon rubber, etc. is used as the insulating material. As shown in FIG. 3, the backup roller 5c has a crown-like shape in which the diameter at the axial ends is larger than the diameter at the center. The shape of the backup roller 5c is not limited to that shown in FIG. 3, but can be determined according to how the pressure is applied between the backup roller 5c and the 2nd transfer roller 7a. By forming the backup roller 5c in such a crown-like shape, uniform pressure can be obtained between the axial ends of the 2nd transfer roller 7a when the 2nd transfer roller 7a is pressed against the backup roller 5c. FIGS. 5 and 6 show pressure distributions in the axial direction when pressure is applied between the backup roller 5c and the 2nd transfer roller 7a. FIG. 5 shows the distributions when the 2nd transfer roller of this embodiment is used, while FIG. 6 shows the distributions when a conventional 2nd transfer roller is used. The 2nd transfer roller of FIG. 5 has an aluminum core, and the insulating rubber portion is formed flat in the axial direction. In this experiment, points (1) to (6) were set at 5 cm intervals in the axial direction along the pressed portion between the backup roller 5c and the 2nd transfer roller 7a each 25 cm long in the axial direction, slips of paper were placed at these points with the rollers pressed together, and the force required to pull out the paper was examined. Each slip of paper used had a thickness of 40 μm, a width of 10 mm, and a length of 50 mm. The force applied to press the rollers together was changed in five steps from (1) to (5). As shown in FIG. 6, in the conventional device, unevenness was noted in the pressure distribution in the axial direction, the pressure at the center decreasing, as the load applied between the rollers were increased. On the other hand, in the device of this embodiment, approximately uniform pressure was provided in the axial direction as shown in FIG. 5. Therefore, no uneven transfer is caused in the axial direction in image forming, and copy image of good quality can be assured.
The intermediate transfer device 4 is constructed as described above. The separator plate 8 is provided to separate copy paper from the intermediate transfer belt 5, and the cleaning device 9 is used to remove the remaining toner on the intermediate transfer belt 5.
An experiment was conducted to form a full color image using the copying machine of the above construction. The intermediate transfer belt 5 had a resistivity of 10 8 to 10 9 Ω cm, and the voltage applied during the 1st transfer to the 1st transfer rollers 6a and 6b was set at 600V for yellow toner, 600V for magenta toner, and 1000V for cyan toner. Different transfer voltages were used because the charge characteristic of toner varies according to the pigments contained in the toner. Generally, the 1st toner transfer can be accomplished with satisfactory results at the applied voltage of 400 to 1000V. If the 1st transfer voltage is too high, the toner layers formed on the intermediate transfer belt 5 take on a high potential, which causes toner particles to repel each other when toner images are superimposed on the intermediate transfer belt, thus resulting in a defective image. The 2nd transfer was performed with good results at the 2nd transfer voltage of approximately 1.6 V.
The intermediate transfer device of this invention is an intermediate transfer device which transfers toner on a photoconductor to an intermediate transfer belt before said toner is transferred onto paper, wherein said intermediate transfer belt being formed of a dielectric having a resistivity of approximately 10 7 to 10 11 Ω cm.
The transfer rollers are positioned in such a way as to press the intermediate transfer belt onto the photoconductor, thus increasing the pressing force of the intermediate transfer belt against the photoconductor. In this situation, when a voltage of polarity opposite to that of toner is applied to the two transfer rollers, the toner on the photoconductor is attracted toward the transfer rollers onto the intermediate transfer belt. At this time, the potential on the reverse surface of the intermediate transfer belt will be such as shown in FIG. 8. That is, a high potential is obtained over a relatively wide area on the reverse surface of the intermediate transfer belt between the two transfer rollers, thus enabling toner transfer to be performed over that wide area. Also, because almost uniform potential is obtained on the reverse surface of the intermediate transfer belt between the two transfer rollers, unevenness of transfer can be prevented. Furthermore, since the transfer rollers do not directly contact the intermediate transfer belt during the toner transfer, there is no possibility of the toner converging on the position facing the transfer rollers, thus preventing the image from being disturbed.
The transfer rollers may be made as idlers that are driven by the rotation of the intermediate transfer belt, so that there is no possibility that the intermediate transfer belt is chafed against the transfer rollers, thus preventing the intermediate transfer belt from being scratched. This will also serve to prevent unevenness of toner transfer.
Also, the voltage applied to the transfer rollers may be limited within the specified range, so that the transfer characteristic of the toner can be enhanced. In other words, this serves to eliminate the possibility of transfer failure due to insufficient electric field, and also the possibility of excessively charging the toner, thus preventing the image from being disturbed due to repulsion between toner particles in high potential toner layers on the intermediate transfer belt.
The intermediate transfer belt in the intermediate transfer device of this invention is formed from a dielectric having a resistivity of approximately 10 7 to 10 11 Ω cm, since a sufficient electric field can be created during transfer, eliminating the possibility of charging the intermediate transfer belt from being charged during the 1st transfer, the toner can be smoothly separated during the 2nd transfer.
It is understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the scope and spirit of this invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the description as set forth herein, but rather that the claims be construed as encompassing all the features of patentable novelty that reside in the present invention, including all features that would be treated as equivalents thereof by those skilled in the art to which this invention pertains. | A toner transfer device which transfers toner on a photoconductor to an intermediate transfer belt applied on a plurality of rollers, wherein at least part of the surface of the photoconductor moves in an arc while being pressed against the intermediate transfer belt, the toner transfer device comprising: a pair of transfer rollers disposed along the intermediate transfer belt between two of the rollers in such a manner that the part of the surface of the photoconductor which moves in an arc is positioned between the transfer rollers, at least part of each transfer roller being located outside each of two tangents, one of the tangents touching the photoconductor and one of the two rollers, the other tangent touching the photoconductor and the other roller, thereby allowing a certain length of the intermediate transfer belt between the two transfer rollers to be pressed against the part of the surface of the photoconductor moving in an arc; and a means for applying voltage to the transfer rollers, the voltage polarity being opposite to that of the toner. | 6 |
RELATED APPLICATION
This Application is related to Ser. No. 09/095,345, filed on the same day herewith, filed Jun. 10, 1998, now U.S. Pat. No. 6,106,748, entitled “Method And Apparatus For Removing Prophylactic Devices From Mandrels”, and assigned to the same Assignee as the present Application
FIELD OF THE INVENTION
The field of the present invention relates to apparatus and methods for making prophylactic devices, and more particularly to making such prophylactic devices from polyurethane.
BACKGROUND OF THE INVENTION
Prophylactic devices are used to prevent the transfer of infection, bacteria and viruses from an environment to a body member on which the device is mounted. Prophylactic devices include but are not limited to catheters, valves, gloves, and so forth. For example, condoms are used to protect the user from venereal diseases and for birth control, and surgical gloves are used to protect the user from infection. In order to allow the protected body member to move freely and to respond to external stimulus, the device must be as thin as possible, but this reduces the protection it provides. For many years prophylactic devices have been made of latex rubber, but when a latex condom is sufficiently thin, it reduces overall strength, is subject to breakage, and there is an increased risk that it will have pin holes that are large enough to permit the passage of viruses such as the HIV. Accordingly, latex condoms must be manufactured and tested with great care and consequent expense. Also, some people are allergic to latex.
It has been found that prophylactic devices made of polyurethane, in contrast to latex, can be very thin so as to provide a good sense of feel while at the same time being very strong, and free from pinholes. Also, polyurethane due to its synthetic nature is typically more nonallergenic than latex.
In U.S. Pat. No. 4,684,490 a method for manufacturing condoms is described in which a mandrel having the general shape and dimensions of a condom is dipped into a solvent solution of a polyurethane polymer and heated in air after being withdrawn therefrom so as to dry the polyurethane. The dried polyurethane which now forms a condom is then removed from the mandrel.
SUMMARY OF THE INVENTION
In accordance with the overall method used in this invention, mandrels having the general shape of the prophylactic device being manufactured are cleaned and subjected to cooling before being dipped into polyurethane or other suitable polymers dissolved in tetrahydrofuran (THF) for example. Other solvents or carriers such as dimethylfluorene (DMF), methyl ethyl ketone (MEK), dimethyl sulfoxide (DMSO), dimethylacetimide (DMAC), alcohols, chlorinated hydrocarbons, ketones, ethers, water (H 2 O), or any other organic solvents known in the art, and blends of such solvents, can also be used. THF is preferred for use in this invention partly because of its high solubility and easy removal or release from the finished film.
After dipping, the mandrels are rotated so as to produce a uniform film of a desired thickness profile and subjected to an elevated temperature so as to drive off the solvent. In a preferred method, the process is repeated starting with progressive cooling, followed by a second dip so that a second film of polyurethane is formed with the first film on the mandrel. The two films tend to become homogenous. Since THF tends to be highly flammable and potentially explosive in an oxygen atmosphere, the steps just described are carried out in a pressurized explosion resistant atmosphere maintaining oxygen below levels to support combustion.
The invention also includes a system for carrying out the aforesaid method in which pallets having mandrels mounted therein are transported through cleaning stations before being transported through a plurality of progressive cooling chambers to a dipping chamber in which there is a reservoir of polyurethane material dissolved in tetrahydrofuran. The viscosity of the solution is maintained in a desirable range by mixing or agitating it at a controlled temperature and keeping the concentration of THF within a given range. It is important that the rate at which the mandrels are lowered into and raised from the solution be precisely controlled, smooth and that there be no vibration. The pallets of mandrels are then rotated as much as 360° about an axis in the plane of the pallet, first in the dipping chamber, and then in a rotation chamber. Bidirectional rotation may be used in some applications. While in these chambers the mandrels themselves are also rotated about their respective axes. The polyurethane film formed on the mandrels by their having been dipped into the polyurethane solution is dried in evaporation ovens at successively higher temperatures, respectively. After the pallets emerge from the last evaporation oven, they are preferably subjected to a repeat of the process just described for a second dipping of the mandrels.
After this is done, the pallets are transported to a series of stations in an air atmosphere that respectively form one or more permanent rings at the open ends of the condoms on the mandrels, apply powder and remove the condoms from the mandrels. Alternatively, a wet takeoff system can be used. The pallets of mandrels freed of condoms are washed in one station, and rinsed in another, before being transported via a staging conveyor to an inspection and redress station. After completion of the inspection and redress, the pallets and mandrels are transported to a drying oven station. After drying, the pallets and associated mandrels are ready to be passed through the chambers just described starting with the cooling chambers, for another cycle making condoms.
Because of the high flammability and explosiveness of the solvent, THF, means are provided for keeping the oxygen concentration below given levels in each of the chambers referred to by introducing N 2 , and operating with the THF in a substantially oxygen free atmosphere. The expense of the operation is reduced by recovering THF from the atmosphere expelled from the chambers by utilizing a closed-loop system that passes through a condensing or absorption system. With this process the N 2 is reused, and heat exchangers are employed for extracting heat for use in the process. In this manner, through recovery of THF, N 2 , and heat, the process is made highly economic, and environmentally friendly. Also, any imperfect polyurethane condoms can be recycled back into the system.
Since the stations in the section where the final product is removed from the mandrels, and the mandrels are cleaned, inspected, redressed, and dried, respectively, are in the ambient or air atmosphere containing oxygen, and the chambers in the section where the product is formed on the mandrels in a nitrogen and oxygen reduced atmosphere, the mandrels are passed from one section to the other via an air lock.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the present invention are shown and described herein with reference to the drawings, in which like items are identified by the same reference designation, wherein:
FIGS. 1A and 1B are block diagrams of the principal components of apparatus for making prophylactic devices in accordance with the invention;
FIGS. 1C, 1 D, 1 E, and 1 F respectively illustrates the manner in which the elevator shown in FIG. 1A operates to position pallets for transfer between different parts of the apparatus;
FIG. 2 is a flowchart of the steps in making a prophylactic device in accordance with the invention;
FIG. 3 is a block diagram of apparatus used to control the temperature, percent O 2 and percent solvent in various chambers of the apparatus of FIG. 1;
FIG. 4A illustrates an elevator and mechanism for rotating the pallets as well as the mandrels;
FIG. 4B is a bottom view of a pallet carrying mandrels;
FIG. 4C is pictorial and side elevational view of a glass mandrel with an electrically conductive coating, as mounted on a mandrel holder for one embodiment of the invention;
FIG. 4D is a bottom view of a pallet showing intermeshed gears for rotating the mandrels about their respective axes;
FIG. 5 is a partial pictorial view of a takeoff station for one embodiment of the invention;
FIG. 6 is a top view within the takeoff station of FIG. 5, looking down on a top shoe shifting plate, and opposing pairs of top plate and bottom plate shoes, respectively;
FIG. 7 is a top view of a bottom shoe shifting plate containing a plurality of bottom plate shoes designated as left-hand shoes;
FIG. 8 is a top view of a top shoe shifting plate with a plurality of top plate shoes designated as right-hand shoes;
FIG. 9 is a top view of an insert table containing a plurality of takeoff inserts for the takeoff station of FIG. 5;
FIG. 10 is a top view of a air nipple table including an air nipple assembly containing a plurality of individual air nipples, for the takeoff station of FIG. 5;
FIG. 11 is a side view of a portion of the assembly of the top and bottom shifting plates, and associated gear assemblies for moving the plates in a reciprocal manner to move pairs of the left-hand- and right-hand shoes either toward one another or away from one another;
FIG. 12A is a partial pictorial view of the assembly of FIG. 11 viewed from a different direction;
FIG. 12B is a side view of a portion of rack pinion gear mechanism for providing reciprocal and opposite movement between the top and bottom shoe shifting plates, respectively, for an embodiment of the invention;
FIG. 12C shows a top view of a portion of the gear mechanism of FIG. 12B;
FIG. 13 is a partial pictorial view of a portion of the takeoff insert table in association with air assist cylinders and power driven gearing for raising and lowing the insert table, and further shows a portion of the associated air nipple assembly for the takeoff mechanism of FIG. 5;
FIG. 14 is an enlarged pictorial view of a portion of an array of takeoff inserts relative to associated air nipples for the takeoff mechanism of FIG. 5;
FIG. 15 is a partial pictorial view of various gearing, motor, and air valve mechanism associated with the takeoff mechanism of FIG. 5;
FIG. 16 shows a top view of a shoe assembly in a closed position relative to an associated mandrel;
FIG. 17 is a detailed partial cross-sectional view of a mandrel carrying a condom with a pair of opposing shoes in a closed position just after partially rolling a condom for removing the condom from the mandrel;
FIG. 18 is a partial pictorial view showing a substantial portion of a mandrel 178 carrying a condom, with the associated shoe assembly in a closed position as in FIG. 17 for removal of the condom;
FIG. 19 is a pictorial view showing a mandrel carrying a condom with the associated shoes in an open position, with the open position being exaggerated for purposes of illustration;
FIG. 20 is a partial pictorial view of a “snapper assembly” in relation to portions of the takeoff mechanism of FIG. 5, whereby the X-Y snapper assembly is moveable relative to the takeoff mechanism;
FIG. 21 is a partial pictorial view showing additional portions of the X-Y snapper mechanism of FIG. 20 in conjunction with a portion of the takeoff mechanism of FIG. 5;
FIG. 22A is an enlarged view of a portion of the X-Y snapper assembly showing details of the suction nozzle assembly thereof;
FIG. 22B is a detailed view of the front of an individual suction nozzle of FIG. 22A;
FIG. 23 is a partial pictorial and partial sectional view of an individual air nipple assembly;
FIG. 24 is a top view of an air nipple of the air nipple assembly of FIG. 23;
FIG. 25A is a backside view of a shoe assembly for the takeoff mechanism of FIG. 5;
FIG. 25B is a top view of the shoe of FIG. 25A;
FIG. 26A shows a back view of a shoe bracket for a top plate shoe or right-hand shoe;
FIG. 26B shows a side view of the shoe bracket of FIG. 26A;
FIG. 27A shows a back view of a shoe bracket for a bottom plate shoe or left-hand shoe;
FIG. 27B shows a side view of the shoe bracket of FIG. 27A;
FIG. 28A shows a simplified partial pictorial view of a dipping solution tank having a sliding cover in an open position for permitting glass mandrels to be dipped into the tank; and
FIG. 28B shows the pictorial view of FIG. 28A with the sliding cover moved to a position to close off holes in the top of the tank to avoid unnecessary evaporation of the dipping solution when not in use.
DETAILED DESCRIPTION OF THE INVENTION
The making of prophylactic devices in accordance with the method of this invention is best explained by the following description of apparatus of the invention that operates in accordance with the method. Although the method could be used to make any prophylactic device, the apparatus will be described in connection with the manufacture of condoms.
The complete method is a closed loop in which mandrels 178 (see FIGS. 4B, 4 C and 5 ) generally shaped like condoms are carried by pallets 176 from cleaning and drying stations to be described that are in a Section 2 (see FIG. 1A) to a succession of chambers in a Section 4 (see FIG. 1B) where at least one polyurethane film is formed on the mandrels 178 . Then the pallets 176 are returned to stations in the Section 2 in which the film on each mandrel 178 , which now has a condom with a permanent ring formed at its open end, is powdered and removed in a dry process, or removed using a wet process. The mandrels 178 are then cleaned, inspected and redressed, if necessary to replace a defective mandrel 178 or strip-off a condom not previously removed. The mandrels 178 are then ready for reuse in producing condoms.
As will become clear, the Section 2 where the mandrels 178 are cleaned and the condoms removed contains an air atmosphere, and the Section 4 where the film is formed on the mandrels contains an inert atmosphere including the solvent used in the film forming process. Preferably, the solvent is THF. The reason is that through experiments, the present inventor found THP to have excellent solubility for polyurethane, relative to other solvents, and it is easily removed from polyurethane. It is important to insure that all solvent is removed from the condom. Because of the explosive nature of THF, the infiltration of air from the Section 2 to the Section 4 must be minimized, and because of the flammability of the THF, its infiltration from the Section 4 to the Section 2 must be minimized even though pallets 176 of mandrels 178 are passed in both directions between the two sections. Minimizing these infiltrations is accomplished by an air lock 6 (see FIG. 1B) between the cleaning and product removal Section 2 and the film forming Section 4.
Note that the present invention provides a system that is capable of manufacturing prophylactic devices consisting of natural and synthetic elastomers. For example, as indicated polyurethane is such as material, as is latex. Other water-based polymers may 1 include nitrite rubber, neoprene rubber, SBS rubber emulsion, polyvinyl alcohols, polyvinyl acetate, polyacrylates, polyethylene glycols, and alkyl cellulose. Other solvent based polymers may include polyisoprene, SBS rubber, silicone rubber, polyolefms, polyamides, polyesters, PVC, polymethylmethacrylate, polyacrylates, polyacetals, polycarbonates, polycaprolactams, and halogenated polymers. Note that the water-based polymer examples are also soluble in solvents. Other polymer materials may also include copolymers, terpolymers, block polymers, and so forth.
The following description of the operation of the system of FIG. 1B starts with the transfer of a pallet 176 of mandrels 178 from an airlock 6 to an elevator chamber 8 . In a manner to be explained in the discussion of FIGS. 1B, 1 C, 1 D and 1 E, the pallet 176 is transported so as to spend successive periods of time isolated in a first cooling chamber 10 , a second cooling chamber 12 , a third cooling chamber 14 , a dipping chamber 16 where the mandrels 178 are coated with a polyurethane film, a rotation chamber 18 , a first evaporation oven chamber 20 , a second evaporation oven chamber 22 and back to the elevator chamber 8 . At this point, one polyurethane film has been deposited on the mandrels 178 so that the pallet 176 could be passed back through the air lock 6 into the Section 2 where the condoms are removed and the mandrels 178 are cleaned in preparation for another trip through the condom forming Section 4 as just described. Preferably, however, a second polyurethane film is formed on the first film by repeating the trip just described, in which event the pallet 176 is conveyed by an elevator in the elevator chamber 8 back to the first cooling chamber 10 . In the same manner layers of more than two films can be formed. Through use of multiple dip capabilities, the present invention provides relative to the prior art faster overall cycle times and minimizes defects. In certain product applications more than two films may be formed on each mandrel 178 .
A detailed description of the apparatus and operations carried out in the various chambers of the film forming Section 4 is as follows. In order to ensure that the mandrels 178 are smooth and can be readily cleaned and stripped they are made of non-porous material such as glass. In an alternative embodiment, the mandrels 178 can be frosted or etched to enhance removal of the film. Note that the mandrels can also be made from any other suitable material, not limited to glass. When they enter the first cooling chamber 10 for the first time, they will be hot because of having been passed through a drying station 100 (see FIG. 1A) in the Section 2, and when they enter it a second time, they are hot because of having come from the second evaporation oven chamber 22 . Because the temperature of the polyurethane solution into which the mandrels 178 will be dipped in the dipping unit chamber 16 in either case is kept at about 50° F. to 70° F., there is a chance that the mandrels 178 will crack, and/or excessive outgassing of the solvent will occur, if the mandrels 178 are at a temperature higher than about 58° F. In order to prevent this from occurring, the pallets 176 of mandrels 178 spend successive periods of time in the cooling chambers 10 , 12 and 14 that are preferably at successively lower temperatures. Means not shown such as conventional heat exchanger configurations through which water or refrigerant of a proper temperature is circulated are provided for maintaining the cooling chambers 10 , 12 and 14 , respectively, at appropriate temperatures between the temperature of the drying station and the temperature of the dipping chamber 16 , which is at about 70° F. An adjustable high velocity and even flow of air is maintained in the cooling chambers 10 , 12 and 14 , by circulation of air in them through respective honeycombed structures 23 , 25 and 27 in their bottoms with blowers 29 . Note that the air flow is adjustable throughout Section 4.
When a pallet 176 is passed from the last cooling chamber 14 into the dipping chamber 16 , it engages a dual axis robotic mechanism that is capable of vertical and rotational movement, simplistically shown in FIG. 4A, that dips the pallet 176 at carefully controlled rates of speed and without vibration into and out of a reservoir 36 of polyurethane material dissolved in THF.
A level control mechanism 38 senses when the level of the polyurethane solution in the reservoir 36 drops below a given level and pumps more polyurethane solution into the reservoir 36 from a tank 40 . Circulation of the solution so as to keep it homogeneous and free from particulate matter is achieved by a filter 42 and a pump 44 . In order to obtain consistent results, the viscosity of the solution in the reservoir 36 is kept constant by sensing the viscosity in the circulation loop with a viscosity sensor 47 and causing an appropriate amount of THF to be injected from a tank 46 into the circulation line with a pump 48 . It is also necessary to maintain the temperatures of the polyurethane solution constant with a suitable temperature control means 50 . The temperature of the polyurethane solution is typically 50° F. to 70° F., with the concentration of THF maintained at 3% to 7% in the atmosphere of chambers 16 and 18 .
Both uniformity and the profile of the thickness of a film of polyurethane solution on the mandrels 178 is significantly improved by rotating the pallet 176 about a horizontal axis by as much as 360°. Whereas the mandrels 178 can also be rotated about their respective axes both in a clockwise and counterclockwise direction in the dipping reservoir chamber 16 , chamber 18 , and evaporation ovens 20 and 22 . This is preferably done simultaneously in the dipping chamber 16 and rotation chamber 18 along with rotation of the pallet 176 . The axial mandrel 178 rotation is controlled at speeds up to one hundred rpm, and the 360° pallet 176 rotation is controlled to speeds up to six rpm.
Evaporation of the THF solvent in the film deposited on the mandrels 178 in the dipping solution reservoir chamber 36 so as to form polyurethane condoms on the mandrels is achieved in the dipping and rotation chamber 16 , rotation chamber 18 , and evaporation oven chambers 20 and 22 . Circulating air for the oven chambers 20 and 22 is respectively provided by blowers 52 and 54 . Air circulation in chambers 16 and 18 is provided by a common blower 53 . Evenly controlled flow is achieved by causing the air to flow downwardly along the outside surfaces of the oven chambers 20 , 22 which are equipped with heat exchangers (not shown), and upwardly through their center through honeycombed structures 56 and 58 , respectively.
Accordingly, in the illustrated embodiments of the invention provided herein evaporation is used to drive THF from the film. However, with polyurethane film formula structures water quenching or stripping can also be used rather than evaporation to remove the THF from the film formed.
For optimum operation, the temperature and THF concentration in the chambers 8 , 10 , 12 , 14 , 16 , 18 , 20 and 22 must be maintained within appropriate ranges, and for safe operation, the concentration of O 2 in these chambers is maintained at sufficiently low levels. In order to reduce cost, the solvent THF is recovered. One way of performing these functions is to use apparatus such as shown in FIG. 3 for each chamber of film forming Section 4, herein designated as 61 , for representing each independent chamber. All of the aforesaid temperatures are interdependent, along with the dipping speed, dipping times, rotational speeds of mandrels 178 , withdrawal and insertion rates, angular positions, velocities, and so forth. For example, in one embodiment oven 20 is maintained at 120° F., oven 22 at 140° F., cooling station 10 at 40° F., cooling station 12 at 42° F., cooling station 14 at 41 ° F., and dipping and rotation stations 16 and 18 at 60° F.
The required low concentration of O 2 is secured by using detectors 62 (see FIG. 3) to constantly sample gas from the chamber 61 via tubes 64 and provide an indication to a controller 66 of the concentration of O 2 . When an indication of too high a concentration occurs, the controller 66 causes an inert gas such as N 2 from a source 68 to be introduced into the chamber 61 via a tube 72 until a sufficiently low concentration of O 2 is indicated. This is the source of N 2 that will be found in all the chambers of the film forming Section 4. Note that the O 2 detection systems are redundant throughout the present system.
The following table suggests the maximum concentrations of the solvent, THF, that preferably should be maintained in the various chambers. The maximum values attainable in the below listed zones 3 and 4 (see Table 1) may be limited as necessary to prevent solvent condensation on equipment within each zone.
TABLE 1
ZONE
SOLVENT
NO.
ZONE
CONCENTRATION
(1)
Elevator chamber 8
Less than 1% THF
(2)
Cooling chambers 10, 12, 14
Less than 1% THF
(3)
Dipping chamber 16 and pallet rotation
1-11% THF
chamber 18
(4)
Solvent evaporation oven 20
1-11% THF
(5)
Solvent evaporation oven 22
Less than 2% THF
In order to establish and maintain the THF concentrations set forth in Table 1, solvent sensors 74 (see FIG. 3) provide signals to the controller 66 indicative of the THF concentration in the chamber 61 . The controller 66 modulates return valves (not shown) from the recovery system and controls N 2 return from the source 78 into the chamber 61 via the tubes 72 until the THF concentration is reduced to or maintained at the the desired level. The gasses expelled from the chamber 61 via a tube 76 are transported to a means 78 for recovering the THF, which may be a BRAYCYCE® solvent recovery system, for example. The THF recovered is delivered to the tank 46 of FIG. 1 B. The heat generated by the process in the recovery system is made available for heating fluid flowing in the heat exchangers, not shown, of the evaporation oven chambers 20 and 22 , and drying oven 100 , chamber 114 , wash tank 94 , and rinse tank 96 . Note that solvent laden N 2 from the process is transferred from chamber 61 to THF recovery source 78 . The solvent is condensed out, and the process N 2 is transported back to chamber 61 via tubes 72 .
If it is desired to gain access to the film forming Section 4, the controller 66 operates pump 44 (see FIG. 1B) to pump dipping solution from reservoir 36 into evacuation tank 45 . The atmosphere of Section 4 is then recirculated through the solvent recovery system 78 until solvent or THF levels are reduced to acceptable levels. Next, filtered atmospheric air is introduced via air supply fan 71 (see FIG. 3) into Section 4 to bring oxygen levels to a safe level for human entry. This is done for all chambers of Section 4.
The temperature of a chamber generally designated as 61 is controlled by sensing the temperature of the chamber 61 with a means in a temperature control 80 that sends a signal to the controller 66 . As the temperature varies about a desired value, the controller 66 causes the temperature control 80 to vary the amount of cooling/heating fluid flowing through heat exchangers 84 that are in the air recirculation stream of chamber 61 , that is in each chamber of Section 4, respectively.
Section 2
When a pallet 176 of mandrels 178 has been fully processed in the film forming Section 4, it is transferred from the elevator station 8 to the air lock 6 and is then transferred directly to the lower level 83 (see FIG. 1A) of a robotic transport unit 85 . The transport unit 85 is successively positioned over stations 86 , 88 , 90 , 94 and 96 . At each station the transport unit lower level 83 is lowered so that the function of the station can be carried out.
In FIG. 1A, the transport unit 85 is shown as being in registration with the station 86 wherein the open ends of the condoms on the mandrels are rolled down a short distance to form rings. The rings are permanent, and can be made so in different ways known in the art other than by rolling. For example, by gluing, bonding, sewing, or extruding a ring on the condom. However, in this example, as indicated, the ring is formed by partially rolling the open end of the unpowdered condom to form the ring, which becomes permanent because the material bonds to itself at this time. The condoms are powdered in the station 88 and removed from the mandrels 178 in the station 90 , and via the X-Y snapper station 92 the condoms are removed from the takeoff station 90 . The condoms are collected and placed into a tumbler apparatus at station 93 to permit the condom material the additional time necessary to obtain sufficient crystallization for obtaining winkle free condoms. The tumbler apparatus (not shown) can be clothes dryer or washer modified for tumbling the condoms at ambient temperature. The mandrels 178 are washed in the station 94 by soaking them in an ultrasonically activated cleaning solution or R.O (reverse osmosis) water, and rinsed in the station 96 with hot R.O water. R.O water is used to avoid environmentally sensitive discharges as would be experienced with deionized water systems and regeneration of the same. Although R.O water is preferred for use in the cleaning process, tap and/or deionized water can also be used.
The pallet 176 of rinsed mandrels 178 is moved onto a staging conveyor 97 which conveys the pallet 176 to an inspection and redress station 99 . The mandrels 178 that may be defective are replaced, and condoms or condom fragments if any are removed from the mandrels 178 . The redressed pallet 176 is then conveyed from the redress station 99 to the drying oven 100 , and then to level 87 of the transport unit 85 . Note that the inspection and redress station 99 can also be used to change a pallet 176 of mandrels 178 to make a different style of condom or product, or remove a defective pallet 176 on the fly.
The temperature in the oven 100 is regulated by a temperature controller section 104 included in controller, in this example, preferably between 160° and 180° F. Dry make-up air is drawn from a source 106 and through a filter 108 by fans 110 and with recirculated air directed upwardly through a honeycomb structure 112 just below the bottom 98 of the oven 100 . In order to obtain consistent drying, the relative humidity in the oven 100 is controlled by automatic modulation of the exhaust air flow, by measuring the humidity and opening an exhaust damper to expel moisture laden air. The space over the stations 86 , 88 , 90 , 92 , 94 and 96 is enclosed as indicated at 114 , and the temperature therein is removed by forced ventilation with a fan 116 that draws air through a filter 118 , and through heat exchanger 117 , and expelled by two exhaust fans (not shown) on each end of the chamber 114 .
The transport unit 85 removes pallet 176 of the dried mandrels 178 from oven 100 on its upper level 87 , and transports pallet 176 to air lock 6 , for reintroduction into Section 4, after removing a pallet 176 from air lock 6 to level 83 of the transport unit 85 . The pallet 176 and associated mandrels 178 are then moved through the various stations of Section 4 to form condoms on the mandrels 178 , as previously described.
When the system of FIGS. 1A and 1B is in normal operation, twelve pallets 176 are being processed at various stations and chambers. In other embodiments, more or less pallets 176 may be provided. A pallet 176 that is in the drying oven 100 can be replaced or accessed if necessary by opening a door 120 without interrupting the operation of the system. This is a less preferred access than that provided by the inspection and redress station 99 .
The sequence of operation of the system of FIG. 1A as set forth in FIG. 2 and in the Table 2 below, is controlled by the controller 66 . Table 2 shows a time sequence of events occurring in FIG. 1B, and is a practical example, not meant to be limiting. Because this system is programmable, and fully multitasking, flexibility is provided to adapt to other processes and/or cycle times with minimum physical modifications.
TABLE 2
Preferred
Range
Event
(In Seconds)
(In Seconds)
(1)
Transfer from drying oven 100 to air
40
30- 50
lock 6
(2)
Air lock 6 cycle to purge air and
80
60- 120
introduce nitrogen
(3)
Transfer from air lock to cooling
10
7- 20
chamber 10
(4)
To cooling chamber 10
90
80-120
(5)
To cooling chamber 12
90
80- 120
(6)
To cooling chamber 14
90
80-120
(7)
First dip in dipping unit chamber 16
85
70-120
(8)
Rotate and distribute film in rotation
70
60- 120
chamber 18
(9)
Dry film in oven chamber 20
90
80-120
(10)
Dry film in oven chamber 22
90
80-120
(11)
Transfer in elevator chamber 8 to air
20
15- 25
cooling chamber 10
(12)
To cooling chamber 10
90
80- 120
(13)
To cooling chamber 12
90
80-120
(14)
To cooling chamber 14
90
80-120
(15)
Second dip in dipping chamber 16
85
70-120
(16)
Rotate and distribute film in
70
60- 120
chambers 16 and 18
(17)
Dry film in oven chamber 20
90
80-120
(18)
Dry film in oven chamber 22
90
80-120
(19)
Transfer to air lock chamber 6
20
15-25
(20)
Air lock 6 opened to air
80
60-120
(21)
Discharge from air lock 6 onto
10
7- 20
transport unit 95
(22)
Form ring roll, station 86, and
30
20- 80
transfer to powder station 88
(23)
Powder application and transfer to
20
10- 80
takeoff station 90
(24)
X-Y snapper 92 removal of finished
30
20- 120
product from takeoff station 90, and
transfer of mandrels 178 to wash
station 94
(25)
Wash mandrels 178 in station 94 and
25
15- 45
transfer to rinse station 96
(26)
Rinse in station 96
25
15-45
(27)
Transfer to staging conveyor 97 for
10
7- 15
conveyance to inspection and
redress station 99
(28)
Redress
180
120-240
(29)
Transfer to drying oven 100 and
10
7- 15
transport unit 95
(30)
Air dry mandrels 178 in drying oven
180
160- 240
100
PREFERRED GRAND TOTAL . . . 1,980 SEC.
(33 min or 11 pallets × min./cycle)
Operation of Air Lock
The air lock 6 , FIG. 1B, is provided with what is called an air side door 121 opening into Section 2, which, it will be recalled has normal air atmosphere. Air lock 6 also includes a nitrogen side door 122 opening into the elevator chamber 8 of Section 4, which, as previously mentioned can have a nitrogen or other inert atmosphere with a slight concentration of THF.
A pallet 176 of clean mandrels 178 from the Section 2 is passed into the film forming Section 4 by opening the air side door 121 , moving the pallet 176 into the air lock 6 and closing the air side door 121 , the nitrogen side door 122 being closed. A vacuum pump 123 pumps the air lock 6 down to a deep vacuum that is preferably less than 12 torr, which is less than 1% of the average atmospheric pressure, in order to minimize air (oxygen) infiltration into the Section 4. Air from the pump 123 exits at 127 . The vacuum is then broken by permitting nitrogen to flow into the air lock 6 from a receiver tank 126 or any suitable source, thereby equalizing its pressure with that in Section 4. The nitrogen side door 122 is then opened and the pallet 176 is passed into an elevator mechanism (not shown) in the elevator chamber 8 .
A pallet 176 can be passed from the film forming Section 4 to the Section 2 by passing it from the elevator section 8 into the air lock 6 . The nitrogen side door 122 is then closed, and vacuum pump 124 pumps the air lock 6 to less than 12 torr vacuum, but preferably sends its exhaust into a receiver tank 126 rather than existing into the atmosphere via outlet 125 . The vacuum is broken by connecting the air lock 6 to a source 128 of dry filtered air, the air side door 121 is opened and the pallet 176 is passed onto the lower level 83 of the transfer or transport unit 85 . The purpose of the receiver tank 126 is to conserve nitrogen because it can be the source of nitrogen when vacuum in the air lock 6 is to be broken by admitting nitrogen into it.
Elevator
The elevator in the elevator chamber 8 , not shown in detail in FIG. 1B, has two shelves 130 and 132 that are spaced by half the equal heights of the air lock 6 , the evacuation oven chamber 22 and the cooling chamber 10 . When the shelves 130 and 132 are in the positions shown in FIG. 1B, a finished pallet 176 can be moved from the oven chamber 22 onto the elevator shelf 130 , and a new clean pallet 176 can be moved from the air lock 6 onto the shelf 132 . In FIG. 1C, the finished pallet 176 can be moved from the shelf 130 to the air lock 6 . In FIG. 1D, the new pallet 176 can be moved from the shelf 132 to the cooling chamber 10 . If a pallet 176 is to be recycled so as to form a second polyurethane film on the mandrels 178 , the shelf 130 is placed even with the bottom of the oven chamber 22 (see FIG. 1 E), and the pallet 176 in the oven chamber 22 is moved onto it. Then the elevator lowers the shelf 130 to the bottom of the cooling chamber 10 (see FIG. 1F) so that the pallet 176 can be placed in that chamber a second time. Note that FIGS. 1B through 1F are not drawn to scale or in perspective, and are meant for purposes of illustration only.
Rotation
In each of the dipping unit chambers 16 and rotation chamber 18 , the dipping solution reservoir 36 , and evaporation oven 20 , the mandrels 178 are rotated about their axes. In chambers 16 and 18 the mandrels 178 , as well as the pallets 176 in which they are mounted are rotated about an axis in their planes. One way of achieving these rotations in the dipping chamber 16 as well as performing the dipping function is illustrated in FIG. 4 A. These rotations produce walls of desired thickness profiles in the prophylactic devices formed on the mandrels 178 .
In FIG. 4A, a chain 134 is mounted about upper and lower sets of sprockets 136 and 138 , and a chain 140 is mounted about upper and lower sets of sprockets 142 and 144 . The sprockets 136 , 138 , 142 and 144 are mounted on the walls of the chamber 16 for moving a robot 141 in a vertical plane, and the shafts plans 146 , driven by an electric motor 148 that is also mounted on a wall of chamber 16 is connected between the centers of the sprocket sets 136 and 142 so as to be able to rotate them.
Gear 150 is secured to the elevator platform 154 in such manner that it does not rotate. The elevator platform 154 is mounted for rotation about the center of gear 150 by a chain about gear 150 driven by a motor 156 and a gear set (not shown). In this example, the motor 162 is affixed to the platform 154 . The motor 162 has a vertical shaft 166 . Motor 164 is also affixed to the platform 154 and turns roller sets 172 and 174 . Projections 168 and 170 extend downwardly from the platform 154 and have powered roller sets 172 and 174 , respectively, driven by motor 164 , mounted on them. A pallet 176 that is shown as being mounted on the rollers 172 and 174 has mandrels 178 extending downwardly from it as shown in the bottom view of FIG. 4 B. As will be described in connection with FIG. 4C, gears 208 are coaxially mounted on the upper ends of the mandrels 178 that are intermeshed in such manner that rotation of one gear 208 rotates all the others. One gear 208 is rotated by engagement with the shaft 166 of the motor 162 . In order to permit the pallet 176 to be moved in and out of the chamber 16 , it is necessary that provision be made for vertical movement of the shaft 166 . Rotation of the gear sets 136 , 138 , 142 and 144 by operation of the motor 148 raises or lowers the entire assembly 141 between chains 134 and 140 . The assembly 141 is lowered when the mandrels 178 are to be dipped into the dipping solution reservoir 36 , and is raised when the pallet 176 and mandrels 178 are to be rotated. It is also raised when a pallet 176 and its attached mandrels 178 are to be transferred to the rotation chamber 18 .
When the pallet 176 is in position, it can be raised or lowered by raising and lowering the platform 154 by operation of the motor 148 . Rotation of the pallet 176 about an horizontal axis is effected by turning motor 156 and its gear set in a chain about gear 150 , and also concurrently or independently rotation of the mandrels 178 about their respective axes is achieved by operation of the motor 162 .
The structure for rotating the pallet 176 and the mandrels 178 when the pallet 176 is in the rotation chamber 18 is the same as in FIG. 4A, but no vertical movement is required so that the motor 148 , the sprockets 136 , 138 , 142 and 144 and the chains 134 and 140 are not required.
In FIG. 4C, a mandrel holder 200 , all in one piece, that is made of material that does not react with the solvent, has a groove 202 molded and/or machined into it in which an O-ring 204 is seated. In this example, a gear section 208 is coupled via a step-down hub 206 to the groove section 202 . A central shaft 201 is positioned between groove section 202 and a similar groove section 210 on which an X-ring 212 is retained. A hollow glass mandrel 178 fits over and is held by the O-rings 204 and 212 . One end of the mandrel 178 is preferably shaped like a nipple 216 . After the films are formed on the glass mandrel 178 in the processing Section 4 of FIG. 1B, they are coated with silica powder in the powder station 88 of FIG. 1 A. Typically the powder size is about 25 to 40 microns, and is charged at 20,000 to 30,000 volts. The glass mandrel 178 is provided with a conductive coating 218 that is connected via an electrical conductive O-ring 204 to a source of reference potential, such as ground so as to create an electrostatic field that attracts the powder and increases its adherence to the film, in this example. This electrical connection is provided by an electrically conductive brush (not shown) connected between O-ring 204 and shaft 220 .
Each mandrel 178 assembly just described is attached to the pallet 176 by a shaft 220 that projects from the center of the gear 208 and through a cylindrical bearing 226 . A washer 224 is mounted on the shaft 220 at the side of the pallet 176 that is opposite to the gear 208 and engages a bearing 226 . A retention nut 228 on the shaft 220 abuts against washer 224 .
Rotation of the mandrel 178 assemblies about the axis 220 is achieved by engaging their gears 208 as illustrated in FIG. 4 D and connecting the shaft 166 of the motor 162 to a central one of gears 208 to act as a drive gear. When shaft 166 is engaged in a socket (not shown) of the central gear 208 , and with shaft 166 rotating, each adjacent pair of the gears 208 rotate in opposite directions.
The details of the apparatus associated with the takeoff station 90 , and with the X-Y snapper station 92 , will now be described with reference to FIGS. 5 through 27B. In general terms, the takeoff station 90 includes three main subassemblies. With reference to FIG. 5, in a simplified view of the subassemblies located below a plurality of mandrels 178 projecting from a pallet 176 retained by transport unit 85 , the first subassembly includes a top shoe shifting plate 300 positioned over a bottom shoe shifting plate 302 . The top shoe shifting plate 300 includes a plurality of top plate shoes or right-hand shoes 310 , and the bottom shoe shifting plate includes a plurality of bottom plate shoes or left-hand shoes 308 mounted to it, as will be described in greater detail below. Each right-hand shoe 310 is paired with an individual left-hand shoe 308 . Located immediately below the bottom shoe shifting plate 302 is a second subassembly that includes an insert table 304 upon which are mounted a plurality of takeoff inserts 312 . The third subassembly is located below the insert table 304 , and includes an air nipple table 306 upon which are mounted a plurality of air nipple assemblies 314 . Each air nipple assembly 314 includes an air connector assembly 320 secured to the air nipple table 306 , and vertically oriented tubing 318 projecting upward from the air connector assembly 320 . An air nipple 316 is mounted at the top of each of the tubes 318 , as shown. Each of the air nipples 316 are associated with an individual one of the takeoff inserts 312 and individual one of a pair of shoes 308 and 310 .
In FIG. 6, a top view looking downward upon the top shoe shifting plate 300 , shows that in this example there are fifteen columns by twenty-seven rows of pairs of top plate or right-hand shoes 310 and bottom plate or left-hand shoes 308 , the pairs totaling 405 . Note that with respect to the right- and left-hand orientation, FIG. 6 is being viewed from the right side of the drawing looking in toward the right side of the top shoe shifting plate 300 . The bottom plate shoes or left-hand shoes 308 of the bottom shoe shifting plate are shown in FIG. 7 looking down upon the top of the bottom shoe shifting plate 302 . The bottom plate shoes 308 project through holes (not shown) in the top shoe shifting plate 300 to be positioned in opposing relationship with their respective top plate shoes 310 , as shown in FIG. 6 . In this regard, as shown in FIG. 8, the top plate or right-hand shoes 310 are positioned as shown on the top shoe shifting plate 300 prior to moving the bottom plate shoes 308 through holes in the top shoe shifting plate 300 (the holes are not shown in this example) for positioning in opposing relationship with respective ones of the top plate or right-hand shoes 310 .
A top view of the insert table 304 is shown in FIG. 9 . The takeoff inserts 312 are in this example positioned adjacent to one another and in juxtaposition, in a configuration of fifteen columns by twenty- seven rows, as shown. Each insert 312 includes a hole 313 that is circular in this example, and is concentric with and smaller in diameter than the diameters of both an underlying hole (not shown) through insert table 304 , and a rolled up condom.
FIG. 10 shows a top view of the air nipple assembly 314 looking down upon the air nipple table 306 . As shown, the air nipple assembly 314 includes fifteen columns by twenty-seven rows of air nipples 316 , which are juxtaposed to one another.
Note that in an engineering prototype machine, the right-hand and left-hand shoes 310 , 308 were made from Amodel®, the takeoff inserts 312 from Delrin®, and the air nipples 316 from Teflon®. However, any other suitable materials can be used.
In FIG. 11 a simplified view is shown of a portion of the mechanism for providing reciprocal motion between the top and bottom shoe shifting plates 300 and 302 , respectively, whereby if one plate is moving in one direction, the other is moving in the opposite direction. In this manner, each of the pairs of shoes 308 , 310 are selectively moved toward one another, or away from one another, as will be explained in greater detail below. A support post 309 has a gear box assembly 301 bolted to it via a bolts 311 , as shown. Another gear assembly 303 is mounted upon the bottom shoe shifting plate 302 via the button head screws 314 . The gear box 301 is driven by a stepper motor (not shown) for causing a screw 304 to rotate in a clockwise or counterclockwise direction for causing the gear assembly 303 to move back-and-forth on the screw 304 , for in turn causing the bottom shoe shifting plate 302 to move in the direction of the gear assembly 303 . A rack and pinion gearing located between the shifting plates 300 and 302 , causes the top shoe shifting plate 300 to move in a direction opposite to that of the bottom shoe shifting plate 302 . Note that the bottom plate shoes 308 are secured to bottom shoe brackets 327 , which in turn are secured to the bottom shoe shifting plate 302 . Similarly, the top plate shoes 310 are secured via shoe brackets 325 to the top shoe shifting plate 300 .
In FIG. 12A, a partial pictorial view looking in at an angle is shown of the top shoe shifting plate 300 , a number of bottom plate and top plate shoes 308 , 310 , and the gear box 301 , and gear assembly 303 . A portion of the rack and pinion gearing can be seen through an oval hole 309 , in this example, in the top shoe shifting plate 300 . Details of the rack and pinion gear mechanism between the top shoe shifting plate 300 and bottom shoe shifting plate 302 are shown as a side view in FIG. 12B, and as a top view in FIG. 12 C. As shown, the rack and pinion gearing includes a rack gear 333 mounted on the bottom shoe shifting plate 302 , and a pinion gear 337 connected between rack gear 333 and a rack gear 335 mounted on the bottom of the top shoe shifting plate 300 .
In FIG. 13, a pictorial view is shown of a corner portion of the mechanism used for raising and lowing the insert table 304 remains level during lifting and lowering. A pinion gear 337 contacts with a rack gear 339 for providing a means to insure the insert table 304 remains level during lifting and lowering. Lifting and lowering power is provided by a pneumatic cylinder 333 a for providing power to lift and lower the insert table 304 . Note that four air cylinders areh used, with one being located in each corner of the insert table 304 (e.g. see cylinder 333 b in FIG. 21 ). A plurality of position detecting transducers are used in the system, two of which ( 341 and 343 ) are shown in FIG. 13 . Such detectors may act as a means for limiting the upward or downward movement particular ones of the mechanical assemblies of the takeoff station 90 mechanism, and as housing means.
In FIG. 14, an enlarged view of a number of air nipples 316 located beneath a plurality of takeoff inserts 312 is shown. Each of the takeoff inserts 312 includes a circular hole 313 that has a chamfer about the circumference of the underlying holes of insert table 304 . As will be explained below, a condom 307 removed from a mandrel 176 , will during one phase of the takeoff operation be held on top of its associated takeoff insert 312 , as shown on one of the inserts 312 in FIG. 14 in the upper left-hand portion. Note that the overall takeoff geometry described herein can be changed to accommodate different products.
FIG. 15 is a pictorial view of a portion of the takeoff apparatus including a gear box 345 that is driven by a servo motor assembly 346 for moving the air nipple table 306 (see FIG. 5 ). Also shown in FIG. 15 are vertical frame members 349 , lateral frame members 351 , an air regulator 354 supplying an air manifold 356 for connection to the air nipple table 306 , and electrical box 347 . Note the relative locations of the insert table 304 , and air nipples 316 , as partially shown in FIG. 15 .
As shown in FIG. 16, looking down at a mandrel 178 located between a bottom plate shoe 308 and a top plate shoe 310 , the shoes are resiliently mounted to their respective shoe brackets 327 , 325 . More specifically, a bottom plate shoe 308 is mounted via two mounting posts 321 to a bottom plate shoe bracket 327 . A helical spring 317 is mounted on a post 321 of shoe 308 between shoe 308 and the inside face of the shoe bracket 327 . The mounting post 321 is secured to the outside face of the shoe bracket 327 via a retainer clip 323 , as shown. Similarly, the opposing top plate shoe 310 is resiliently mounted to its associated top shoe bracket 325 . Note that the bottom shoe brackets 327 are secured to the bottom shoe shifting plate 302 via mounting feet 331 located at the bottom of the brackets 327 , and similarly the top shoe brackets 325 are mounted on the top shoe shifting plate 300 via mounting feet 329 located at the bottom of the shoe brackets 325 . The spring biasing provided by the helical springs 317 is used to substantially reduce the chance of damaging a condom 307 on a glass mandrel 178 due to excess force being applied by the pairs of shoes 308 and 310 when they move toward one another and close upon their associated mandrels 178 , as will be explained in greater detail below.
With reference to both FIGS. 16 and 17, note that each one of the shoes 308 and 310 include a projecting flange 308 a , and 310 a , respectively. Also, the cross-sectional view of FIG. 17 shows the shoes 308 and 310 in a closed position upon a mandrel 178 just after partially rolling up the condom 307 to remove it from the mandrel 178 . Note that the closed pair of shoes 308 and 310 provide for engaging a respective condom 307 , whereby as will be explained in greater detail below, when mandrel 178 is moved upward to a position shown in FIG. 17, this movement causes the condom 307 to be rolled downward toward the end of the mandrel 178 . In FIG. 18, a more complete pictorial view is provided for showing substantially the entire mandrel 178 carrying a condom 307 formed thereon, along with two mounting brackets 325 and 327 , and the associated other mechanical features described for FIG. 16 above. In FIG. 19, the pair of shoes 308 and 310 are shown in an open position before being moved into engagement with the condom 307 after mandrel 178 is raised a predetermined amount, as previously described.
After the condoms 307 have been removed from their respective mandrels 178 , and powdered at the interior of their closed ends, the condoms 307 are resting on top of the takeoff inserts 312 , respectively, awaiting removal from the takeoff station 90 , as will be explained in greater detail below. The condoms 307 are removed from the takeoff insert 312 via the X-Y snapper station 92 (see FIG. 1 A), a portion of which is shown in FIG. 20 . As shown, a plurality of snapper tubes 356 , three in this example, each have a snapper suction nozzle 358 attached to their open end proximate takeoff station 90 (see FIG. 1 A). A portion of the snapper tubes 356 are mounted upon a trolley 362 for moving the nozzles 358 transverse to the insert table 304 , that is in the X-direction, in this example. A track 364 is provided for the trolley 362 . The nozzles 358 each have a condom entry 360 , as shown, and as further shown in FIG. 21, the X-Y snapper station 92 also includes suction tube CAT racks 366 including links 370 for carrying flexible suction tubes 368 , as shown. The flexible suction tubes 368 are connected to the ends of the suction tubes 356 opposite the suction nozzles 358 , as shown. A motor 372 is located for driving a trolley 374 for moving the suction tubes 356 and associated nozzles 358 into position under the insert table 304 for sucking up condoms 307 from the takeoff inserts 312 . In this regard, note that trolley 374 is driven for moving the suction nozzles 358 in a Y-direction under the insert table 304 , whereas trolley 362 is motor driven (motor not shown) for moving the nozzles 358 in an X-direction, as previously mentioned. Note also a track 364 ′ is located for permitting another X-movement trolley (not shown) to move transversely in the same manner as trolley 362 .
An enlarged and detailed view of the assembly of the nozzle 358 is shown in FIG. 22A, and in FIG. 22 B. With reference first to FIG. 22A, the snapper tubes 356 are secured into position at the nozzle end between a top plate 378 and bottom plate 382 , between which spacers 384 are located as shown. The plates 378 , 382 are secured to the spacers 384 through use of screws 379 , as shown. Bushings 380 are located as shown on the projecting fingers 381 of the top plate 378 . The hard bushings 380 are made higher than the top of the nozzles 358 to adjust the spacing of the nozzles 358 from the bottom surface of the insert table 304 . The bushings 380 are typically made of Nylatron®, or UHMW®, or other suitable plastic material. The bottom front portion 390 of each of the nozzles 358 , include an opening 392 (see FIG. 22 B), in which is mounted a butterfly valve 388 that is rotatable about an axle 387 secured at each end of the collar like member 390 via a retainer cap 386 . The butterfly valve 388 is rotated to close off the opening 392 of its associated nozzle 358 when the nozzle 358 is positioned for sucking a condom from a takeoff insert 312 . At other times, the butterfly valve 388 is positioned to open the port hole 392 . The port 392 is kept open at all times other than when a condom 307 is to be removed from a takeoff insert 312 , to avoid excess vacuum pressure that may pull condoms off of the takeoff inserts 312 at an undesirable angle, causing damage to the condoms 307 .
In FIG. 24 a top view is shown of an air nipple 316 , and in FIG. 23 a partial cross-sectional and pictorial view is shown of the air nipple 316 as installed in a air nipple assembly 314 . As shown, an air connector assembly 320 is secured to the top of the air nipple table 306 (see FIG. 5 ). The bottom of the associated tubing 318 is secured to the air connector assembly 320 by air seal collar 404 . Air nipple 316 is held captive on the other end of the tubing 318 via a roll pin 394 , as shown. The air nipple 316 includes a slot way 396 to permit the air nipple 316 to move vertically in a range by sliding on the tube 318 , with the roll pin 394 also providing a stop for limiting downward movement. A spring 398 is positioned as shown between the top of tubing 318 and the top of a hole 399 extending through the air nipple 316 from the bottom to a point just below the nipple-like top portion or tip 397 . A recess 400 is provided in the top of the air nipple 316 for receiving a Gore-tex® insert, in this example, to cushion any contact between the tops of the air nipples 316 and the bottoms of the condoms 307 on glass mandrels 178 during manufacture of the condoms 307 . As further shown in the top view of the air nipple 316 in FIG. 24, four orifices 406 are included about the circumference of the top portion 397 . In this manner, air driven through air inlet 402 and exiting from the orifices holes 406 , causes a condom 307 resting upon the nipple portion 397 to remain inflated during the application of powder to the exposed areas of the condom 307 , and also causes the condom's tip to be inverted.
Greater details of the configuration of the shoes 308 and 310 are provided in FIG. 25A showing a back view of the shoes 308 , 310 , and a top view thereof as shown in FIG. 25 B. Note that a plurality of mounting posts 321 are vertically orientated, spaced apart, and located in the center in the back of each of the shoes 308 , 310 , as shown. Note that the mounting posts 321 each include a reduced diameter tip 321 a for receiving a retainer clip 323 , as previously explained. Greater details of a top shoe mounting bracket 325 are shown in FIG. 26 A. Note that a plurality of holes 325 a are provided for receiving the tips 321 a of the mounting post 321 . The mounting flanges 329 are used to secure the shoe bracket 325 to the top of the top shoe shifting plate 300 . As shown in FIG. 26B, the shoe bracket 325 includes a lower extended portion 325 b from opposing side flanges 325 c . Similarly, as shown in FIG. 27A, and FIG. 27B, the bottom shoe mounting brackets 327 includes a plurality of holes 327 a for receiving the reduced diameter tips 321 a of a shoe 308 , and mounting feet or flanges 331 . Also, opposing side flanges 327 c are provided as shown in FIG. 27 B. Note that the bottom extended portion 327 b of the bottom shoe bracket 327 is longer than the extended portion 325 b of the top shoe bracket 325 , for permitting the bottom plate shoes 308 to be properly positioned relatively to the top plate shoes 310 , in this example. Note also that many other configurations can be used for providing the mounting of the shoes 308 and 310 , and the present configuration as shown is not meant to be limiting. Nor are any other features as described above meant to be limiting.
With reference particularly to FIGS. 1A, 5 , 6 , 9 , 10 , 12 A-C, 13 , 14 , 17 , and 19 through 24 , the operation for the take off mechanism begins with the dipping transport unit 85 which includes the carrier or pallet 176 for the mandrels 178 positioned with the polyurethane condoms 307 formed on mandrels 178 ready for takeoff over the takeoff station 90 . Note that each of the pairs of shoes 308 , 310 , are opened by moving the top and bottom shoe plates 300 , 302 , respectively, in opposite directions to move the individual shoes 308 away from their associated shoes 310 , respectively. To close each pair of shoes 308 , 310 , the movement of the shoe plates 300 , 302 , is reversed. The take off operation is initiated by opening the pairs of shoes 308 , 310 on the take off mechanism, followed by lowering the pallet 176 to lower the mandrels 178 . Once the respective pairs of shoes are opened, the mandrels 178 are lowered for the first stroke and the ring 319 of each condom is positioned near the bottom of the associated shoes 308 , 310 . The respective shoes 308 , 310 are then closed to a predetermined position, and then the pallet 176 is moved upward rolling the condoms 307 approximately one-third down their associated glass mandrels 178 (see FIGS. 17 and 18) via the frictional contact between shoes 308 and 310 and the rings 319 of the condoms 307 (see FIG. 19 ). The shoes 308 , 310 are opened again, and the condoms 307 and associated mandrels 178 are repositioned with the rings 319 at the bottom of their associated shoes 308 , 310 . The individual pairs of shoes 308 , 310 are then closed to a predetermined position against the ring 319 of their associated condom 307 , and again the associated mandrels 178 are withdrawn or moved upward for rolling the associated condoms 307 approximately three-quarters or more down their respective mandrel 178 . In the final and third stroke, the pairs of shoes 308 , 310 are opened again, the associated mandrels 178 are reinserted their required depth into their associated pairs of shoes 308 , 310 , respectively, and the shoes 308 , 310 are closed. At this time, the air nipple table 306 holding the four-hundred-and-five air nipples 316 , in this example, is raised with air blowing out of orifices 406 of nipples 316 , respectively, and then transfers upward at the same rate of upward movement of the glass associated mandrels 178 , respectively, maintaining about a sixteenth to a thirty-second inch space between the tip 397 of each air nipple 316 , and the tip of the associated glass mandrel 178 , while the associated condom 307 is being rolled up by its shoes 308 , 310 . At the final withdrawal, the tips 397 of each air nipple 316 are at a position above the shoes 308 , 310 with the associated condoms 307 deposited on them in an inside out or upside down orientation mode, respectively. Next, the pairs of shoes 308 and 310 are opened. The air nipple table 306 is then lowered, causing the rolled up condoms 307 on respective air nipples 316 to move down through associated shoes, 308 , 310 . The condoms 307 are deposited on respective takeoff inserts 312 since the diameter of the condoms 307 is larger than the diameter of holes in the inserts 312 . The associated air nipples 316 continue to move downward to a position below the insert table 304 . Next, a set of tubes (not shown) underneath the bottom shoe shifting plate 302 sprays powder on the tips or nipples of the condoms 307 , because at that time the tip is the only portion of each condom 307 that is unrolled and unpowdered. The powdering prevents condoms 307 from sticking together, and occurs just before the insert table 307 is raised up. After powdering, the insert table 304 is raised to an uppermost position, the X-Y snapper nozzles 358 are then swept underneath the insert table 304 , for withdrawing or sucking the condoms 307 through the takeoff inserts 312 down through the snapper tubes 356 , which at least partially unrolls the condoms 307 . Note that both the chamfer and diameter of the hole through each of the takeoff inserts 312 are configured to maximize the extent of partially unrolling condoms 307 passing through, while preventing damage thereto. The takeoff inserts 312 can consist of any suitable material, such as a plastic material (Teflon®, nylon, and so forth).
The air nipple table 306 carrying the air nipple assemblies 314 (see FIG. 5 ), is raised and lowered by a servo motor (not shown) located to the side of the table 306 that is driving chain driven gears (not shown), along with an air assist lift mechanism (not shown) in order to take the load off the servo motor. The table 306 carrying the takeoff inserts 312 is driven upward and downward through use of a rack pinion mechanism 337 , 339 connected to an air assist cylinder 333 a (four cylinders are used, via at each corner, such as cylinder 333 b in FIG. 21, but the two other air cylinders are not shown). The pairs of takeoff shoes 308 , 310 are in opposing relationship, and are alternately connected to upper and lower or top and bottom shoe shifting plates 300 , 302 , respectively, as previously mentioned. The plates 300 , 302 are driven in reciprocal motion through use of a rack pinion drive mechanism 333 , 335 , 337 that is driven by a single stepper motor (not shown). The stepper motor drives two- Gear Boxes (not shown) to drive rack pinion mechanisms (not shown) at either side of the plates 300 , 302 upon which the shoes 308 , 310 are mounted. Rotating rods (not shown) drive gears (not shown) that in turn drive a pinion gear 337 either clockwise or counterclockwise for causing the lower shoe plate 302 to move horizontally in one direction and the upper shoe plate 300 to move horizontally in the opposite direction, for simultaneously opening and closing all of the pairs of shoes 308 , 310 of the takeoff station 90 , in order to roll-up a condom 307 on each of the respective mandrels 178 . The number of times that the shoes 308 , 310 are so closed and opened, along with upward and lower movement of each one of the mandrels 178 is in this example as previously described in the above paragraphs. However, in other embodiments, the number of times of opening and closing shoes 308 and 310 can be more or less than three. The opposing shoes 308 , 310 are retained on lower and upper plates 300 , 302 , respectively, via spring biasing attachment means, for permitting the shoes to resiliently contact the condoms during a takeoff cycle, as described in detail above.
A redress and inspection station 99 is located at the end of the drying section after the staging conveyor station 97 , and permits the pallets 176 to be selectively brought out after washing and rinsing for access by the operators in order to either replace or tighten mandrels 178 , strip-off any condom 307 that may have not been removed during prior processing, or otherwise make whatever repairs or adjustments that are necessary as previously mentioned. The nipple support Teflon® air nipples 316 each have a Gore-tex® tip in order to prevent cutting of a condom 307 if the tip of an associated condom 307 happens to come in contact with the bottom of one of the mandrel tubes 178 . Also, the air nipple table 306 retains the air nipple assemblies 314 . The air nipples 316 each have nipple holders formed at their tips 397 (see FIG. 23 ), and each have a manifold built into their bottom portions for permitting air to flow up through the center of the main support tubes 318 , through the associated air nipples or tip 316 , and out of small holes or orifices 406 in the center portion of the tip 397 of the air nipples 316 , respectively, in order to expand the nipple portions of the condoms 307 for proper powdering. On the third stroke or step of the condom removal operation, the air nipples 316 move upward to lift up the condoms 307 , then the shoes 308 , 310 opened, and the air nipples 316 drop backdown, whereby the condoms 307 are deposited on the takeoff inserts 312 of the insert table 304 , the insert table 304 moves down, followed by spray bars (not shown) being operated for spraying powder onto the nipple ends of the condoms 307 , as previously described. Then the insert table 304 is raised, whereafter the X-Y snapper system 92 is operated in order to sweep the snapper suction heads 358 under the insert table 304 for sucking the condoms into the takeoff tubes 356 , and then into a central tube (not shown) for deposit into a receptacle on the outside of the machine, as described in detail above.
Note that the datums or home positions are all established relative to a stepper motor (not shown) associated with the X-Y snapper system 92 , and the stepper motor (not shown) associated with the shoe shifting plates 300 , 302 . A proximity detector or transducer is used in order to provide a datum signal for signaling the system that the shoe plates 308 , 310 are at a home position. Note also that proximity sensors (not shown) are used for detecting whether the insert table 304 , and the air nipple table 306 are in upper or lower positions, respectively. Note further that the air nipple table 304 uses a servomotor (not shown), whereas the X-Y snapper system 92 and the shoe plates 300 , 302 use stepper motors, in this example. The stepper motors and servo motors can all be programmed very precisely to 0.002 inch for positioning the glass mandrels 178 relative to the shoes 308 , 310 , relative to the insert table 312 , and relative to the air nipple table 306 .
The present invention has been used in experimental or test runs to produce polyurethane condoms 307 having thicknesses ranging from 0.035 mm to 0.060 mm, and lengths from 175 mm to 190 mm. The condoms 307 had a tapered configuration.
In another embodiment of the invention, as shown in FIG. 28A, the previously mentioned reservoir dipping tank 36 of polyurethane material dissolved in THF (see FIG. 1B) includes a sliding top cover plate 402 that includes holes 406 , as shown. The top 400 of tank 36 includes holes 404 . A drive arm 408 of an air cylinder 410 is attached to one end of the sliding plate 402 for selectively moving the sliding plate 402 between a first or open position (see FIG. 28A) for exposing holes 404 through associated holes 406 , and a closed position (see FIG. 28B) for substantially closing off the holes 404 in the top 400 of the tank 36 . In the open or dipping position of the sliding plate 402 , the holes 406 are in a position where they are concentric with associated underlying holes 404 through the otherwise closed off top 400 of the dipping tank 36 . In this open position, the holes 406 of the sliding plate 402 , and the underlying associated holes 404 in the top 400 of the tank 36 are respectively each configured to have the minimum diameter required for permitting an associated mandrel 178 to be passed through the holes into the dipping solution in the tank 36 . By maintaining the minimum diameter necessary for the plurality of overlying holes 406 and 404 , respectively, the THP concentration about the associated mandrels 178 is kept substantially rich or high as the mandrels 178 are withdrawn from the tank 36 to prevent premature rapid evaporation of the THF solvent, for in turn permitting control of the withdrawal rate. Also, by maintaining a high concentration of THF vapors about the mandrels 178 as they are dipped into the dipping solution contained in tank 36 , the entry rate of dipping can be more finely controlled to minimize film defects.
Although various embodiments of the invention are shown and described herein, they are not meant to be limiting. Various modifications may occur to those of skill in the art, which modifications are meant to be covered by the spirit and scope of the appended claims. For example, with certain modification, the present system of the invention can be used to produce other than condom products, such as catheters and other medical devices, finger cots, gloves, coating processors, and so forth. Also, in an alternative embodiment, the takeoff inserts 312 can be eliminated by making the underlying holes in insert table 304 (see FIG. 9) to each have a chamfer and a diameter less than that of a rolled up condom 307 . However, the preferred embodiment of the invention includes the takeoff inserts 312 . | Prophylactic devices are made in an inert atmosphere by cooling mandrels on which the devices are to be deposited, dipping the mandrels into a polymeric material in a solvent/carrier and a mold release agent, rotating the mandrels during and after the dipping, and evaporating the solvent after dipping. The apparatus includes an air lock between a section in which these functions are performed and a section located in an air atmosphere for removing the devices from the mandrels, followed by cleaning the mandrels for use in a subsequent production run for making devices. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2004-083583, filed Mar. 22, 2004, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a radio apparatus which provides services to other devices through radio communications, and a link loss recovery method in radio communications with other devices.
[0004] 2. Description of the Related Art
[0005] A cellular phone (radio apparatus) which can perform short-range radio communications using a Bluetooth technique operates as a server, and can provide various services to other devices (devices such as car equipments and personal computers) with a radio communication unit. For example, a cellular phone can provide a handsfree service. The user using the device provided with the handsfree service from the cellular phone can talk with the other party connected via a communication network by the cellular phone, by using a microphone or a speaker for telephone conversation provided on the device.
[0006] Such a cellular phone performs reconnection with the device when a communication link with the device is disconnected (link loss). For example, “MCPC TR-00x Ver.1.0 HANDSFREE PROFILE Technical Reference” Ver1.0, Dec. 25, 2003, p. 15 discloses, as a recommended matter for service level connection, that the car equipment performs reconnection of the service level connection when a link loss occurs in the service level connection between the cellular phone and the car equipment.
[0007] Usually, to recover the link loss, it is necessary to render one of the cellular phone and the device a state of waiting a connection request (server state). When the device in the server state receives a connection request from another device, it establishes a communication link with the other device. Therefore, if the cellular phone becomes a connection request waiting state (server state) after a link loss, the cellular phone may receive a connection request from another device different from the device connected with the cellular phone before link loss. In such a case, if the cellular phone establishes a communication link with another device in response to a connection request, it is impossible to continue to provide the service to the device connected before the link loss.
BRIEF SUMMARY OF THE INVENTION
[0008] According to an embodiment of the present invention, a radio apparatus which conducts radio communication by establishing a communication link with a first device, the apparatus characterized by comprising: a first store unit configured to store first identifying information which identifies the first device with which the communication link has been established; a receive unit configured to receive a connection request from one of a plurality of devices including the first device when the communication link is disconnected; a obtain unit configured to obtain second identifying information, which identifies a second device, from the second device from which the connection request is received; a first determine unit configured to determine whether the first identifying information agrees with the second identifying information; and a first establish unit configured to establish a communication link with the second device from which the connection request has been received, if it is determined that the first identifying information agrees with the second identifying information.
[0009] According to the embodiment of present invention, the first identifying information which identifies the given device, with which a communication link has been established, is held. If the communication link is disconnected and a connection request from another device occurs, it is determined whether the second identifying information which identifies the another device agrees with the first identifying information. Then, if it is determined that they agree, a communication link with the another device is established. Therefore, after disconnection of a communication link, it is possible to recover the communication link by proper reconnection with the device which was connected before the disconnection.
[0010] Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0011] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
[0012] FIG. 1 is a block diagram illustrating a structure of a system in this embodiment of the present invention.
[0013] FIG. 2 is a block diagram illustrating a structure of a radio communication terminal 10 in the embodiment.
[0014] FIG. 3 is a flow chart for illustrating a link loss recovery method in the embodiment.
[0015] FIG. 4 is a diagram illustrating a sequence of operations of the radio communication terminal 10 and devices A and B when a link loss occurs in the embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0016] An embodiment of the present invention will now be explained with reference to drawings.
[0017] FIG. 1 is a block diagram illustrating a structure of a system in this embodiment. In FIG. 1 , a radio communication terminal 10 configured as a cellular phone, for example, operates as a server terminal which provides services. Devices A, B and C which can conduct radio communications with the radio communication terminal 10 request provision of services from the radio communication terminal 10 . Examples of the services which the radio communication terminal 10 provides are handsfree service, and data communication service, etc. For example, if the devices A, B and C are provided with handsfree services from the radio communication terminal 10 , users who use the devices A, B and C can talk with the other party connected via a communication network by the radio communication terminal 10 , by using a microphone or a speaker for telephone conversation provided on the devices.
[0018] The radio communication terminal 10 is configured as, for example, a cellular phone, and has a communication unit which performs radio communications with a base station held in the mobile communication network. Further, the radio communication terminal 10 has a communication unit for conducting short-range radio communications among the devices A, B and C according to the Bluetooth technique, for example.
[0019] FIG. 2 is a block diagram illustrating a structure of the radio communication terminal 10 in the embodiment. As shown in FIG. 2 , the radio communication terminal 10 is provided with a control unit 12 , a short-range radio communication unit 14 , a radio telephone communication unit 16 , a service management unit 18 , an HFP service control unit 20 , a DUN service control unit 22 , a speech input unit 24 , a speech output unit 25 , an input unit 26 , and a display unit 27 .
[0020] The control unit 12 comprises a CPU, a ROM and a RAM, etc. The CPU controls the above units according to control programs and control data stored in the ROM. Control by the control unit 12 achieves speech data communication via the mobile communication network, communications with the radio communication terminal 20 , and provision of various services to the devices, etc.
[0021] The short-range radio communication unit 14 controls short-range radio communications according to, for example, the Bluetooth technique. If a link loss occurs in a communication link with a device when the terminal is providing services to the device under management by the service management unit 18 , the short-range radio communication unit 14 is started in a server state, and comes into a state of waiting connection from a next device.
[0022] The radio telephone communication unit 16 carries out communications with the base station held in the mobile communication network of the mobile communication system.
[0023] The service management unit 18 controls execution of various services, such as handsfree service provided by the HFP service control unit 20 , and data communication service provided by the DUN service control unit 22 . The service management unit 18 holds the states of the services to be provided to the devices. If a link loss occurs in a communication link with a device to which a service is being provided, the service management unit 18 stores the device address of the device in an address storing unit 18 a . Further, the service management unit 18 determines whether a connection request received by the short-range radio communication unit 14 from one of the devices is a connection request from the device which was connected to the terminal before occurrence of the link loss, by using the device address held in the address storing unit 18 a . If it is the device which was connected to the terminal before occurrence of the link loss, the service management unit 18 establishes a link with the device by the short-range radio communication unit 14 .
[0024] The HFP service control unit 20 controls the handsfree function of the cellular phone on the basis of predetermined “Hands Free Profile”, for example. The DUN service control unit 22 controls the data communication function on the basis of predetermined “Dial-up Network Profile”, for example. Besides the handsfree function and the data communication function, services may be provided to devices connected via the short-range radio communication unit 14 , by using other functions. Examples of other functions are a function of transmitting/receiving an object, such as a telephone book, based on “Object Push Profile”, and a function of transmitting/receiving images based on “Basic Imaging Profile”.
[0025] The speech input unit 24 comprises a microphone, an amplifier, a band-pass filter, and an A/D converting circuit, etc. The speech input unit 24 generates transmission speech data from user's transmission speech inputted thereto.
[0026] The speech output unit 25 comprises an A/D converting circuit, an amplifier, and a speaker, etc. The speech output unit 25 outputs an amplified speech in accordance with received speech data.
[0027] The input unit 26 controls inputs provided from buttons and keys operated by the user.
[0028] The display unit 27 controls display on a display device.
[0029] Next, a method of recovering a link loss in the embodiment is explained with reference to the flowchart shown in FIG. 3 .
[0030] Further, FIG. 4 is a diagram illustrating a sequence of operations of the radio communication terminal 10 and devices A and B when a link loss occurs in the embodiment.
[0031] For example, suppose that a user holding the radio communication terminal 10 rides in an automobile with the device A (car equipment). In this case, suppose that the short-range radio communication unit 14 of the radio communication terminal 10 is started in the server state, and is in the state of waiting a connection request from other devices. Further, suppose that the device A is started in a client state, and transmitting a connection request.
[0032] When the short-range radio communication unit 14 receives the connection request from the device A, the unit 14 establishes a communication link with the device A by a predetermined procedure (step A 1 ) ( FIG. 4 ( 1 )). When the communication link with the radio communication terminal 10 (short-range radio communication unit 14 ) is established, the device A designates use of the handsfree service to the radio communication terminal 10 .
[0033] The service management unit 18 of the radio communication terminal 10 starts the HFP service control unit 20 in response to the service designation from the device A, to start provision of the handsfree service to the device A. Specifically, the radio communication terminal 10 mediates a telephone conversation between the device A and the party to which the device A is connected via the mobile communication network by the radio telephone communication unit 16 . The service management unit 18 switches a path of speech data to the device A side, to allow a telephone conversation between the device A and the party to which the device A is connected via the mobile communication network. Specifically, the unit 18 performs control such that speech data transmitted/received by the radio telephone communication unit 16 is transmitted to the device A via the short-range ratio communication unit 14 .
[0034] The device A transmits speech, which has been inputted through a microphone mounted thereon, to the party of the telephone call via the radio communication terminal 10 . The device A also receives speech from the party via the radio communication terminal 10 , and outputs it from a speaker mounted thereon.
[0035] If the service management unit 18 detects occurrence of a link loss (abnormal disconnection) in the state where the communication link with the device A is established and when the device A is in a telephone call by using the handsfree function (step A 2 , Yes) ( FIG. 4 ( 2 )), the service management unit 18 starts two timers. Specifically, the service management unit 18 starts a first timer (not shown) for counting to 5 seconds, for example, from the link loss, and a second timer (not shown) for counting to 30 seconds, for example, from the link loss (step A 3 ).
[0036] The radio communication terminal 10 is configured to disconnect the telephone call with the party via the mobile communication network by the radio telephone communication unit 16 when 5 seconds has passed from the link loss, and to stop the process of recovering the communication link through short-range radio by the short-range radio communication unit 14 when 30 seconds has passed from the link loss.
[0037] The service management unit 18 obtains a device address of the device A, with which the link was established before the link loss, from the short-range radio communication unit 14 , for example, and records it in the address storing unit 18 a (step A 4 ) ( FIG. 4 ( 3 )).
[0038] Then, the short-range radio communication unit 14 is set to a server state, and a state of waiting a connection request from the devices (step A 5 ) ( FIG. 4 ( 4 )).
[0039] During these steps, the first timer and the second timer count the time which has passed from the link loss (steps A 11 , A 13 ). If the first timer has counted to 5 seconds (step A 13 , Yes), the radio telephone communication unit 16 disconnects the telephone call with the party connected via the mobile communication network (step A 14 ).
[0040] Further, if the second timer has counted to 30 seconds (step A 11 , Yes), the service management unit 18 ends the processing for link loss recovery (step A 12 ).
[0041] In the meantime, if the short-range radio communication unit 14 receives a connection request from a device, the service management unit 18 obtains a device address from the device which has sent the connection request, and compares the obtained device address with the device address recorded in the address storing unit 18 a , that is, the device address of the device with which link was established before the link loss (step A 7 ) ( FIG. 4 ( 6 )).
[0042] In this case, suppose that the connection request is received from the device B (such as personal computer (PC)) which was not connected with the radio communication terminal 10 just before the link loss ( FIG. 4 ( 5 )).
[0043] In this case, the compared device addresses are determined as different (step A 8 , No). The service management unit 18 causes the short-range radio communication unit 14 to transmit a rejection response to the device B which sent the connection request, to notify the device B of rejection of connection (step A 10 ) ( FIG. 4 ( 7 )).
[0044] Therefore, if a link loss occurs and then the terminal becomes a state of waiting a connection request from the device to recover the link loss, the radio communication terminal 10 can reject a connection request from a device different from the device which was connected before the link loss.
[0045] In the meantime, suppose that a connection request is received from the device A (car equipment) which was connected with the radio communication terminal 10 before the link loss ( FIG. 4 ( 8 )).
[0046] In the same manner as the above, the service management unit 18 obtains a device address of the device which has sent the connection request, and compares the device address with the device address recorded in the address storing unit 18 a (step A 7 ) ( FIG. 4 ( 9 )).
[0047] In this case, the compared device addresses are determined as the same (step A 8 , Yes). The service management unit 18 causes the short-range radio communication unit 14 to transmit a connection response to the device A which has sent the connection request, to notify the device A of permission to connect with the terminal, and establishes a communication link with the device A (step A 9 ) ( FIG. 4 ( 10 ) ( 11 )).
[0048] As described above, if a link loss occurs when a communication link is established with a device and service is being provided to the device, the radio communication terminal 10 holds the device address of the device to which the service was provided. Thereby, when the link loss is recovered, the radio communication terminal 10 can receive only a connection request from the device having the held device address.
[0049] Therefore, even if a link loss occurs in the communication link with the device A, the radio communication terminal 10 thereafter establishes a communication link with the device A again by link loss recovery, and can continuously provide the handsfree service to the device A.
[0050] In the above description, explained is the case where the radio communication terminal 10 is started as server and establishes a communication link with the device A. However, also in the case where the radio communication terminal 10 is started as client and establishes a communication link with the device A, it is possible to recover a link loss in the same manner as the above.
[0051] For example, suppose that the radio communication terminal 10 is started as client to provide a desired service, and establishes a link with the device A. If a link loss occurs in this case, the terminal holds the device address of the device A in the same manner as the above, and changes to the server state, waiting a connection request from the device for a preset time. Further, if it receives a connection request from a device and the device address of the device is the same as the device address of the device which was connected before the link loss, the terminal accepts the connection request and recovers the link loss.
[0052] Further, in the above explanation, the radio communication terminal 10 holds the device address obtained from the connected device, and determine, by using the device address, whether a device which has sent a connection request after the link loss is the device to be linked with. However, the device to be linked with may be determined on the basis of data other than the device address.
[0053] For example, suppose that the short-range radio communication between the radio communication terminal 10 and a device is established by a method according to the Bluetooth standard. In this case, a link key (private key) can be used to mutually authenticate connection between specific terminals. The link key is generated when terminals are first connected, on the basis of the same PIN (Personal Identification Number) code inputted to each of the terminals, and recorded in a device list in association with the device address of the terminal being the connection party. If a link loss occurs in a link with the device for which the link key was generated, the service management unit 18 holds the link key set for the device, and recovers the link loss by using the link key in the same manner as the above.
[0054] Further, in the above description, explained is the case where only the device A is connected to the radio communication terminal 10 and provided with the handsfree service. However, a plurality of devices may be simultaneously connected to the radio communication terminal 10 , and the devices may be provided with different services, such as services by the dial-up network function (DUN), the function of transmitting/receiving an object such as a telephone book (OPP), and the function of transmitting/receiving images (BIP).
[0055] In this case, the radio communication terminal 10 holds device addresses (or link keys) of the devices in association with respective services provided to the devices. Then, the terminal 10 compares the held device address, associated with the service requested by a device, with the device address of the device which requests the service, and thereby determines whether the device is a device with which a communication link is to be established. Thereafter, the terminal 10 executes link loss recovery in the same manner as the above.
[0056] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general invention concept as defined by the appended claims and their equivalents. | A radio apparatus which conducts radio communication by establishing a communication link with a given device includes a first store unit configured to store first identifying information which identifies the given device with which the communication link has been established, a receive unit configured to receive a connection request from another device when the communication link is disconnected; a obtain unit configured to obtain second identifying information which identifies the another device from the another device from which the connection request is received, a determine unit configured to determine whether the first identifying information agrees with the second identifying information, a establish unit configured to establish a communication link with the another device from which the connection request has been received, if it is determined that the first identifying information agrees with the second identifying information. | 7 |
FIELD OF THE INVENTION
The present invention concerns delivery of facsimile (fax) documents over a value-added network, such as a store-and-forward network, and more particularly to a method and apparatus for automatically sending an action report via electronic mail (e-mail) and automatically utilizing an e-mail response to resolve problems encountered while delivering a fax document.
BACKGROUND OF THE INVENTION
As a mechanism to carry information over long distances, store-and-forward (S&F) networks offer an efficient, low-cost alternative to the existing public switched telephone network (PSTN). In general, S&F networks operate parallel to, and are accessed by, the PSTN.
FIG. 1 shows schematically PSTN 30 and S&F network 80 connected in parallel between a source fax machine 10 and a destination fax machine 70. An autodialer 12, positioned between the source fax machine 10 and PSTN 30, designates incoming faxes for transmission over either the PSTN 30 or S&F network 80. If, for example, the destination of the incoming fax is not one serviced by the S&F network 80, then the autodialer dials the destination fax number directly to the local exchange 32; the call is then carried in a normal fashion by the PSTN 30 to the destination fax machine 70. In contrast, if the number is one serviced by the S&F network 80, the autodialer 12 dials the telephone number corresponding to that of the source network node 20. The local exchange 32 then routes the call through the PSTN 30 to the source node 20. (Note that, depending upon their proximity, the source fax machine 10 and the source network node 20 may be served by the same or different local exchanges.) Once it has completely received the document, the source node 20 transfers it to the destination network node 40 over dedicated circuits 60. At this point, the destination node 40 dials the destination fax number to its local exchange 36 which in turn transfers the call via the PSTN 30 to the destination fax machine 70. (Note again that, depending upon their proximity, the destination fax machine 70 and the destination network node 40 may be served by the same or different local exchanges.)
In summary, transport of information from the source fax machine 10 to the destination fax machine 70 using the S&F network 80 requires three distinct steps:
(1) Transmission from the source fax machine 10 to the source network node 20 via the PSTN 30;
(2) Transmission from the source node 20 to the destination node 40 via dedicated circuits 60; and
(3) Transmission from the destination node 40 to the destination fax machine 70, again via the PSTN 30.
Store-and-forward networks offer a number of significant advantages over standard telephone networks for transport of facsimile. For example, a fax document can be carried much more efficiently using the packet technology employed by S&F networks. Another advantage of using an S&F network is guaranteed availability. A common annoyance in telephony is the inability to complete a call, usually because the destination device is busy or does not answer. Voice mail systems have been designed to overcome this problem in voice telephony, but a similar practical and cost effective solution does not exist for fax over the PSTN. However, S&F networks offer a viable solution--the S&F network employs a sufficiently large number of telephone circuits such that a customer fax machine never encounters a busy signal. Further, at the destination end, the S&F network has the ability to automatically redial those call attempts which encounter a "busy" or "no-answer" signal. Typically, the calls are redialed periodically over a fixed interval of time, e.g., every ten minutes for a half hour.
Although exceedingly useful when busy signals are encountered, the automatic redial capability is of limited utility in redressing other call completion failures. Other more costly procedures for resolving delivery problems on an S&F network, which require an understanding of document flow through the network, are described below.
Multiple documents are typically coursing through the S&F network at any point in time, and therefore it is important to have some mechanism to monitor the location and status of each. For example, in one known S&F network, a small data file called an envelope is created to track each fax document as it moves through the network. The source node creates the envelope as it receives an incoming fax document. As the fax document moves through the delivery process, the envelope moves among the network devices and is continually updated with the status of the fax. At the termination of the delivery process the destination network node declares the fax document either "delivered" or "not delivered", and records the status in the corresponding envelope which is then returned to the source node.
A special process within the destination node monitors the progress of each call, and duly notes the reason for each failed delivery attempt. The process monitors what are commonly referred to as "call progress features", e.g., busy signals (indicating a busy station set), fast busy (indicating a busy circuit), ringback with no answer, a voice answer indicating a non-working number, a voice answer indicating a disconnected number, etc. The process is also able to detect a variety of responses once the called station goes off hook, including a large number of fax machine failure modes. After a predetermined number of call attempts, if there is no success, the envelope is marked accordingly and returned to the source node.
The source node evaluates each envelope received from the destination node. If the delivery was successful, the envelope is forwarded to a historical database (HD) 54 (see FIG. 2) which provides a basis for constructing customer bills. If the delivery was not successful, the envelope is forwarded to a delivery assist system (DAS) 56 for further processing. DAS has two elements which work in tandem to enable delivery of a fax document: a delivery expert system (DES) 57 and a delivery analysis center (DAC) 58. DES is a rule-based engine which draws upon a large database 59 of information (also contained within DAS) including known fax delivery obstacles, alternative fax delivery numbers, individual customer's faxing preferences, and so forth. DES is used to automatically resolve the majority of undelivered document problems. The customer specific-information is usually gathered at the time the customer initiates the service. Additional information is obtained as a result of ongoing efforts to resolve fax delivery problems, as will become evident. In the event that DES fails to resolve a delivery problem, this fact along with all relevant background information is relayed to DAC 58 where a person experienced in such matters now assumes responsibility for the document.
Often, DES 57 fails in its task because of inadequate information in the DAS database 59. In such cases, the delivery analyst will normally attempt to acquire this information by calling a person at the destination. The analyst then determines a strategy for document delivery. Note that while this prior art method enables the network provider to deliver most fax documents, and provide the customer with an on-going report on alternative delivery attempts, the cost of providing such a service is substantial. Furthermore, the determination of a strategy by the human analyst may take significant time and is not always a best determination of what actions should be taken, in what order. Still further, as the amount of network traffic increases, the number of documents requiring assistance increases and it becomes more and more difficult to provide such humanassisted delivery on a timely and cost-effective basis.
SUMMARY OF THE INVENTION
The present invention is a method for assisting delivery of a fax document from a source to a destination over a selected network, when one or more initial delivery attempts have been unsuccessful. The method includes notifying the sender of the unsuccessful delivery status of the fax document though an inquiry electronic mail (e-mail) message automatically generated by a process in the network. The message includes reasons for the unsuccessful delivery of the fax document and selectable options to facilitate delivery of the fax document. After selecting one or more desired options, the sender of the fax document returns an e-mail response to the network. Upon receiving the response, a network process evaluates and automatically initiates the selected options to facilitate delivery of the fax document.
In one embodiment, the e-mail message includes one or more suggestions for a "preferred method" to facilitate delivery. This reduces the burden on the source in selecting between the options.
The network will automatically decode and implement the return e-mail message from the sender. In this manner, the decoded e-mail message is used to automatically gather information required to facilitate delivery of a fax document, with no input from a human analyst. It is therefore more reliable, more accurate and less expensive than the prior art.
These and other features and benefits of the present invention will be more particularly described in regard to the following detailed description and figures.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic illustration of an S & F network disposed in parallel to a PSTN;
FIG. 2 is a schematic illustration of an apparatus for obtaining further delivery instructions according to the present invention;
FIG. 3a is a representative example of an e-mail action report according to an embodiment of the present invention;
FIG. 3b is a representative example of a response to an e-mail action report according to an embodiment of the present invention;
FIG. 4 is a flow chart describing the method of one embodiment of the present invention; and
FIG. 5 is a block diagram illustrating a central processing unit and memory for use in this invention.
DETAILED DESCRIPTION
In accordance with one embodiment of the present invention, an action report (AR) e-mail process is provided to simplify and automate the process of gathering delivery instructions (DI) for completing the delivery of a fax document. The AR e-mail notifies the sender of the delivery status of a fax document and includes a request for alternate delivery instructions. The AR e-mail is sent automatically by the network to the sender of the fax document, and the network automatically decodes and follows the instructions in a responsive e-mail to complete delivery of the fax document.
As previously described (see FIG. 2), the delivery assist system (DAS) 56 maintains a database 59 which includes a list of destination fax numbers and a set of alternative delivery instructions for each (if available). The delivery expert system (DES) 57 relies upon this database to obtain alternative delivery information. When an undelivered document is directed to a number for which there are not sufficient delivery instructions, then the automated process of obtaining such delivery instructions begins.
In one embodiment, a document destined for a known fax number enters the S&F network through the autodialer. The document is not successfully delivered. The network now automatically checks to determine if alternate delivery instructions are available (e.g., in DAS database 59). If the delivery instruction status is incomplete for this destination, an AR e-mail is automatically prepared and sent to the sender of the fax document. The e-mail is generated by an AR process 55 (a software application) running on a processor at the central control facility 50, which is part of the S&F network and attached to the customer's PC 7 by a dedicated circuit 9 (discussed hereinafter with respect to FIG. 2). The appropriate e-mail address is extracted from a database accessible to the processor, which may form part of the DAS database 59. In this embodiment, a first AR e-mail is automatically prepared and sent out by the AR process to the sender of the fax document (customer's PC 7). The AR e-mail indicates the status of the fax document and reasons for non-delivery. In addition, the AR e-mail includes options from which the sender of the fax may choose to provide further instructions for a redelivery attempt, as well as suggestions for the most appropriate response. If no response is received, the document may be sent to the DAC 58 staffed by persons who will analyze the potential problem and attempt to obtain alternate means for delivering the fax (e.g., by telephoning a person at the destination).
To facilitate an understanding of the present invention, certain background information on S&F networks will first be provided. A known S&F network node contains the following four components:
1. Fax Transmit/Receive Agent (FTR)--As the name implies, this component is responsible for transmitting documents to and receiving documents from fax machines. This machine receives a fax document in an analog format from the PSTN and converts it to a digital format so that it can be transmitted efficiently and inexpensively over a packet network. An identical machine performs the converse transformation at the destination side of the network. This machine will also monitor the progress of a fax delivery attempt and determine reasons for failure, if any.
2. Traffic Administrator (TA)--This component is responsible for monitoring and controlling the movement of the fax document through the S&F network once it leaves the FTR. This is accomplished through the envelope mechanism, previously described.
3. File Server (FS)--This machine is responsible for receiving the fax document from the FTR and storing it until it is notified that the document has either been successfully delivered or canceled.
4. Router--This machine manages the flow of information between and among the other machines which make up the network node. Further, it formats data and manages its transport to other nodes on the network.
In normal operation, upon detecting a ring signal from the telephone network, the source FTR goes off-hook and exchanges information with the calling autodialer. Upon validating the call, it creates two files with unique names: a fax file to hold the incoming fax and a companion file called an envelope. A complete envelope file contains a variety of information generally including the source fax machine number, the destination fax number, the number of pages in the document and the total reception time; that is, all the information required to deliver the fax and bill the customer. Once the files are created, the FTR instructs the autodialer to allow it to interact directly with the source fax machine to initiate the fax reception process. It then begins to receive the fax data and store it in a local buffer under the created filename. Once reception is complete and the call terminated, the FTR transfers the fax file to the file server and then forwards the related envelope file to the source TA to begin the file routing process. Note that all this activity takes place within the source node.
The delivery process begins with an examination of the envelope to determine the document destination. The source TA decides upon an appropriate route and forwards the envelope to a selected destination TA. From there, the envelope is relayed to a destination FTR to begin the delivery process. After retrieving the entire fax document from the source file server, the destination FTR dials the destination fax number to commence delivery.
The following is a more detailed description of an apparatus and method for delivering a fax document in the S&F network (see FIGS. 1 and 2). In addition to the major components illustrated in FIG. 1, a Central Control Facility 50 is shown in FIG. 2 which is operated by the S&F network provider and which communicates via router 52 on dedicated circuits 60 with the source and destination nodes 20, 40 via routers 24, 44 respectively. Central Control is also able to communicate with the customer PC 7 via routers 8, 24 and 52, and dedicated circuits 9 and 60. The automatic method of requesting, obtaining and using alternate delivery instructions via e-mail according to the present invention is incorporated into this general method and apparatus beginning at step 20.
1. The customer loads a document into his fax machine 10 and dials the destination fax number.
2. The autodialer 12 attached to the customer's fax machine screens the dialed number. If it detects a valid destination phone number, it dials the network provider number (i.e., the telephone number of the source network node 20). The Public Switched Telephone Network (PSTN) 30 transfers the call to an FTR 28 at the source node.
3. The source FTR 28 answers and sends out a sequence of Dual Tone Multi Frequency (DTMF) tones on the PSTN 30 to indicate its presence.
4. The autodialer 12 responds with a string of DTMF tones which indicate, among other information, an identifier of the source fax machine 10 (to which it is attached) and the destination fax number.
5. The source FTR 28 validates the received data and acknowledges its receipt with another DTMF signal to the autodialer 12.
6. The autodialer 12 then removes itself from the circuit and the fax session progresses as if the customer's fax machine 10 is connected directly to the destination fax machine 70. In reality, the customer's fax document is entering the S&F network for delivery.
7. When the source FTR 28 receives the fax, it creates a small data file called an envelope to contain information about the fax document. The envelope includes the following information:
document number (assigned by the source FTR);
source fax machine identifier;
destination fax machine telephone number;
customer number.
8. After reception is complete, FTR 28 transfers responsibility for the document. The fax document is transferred to the source File Server (FS) 26. The envelope is transferred to the source Traffic Administrator (TA) 22.
9. Once the source FTR 28 receives notification that the fax document and the envelope were transferred successfully, it deletes the fax document from its database.
10. To initiate the delivery process, the source TA 22 sends the envelope to the destination TA 42. The envelope residing on the destination TA 42 is known as the destination envelope.
11. The destination TA 42 transfers the destination envelope to the least loaded destination FTR 48.
12. Upon receipt of the destination envelope, the destination FTR 48 retrieves a copy of the document from the source FS 26. The fax document is now ready for delivery.
13. In addition, the destination FTR 48 creates a document status update (DSU) containing detailed information about the status of the fax document it is holding for delivery. The destination FTR 48 sends the updates to the destination TA 42 at regular (e.g., two-minute) intervals.
14. The destination TA 42 forwards the DSU to the source TA 22.
15. The source TA 22 uses the information in the DSU to update its copy of the fax envelope.
16. The destination FTR 48 attempts to deliver the document by calling the destination fax machine 70 through the destination country's PSTN 30. The result of the attempt is either:
Successfully Delivery--The document was delivered to the destination fax machine 70.
Failed Attempt--The document was not delivered to the destination fax machine 70 because of one of the following conditions:
Busy Line
No Answer
Nonworking number
Disconnected line
Broken Connection (including one of several types)
Non-Fax (for example, voice detected)
Other (a general term assigned to a number of telephony or faxing errors).
17. If the document is successfully delivered, the destination FTR 48 updates the DSU with the final delivery information and returns it to the destination TA 42, which in turn forwards it to the source TA 22. The envelope is then updated with the new information and transferred to the historical database (HD) 54 for archival storage. At some later time, the information will be retrieved from the system to compute a customer bill. As a final task, the source TA 22 sends a request to the FS 26 to delete the file corresponding to the delivered document.
18. If the document is not successfully delivered on the first attempt, the destination FTR 48 makes additional delivery attempts at regular intervals over some predetermined time period--usually every five minutes for a half hour. At each failure, the delivery attempt time and reason for the failure is noted in the appropriate DSU. If all delivery attempts are futile, the destination FTR 48 declares the document as "Not Delivered," suitably marks the DSU, and sends it to the destination TA 42 for return to the source TA 22.
19. Noting that the document has not been delivered, the source TA 22 forwards the envelope to the Delivery Assist System (DAS) 56 for resolution. The Delivery Expert System (DES) 57 will review the delivery attempt history contained in the envelope and determine a course of action. It may, for example, determine that sending the fax to an alternative destination number is the best strategy for success. It will then peruse its associated database 59 for the required information. If an alternate number is found, it is inserted into the envelope which is then resubmitted to the source TA 22 for standard delivery.
20. In the event that no alternative number is available, an electronic mail (e-mail) message is automatically generated by the AR process 55 with the appropriate e-mail address retrieved from database 59, and the e-mail message sent, via dedicated circuit 9, to customer PC 7 (the sender of the document). The message includes a notification of a non-delivered status, reasons why the document was not delivered, selectable options for redelivery, and a suggestion as to which option is most appropriate under the circumstances (e.g., request for an alternative delivery number).
21. The sender of the document selects one or more options and returns a responsive e-mail with the selected options, via router 8, dedicated circuit 9 and router 24, to the DAS. The options may include resubmitting the document to the same number, providing a corrected or new phone number, rescheduling delivery at a later specified time, canceling the document, or otherwise as the circumstances warrant.
22. The AR process 55 decodes the selected options and automatically uses the information to define the delivery strategy. Where appropriate, the new information is incorporated into the DES database 59.
23. If the network fails to deliver the document with the new information, it is referred once again to DES for further processing. When DES determines that it has exhausted all of its options, it refers the problem to a Delivery Analyst (human operator) for resolution. The Delivery Analyst may call the source or destination of the document for more information, or take other action as is deemed appropriate to facilitate delivery of the document.
FIG. 3a is representative of the electronic mail message 101 automatically generated by the AR process 55 and sent to the sender of the fax document. The message includes a notification of the status of the document 102, reasons why the document was not delivered 103, selectable options for redelivery 104, and a suggestion as to the most appropriate response 105.
FIG. 3b is representative of the electronic mail message response 102 generated by the sender of the fax document. The response message contains selected options 106 which give instructions for redelivery of the document. The message in FIG. 3b is received by DAS 56 which automatically processes the options, allowing the network to renew a delivery attempt (or take some other appropriate action).
FIG. 4 is a flowchart illustrating the e-mail request/response method steps according to one embodiment of the present invention. The process begins with a customer submitting a fax to the S&F network, step 300. Step 310 determines whether delivery of the fax was successful. If it was, then the envelope associated with the fax is marked "delivered" (step 315) and sent to the historical database (step 320) where the process ends. If the fax was not delivered successfully, the envelope associated with the fax is marked "not delivered" (step 330) and sent to the DAS for resolution (step 332).
All incoming envelopes are assigned by DAS to the delivery expert system (DES) for evaluation (step 335). If at any time DES is unable to determine a course of action (step 336), it passes the problem to a human attendant, a Document Delivery Analyst, for further analysis (step 375). First, DES consults its database to determine if it has sufficient information to solve the problem (step 337); if yes, it modifies the envelope (step 362) and resubmits it to the network (step 365) for a new delivery attempt. If DES does not have sufficient information to solve the problem, the AR process automatically prepares an e-mail outlining the reasons for the non-delivered status of the fax (step 340). The e-mail also contains selectable options outlining instructions which may assist in the delivery of the fax. In step 345, the e-mail is sent to the sender of the fax.
If the AR process is unable to implement an e-mail message for any reason (step 336), the delivery problem is relayed to a human operator, a delivery analyst, for resolution.
In step 350, DAS checks to determine if a response to its e-mail has been received. If not, it determines if the maximum response time has elapsed (step 355) and, if not, it again checks for a response from the sender. If the response time has been exceeded, DAS determines how many messages have been sent to the sender (step 370); if, as in this case, it is less than two, the original message is updated (step 372) and sent once again to the sender. In contrast, if the number of messages sent is greater than or equal to two, further automatic attempts to reach the sender are terminated and the undelivered message referred to a delivery analyst for processing, step 375.
Referring back to step 355, if the response time is not exceeded and DAS receives a response in the form of a return e-mail from the sender of the fax (step 350), then the AR process decodes the e-mail response (step 360). The decoding (step 360) allows the AR process to read the options which have been selected by the sender of the fax and to automatically use the instructions contained in the selected options. The fax is then automatically resubmitted to the network based on the instructions in the decoded options (step 365) and the process starts again (step 310).
The resubmitted fax is sent through the network, and any difficulties are resolved as detailed above. This e-mail system of sending and receiving modifiable action reports ensures that any undelivered fax is successfully delivered in a faster, more reliable, less-expensive and more automated method. The network is able to automatically resolve more problems of undelivered documents, and fewer delivery analysts (human operators) are needed.
The above-described embodiments may be implemented with a variety of hardware and/or software configurations. The functionality of the principal network components can be achieved in software applications executing on standard PC platforms. The autodialer may be implemented as a stand-alone programmable device using specially designed hardware or completely in software on a PC which may also utilize a fax modem or other communication device. The choice of whether to use a few or many machines is dependent upon the amount of traffic carried as well as the desired system reliability and redundancy. Note also that the automatic messaging system is not limited to e-mail; automated voice messaging systems may be similarly employed as well.
Various features of the invention may be implemented using a general purpose computer 161 as shown in FIG. 5. The general purpose computer may include a computer processing unit (CPU) 162, memory 163, a processing bus 164 by which the CPU can access the memory, and interface 165 to the network.
The invention may be a memory, such as a floppy disk, compact disc, or hard drive, which contains a computer program or data structure, for providing to a general purpose computer instructions and data for carrying out the functions of the specific embodiment.
In other embodiments, the source fax machine 10 may be for example a desktop computer having a fax modem which connects to an autodialer, or a fax server connected to one or more autodialers (for example servicing a plurality of computers on a local area network). The software residing on the desktop computer or fax server will include the local database of validated fax numbers. Thus, as used herein, "fax machine" includes a desktop computer, fax server or other source of fax documents.
These and other modifications and improvements of the present invention will be understood by a person skilled in the art and are intended to be included within the scope of the claimed invention. | A method and apparatus for assisting delivery of fax documents over a value-added network, such as a store-and-forward network. If an initial delivery attempt is unsuccessful, the network automatically sends an e-mail to the sender of the fax document indicating the status of the fax delivery and reasons for the document's non-delivery. The sender of the fax is prompted to choose from selectable options included in the e-mail which provide instructions to resolve the delivery problem. Upon receipt of an e-mail response, the network automatically decodes the selected options and uses the chosen options to resend the fax document and automatically resolve the delivery problem. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to monitoring of undesirable fluid ingress into subsea control modules.
BACKGROUND OF THE INVENTION
[0002] The hydraulic and electronic components of a subsea well, such as a hydrocarbon extraction well, are typically housed in a sealed vessel termed a subsea control module (SCM), located on a Christmas tree which is mounted on the sea bed above the well bore. An SCM is, typically filled with electrically insulating oil, to alleviate the need to design it to withstand high pressures and provide a first line of defense for the control system against the sea water environment. Typically, an SCM houses hydraulic manifolds, directional control valves and a subsea electronics module (SEM) which is itself a sealed unit. Thus, ingress of sea water resulting from a leak in the SCM housing, or ingress of hydraulic fluid from a small leak in the hydraulic system, will not in itself cause a malfunction of the control system. However, well operators, historically, have needed to know if there is a sea water leak since this will result in corrosion of the components in the SCM and possible failure of the system earlier than expected.
[0003] Existing arrangements consist of sets of metal electrode pairs mounted on an insulating panel or a metal frame with insulating inserts within the SCM, typically four, at equal intervals between the bottom and the top, each connected to an operational amplifier via a low voltage source and a series resistor, thus enabling the detection of the presence of the ingress of electrically conductive sea water, and, in a crude manner, the degree of displacement of the original oil filling. A typical application of the technique is illustrated diagrammatically in FIG. 1 in which a casing 1 of an SCM is shown as a transparent outline to show an electrically insulating panel 2 , mounted on the base 3 of the SCM, with pairs 4 of electrodes mounted on it. FIG. 2 shows circuitry 5 around an operational amplifier 6 , typically housed in the SEM within the SCM, to which the electrode pairs, are connected. Since the resistance across a pair of electrodes when in contact with sea water is very low, i.e. effectively a short circuit, they are shown in a block 7 as simple switch contacts 8 , 9 , 10 and 11 . One of the electrodes of each pair is connected to a voltage source V, typically 2 volts. The gain of the circuit 5 is the ratio of the resistance of a feedback resistor 12 across amplifier 6 and the effective resistance provided by input resistors 13 , 14 , 15 and 16 , each of which is in series with a respective one of the electrode pairs 4 and an input of amplifier 6 . Each of the input resistors is chosen to be of a resistance which is one quarter of that of the feedback resistor 12 . Thus, if there is water ingress into the casing 1 to the level of the lowest electrode pair, then the contacts 8 of the block 7 are effectively closed and the output 17 of the operational amplifier 6 will rise to ¼ of V. Likewise, further ingress of sea water reaching the remaining electrode pairs will result in the output 17 rising to ½ V, ¾ V and V respectively as the contacts 9 , 10 and 11 become effectively closed. Thus, a crude indication of the sea water ingress level is obtained by the electronic circuitry of the SEM reading the output 17 of the circuit 5 and transmitting the information topside, as a digitised version of the analogue signal, to the well operator, typically via the well umbilical, as part of the well housekeeping/diagnostic telemetry.
[0004] A problem with the existing technique is that it is unable to detect the ingress of hydraulic fluid into the SCM resulting from a leak in the hydraulic system in the SCM. Currently, a well operator has relied on hydraulic fluid leak detectors at the fluid source but these cannot confirm whether the leak is actually within the SCM. A further problem is that current flow through the electrode pairs results in their corrosion.
[0005] This invention enables the detection of both the ingress of sea water and hydraulic fluid in the SCM and provides a better indication of the degree of ingress, and reduces corrosion of the sensing electrodes.
[0006] Recent measurements have been made in the laboratory of the change in conductivity of the insulating oil in an SCM with contamination by the hydraulic fluid used for the well control system, which is a glycol based trans-aqua fluid. Results show that the conductivity of the contaminate in the oil is much less than that due to sea water and thus the existing contamination detection technique described before was not sensitive enough to be able to detect the ingress of trans-aqua fluids. Measurements have also shown that sea-water and trans-aqua hydraulic fluid (glycol) in insulating oil result in an immiscible fluid with both contaminants having a greater density than the oil. Thus, ingress of these contaminants displaces the transformer oil from the base of the SCM upwards. This invention provides an improved method for the monitoring of undesirable fluid ingress into an SCM to enable detection of the ingress of trans-aqua hydraulic fluid as well as sea water, whilst still providing a zoned measure of the degree of ingress and using a variety of methods of measurement which also reduces, substantially, corrosion of sensing electrode pairs.
SUMMARY OF THE INVENTION
[0007] According to the present invention from one aspect, there is provided a subsea control module having a casing inside which there is at least one pair of electrodes, there being electronic means connected with the electrodes of the or each pair for monitoring at least one electrical characteristic between the electrodes as a result of a fluid to which the electrodes are exposed, wherein the or each pair of electrodes comprises an array in which each electrode of the pair has finger portions interleaved with finger portions of the other electrode.
[0008] There could be at least one such array on a base of the casing. Preferably, there is a plurality of such arrays on the base of the casing, each of which; for example, is at or near a respective corner of the casing.
[0009] Preferably, there is such an array disposed on a side wall of the casing and covering a zone of the side wall. In this case, said array disposed on a side wall could cover a lower zone of the side wall, which array, for example, also covers a portion of the base of the casing. Said portion of the base of the casing could be at or near a corner of the casing.
[0010] Preferably, there is at least one further such array after said array disposed on a side wall of the casing, the or each further such array covering a respective zone up the side wall of the casing.
[0011] Said at least one electrical characteristic could comprise at least one of resistance and capacitance.
[0012] Preferably, the or each array is disposed on a mat of electrically insulating material. Preferably, said electronic means is provided by a subsea electronics module of the control module.
[0013] According to the present invention from another aspect, there is provided a subsea control module having a casing inside which there are a plurality of electrode pairs, there being electronic means connected with the electrodes of each pair for monitoring at least one electrical characteristic between the electrodes of the pair as a result of a fluid to which the electrodes are exposed, wherein said electrode pairs are disposed on a base of the casing.
[0014] Preferably, there are also a plurality of further electrode pairs, each of which covers a respective zone up a side wall of the casing, said electronic control means being connected with the electrodes of each of the further electrode pairs.
[0015] Preferably, for both aspects of the invention, the electronic means applies a signal between the electrodes of the or each pair of electrodes for selected periods of time at selected intervals.
[0016] A module according to the invention could include pressure sensing means for sensing the pressure of fluid in the casing for use in providing an indication of an increase in pressure due to fluid leakage within the casing.
[0017] A module according to the invention could include release means for releasing fluid from the casing in response to an increase in fluid pressure within the casing above a threshold.
[0018] There could be a flowmeter coupled with said release means for providing an indication of the release of fluid.
[0019] According to the present invention from a further aspect, there is provided a subsea control module having a casing inside which there is at least one electrode pair, there being electronic means connected with the electrodes of the or each pair for monitoring at least one electrical characteristic between the electrodes of the pair as a result of a fluid to which the electrodes are exposed, wherein said electronic means applies a signal between the electrodes of the or each pair of electrodes for selected periods of time at selected intervals.
[0020] According to the present invention from yet a further aspect, there is provided a subsea control module including pressure sensing means for sensing the pressure of fluid in a casing of the module for use in providing an indication of an increase in pressure due to fluid leakage within the casing.
[0021] According to the present invention from yet a further aspect, there is provided a subsea control module including release means for releasing fluid from a casing of the module in response to an increase in fluid pressure within the casing above a threshold.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 illustrates a prior art system;
[0023] FIG. 2 illustrates circuitry for use with the system of FIG. 1 ;
[0024] FIG. 3 illustrates a system according to an embodiment of the invention;
[0025] FIGS. 4 , 5 and 6 illustrate forms of circuitry for use with the system of FIG. 3 ; and
[0026] FIG. 7 shows how pressure release means can be provided.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Referring to FIG. 3 , the individual electrode pairs of the system of FIG. 1 are replaced with electrode pairs, in each of which each electrode of the pair has finger portions interleaved or interlaced with finger portions of the other electrode to form an electrode array. The arrays are on an electrically insulating mat 18 , typically mounted on the internal base 3 of the casing 1 of the SCM and extending up a side wall of the SCM. Typically, each array is printed in copper on to a flexible printed wiring board and then gold plated for protection against corrosion, the board being mounted on a frame. The mat is divided into four sections, a lower section with a first electrode array 19 , including a horizontal portion 19 a on an electrically insulating mat on the base 3 at or near a corner of the casing 1 , and a vertical portion, with the latter rising to a quarter of the height of the SCM. The other three sections have respective electrode arrays 20 , 21 and 22 and cover half, three quarters and the top quarter of the height of the SCM, resulting in four vertical detection zones. Three other small horizontal gold plated electrode arrays with interleaved electrode pairs in the form of arrays 23 , 24 and 25 are also mounted on the SCM base 3 on electrically insulating mats, at or near each of the other three corners respectively. The electrode pairs of each of the detection zones and the three corner mats are connected to conditioning and detection circuitry housed in the SEM within the SCM. The vertical arrays 19 to 22 provide a measure of the quantity of ingress of undesirable fluid into the SCM, i.e. up to a quarter, half, three quarters and full displacement of the original insulating oil by sea-water or hydraulic fluid or both. The electrode array 19 by virtue of portion 19 a , and the electrode arrays 19 , 23 , 24 and 25 provide early detection of small quantities of sea-water and/or hydraulic fluid ingress even when the installation of the SCM is not truly vertical and are typically connected in parallel to the conditioning and detection circuitry and treated as one array.
[0028] FIG. 4 shows a block diagram of the conditioning and detection circuitry for the detection of fluid ingress using changes of resistance between the electrodes of the arrays. With the SCM filled with clean, uncontaminated oil, the resistance between the terminals of any of the electrode array 19 to 25 is very high, typically tens of megohms. With a small ingress of trans-aqua fluid, e.g. enough to cover arrays on the mats mounted on the SCM housing base, the resistance will fall typically to a few hundred kilohms. Ingress of sea water will also be detected by the system as only a small amount of ingress will cover at least one of the arrays of the mats on the SCM base and reduce the resistance between the electrodes of the array to only a few tens of ohms. The electrode pair on each mat, for example that of array 19 , is fed from a low voltage DC source 26 , typically 2 volts, via a current measuring resistor 27 and isolator switches 28 and 29 . The current flow through the electrode pair produces a voltage fed to a differential amplifier 30 , which produces an analogue output, converted to a digital message that is added to the well monitoring telemetry, fed topside, via the well umbilical. Although only one electrode array ( 19 ) is shown in FIG. 4 , the other arrays 20 - 25 are selected in turn by isolator switches similar to 29 of FIG. 4 . The connection of the low voltage source 26 to the arrays is controlled by the isolator switch 28 , which is operated by a digital control system also located typically in the SEM. The isolator switch 26 is closed only for a brief period, just long enough for the conditioning and detection circuitry to make a measurement, and repeated infrequently. Since the ingress of fluid is typically a slow process, measurement cycle time to measurement execution time ratios in excess of 10,000 to 1 are adequate. This reduces the corrosion of the electrode pairs on a mat due to electrolytic action to a negligible level. The process described above is repeated for the detection of sea-water ingress, by the same low voltage source 26 , connected to the arrays via a current measuring resistor 31 and an isolator switch 32 , producing an output to the well telemetry system from a differential amplifier 33 . Since the resistance between the electrode pairs on mats resulting from hydraulic fluid ingress is much greater (kilohms) than that resulting from sea water ingress (tens of ohms), the value of the measuring resistor 27 is much greater than the resistor 31 to produce a greater detection circuitry gain. Although the ingress of sea-water will swamp the hydraulic fluid ingress detection circuitry, this is of little concern since the detection of sea water ingress is itself sufficiently serious to warrant corrective action by the well operator.
[0029] FIG. 5 shows a block diagram of alternative conditioning and detection circuitry for the detection of fluid ingress utilising the change of capacitance between the electrode pair on any of the mats. This method can also be employed as an addition to the resistance measuring method, to provide greater confidence to the well operator that the detection of hydraulic fluid ingress, in particular, is accurate. A low voltage AC source is connected across two of the arms of a bridge circuit comprising three capacitors 35 , 36 and 37 and the electrode pair of array 19 , with two isolator switches 38 and 39 . The other two arms of the bridge are connected to AC amplification and detection circuitry 40 , to produce a DC output which is fed to the telemetry system of the well. The values of the capacitors 35 , 36 and 37 are chosen to match the capacitance between the electrode pair of array 19 when immersed in the oil within the SCM, so that the bridge circuit is balanced and there is no output to the circuitry 40 . Ingress of hydraulic fluid into the SCM results in a change of capacitance between the electrode pair of array 19 and thus an AC output from the bridge and into the amplification and detection circuitry 40 , which in turn produces an output to the well telemetry system. A variation of this method is to electronically adjust the value of the capacitor 36 , to maintain the balance of the bridge, i.e. zero output from the amplification and detection circuitry 40 , and use a measure of the bridge balancing capacitance as the source to the well telemetry system. Again, the arrays 19 , 23 , 24 and 25 are typically connected in parallel to the conditioning and detection circuitry and treated as one array and monitoring of other zones achieved by selecting the arrays 20 , 21 and 22 by additional isolator switches.
[0030] FIG. 6 shows a block diagram of an alternative method of detecting a change of capacitance due to undesirable fluid ingress. This method utilises the change of capacitance between the electrodes of array 19 , resulting from the change of dielectric constant of the fluid it is immersed in, when there is ingress of sea-water and/or hydraulic fluid. The change of capacitance results in a change of frequency of an oscillator 41 which can be measured and translated into a DC output using a frequency measuring circuit 42 , such as a discriminator and detector, as an output to the well telemetry system. The array 19 is selected by isolator switches 38 and 39 and different zones can be monitored by further isolator switches selecting the arrays. Again, the arrays 19 , 23 , 24 and 25 are typically connected in parallel to the conditioning and detection circuitry and treated as one array, and monitoring of other zones achieved by selecting the arrays 20 , 21 and 22 by additional isolator switches.
[0031] Leakage of hydraulic fluid in the SCM results in an increase in pressure within the outer casing 1 . This can be monitored, typically, by a diaphragm type pressure sensor 43 , mounted on the wall of the SCM outer casing 1 , and connected to the SEM within the SCM and its output also fed into the well monitoring telemetry system. The detection of hydraulic fluid ingress by the methods described above can thus be supported by a change of pressure, giving greater confidence of the detection process to the well operator.
[0032] An alternative or additional method of monitoring leakage of hydraulic fluid into the SCM, to provide even greater corroboration of the electrical detection method, is to fit a differential pressure release valve and a flowmeter to the SCM casing as illustrated in FIG. 7 . The pressure release valve 44 , is set, typically, to open when the pressure in the SCM exceeds the external environmental pressure by 5 psi, resulting from a hydraulic fluid leak. When the valve 44 opens the flow of liquid from the SCM to the environment is detected by the flowmeter 45 , whose electrical output is connected to the well monitoring telemetry system, thus advising the well operator to a fluid leak.
ADVANTAGES OF USING THE INVENTION
[0033] The key advantage is that the invention permits detection of hydraulic fluid leakage within the SCM in the absence of sea water ingress, and provides an indication of the degree of leakage, neither of which are possible with existing SCM ingress fluid ingress detection systems. Furthermore the system detects the ingress of sea water as well. Corrosion of the detection electrodes is also virtually eliminated. | A subsea control module has a casing ( 1 ) inside which there is at least one pair of electrodes, there being electronic means ( 26 - 33 ) connected with the electrodes of the or each pair for monitoring at least one electrical characteristic between the electrodes as a result of a fluid to which the electrodes are exposed, the or each pair of electrodes comprising an array ( 19 ) in which each electrode of the pair has finger portions interleaved with finger portions of the other electrode. | 4 |
TECHNICAL FIELD
This invention relates to buildings employing skeletal framing, and to structural members used in fabricating the same. More particularly, this invention relates to buildings whose frames are erected from hollow steel profiles that form both beams and columns that are connected together to form a framework, and that may then be filled with concrete to provide composite building structural members. Specifically, this invention relates to indented, elongated steel structural members having truncated, V-shaped transverse cross-sections that are bolted together to provide unitary structural assemblies, and that may thereafter be filled with concrete to form reinforced concrete building structures.
BACKGROUND OF THE INVENTION
Structural members comprising interconnected steel beams and girders are typically used in the construction of modern buildings not only in many single story structures, but particularly in multi-story buildings, since their use is often required to provide the strength necessary to prevent collapse of the structure. Buildings so constructed are not only sturdy, but have a functional life expectancy that in most cases far exceeds the economics of their continued existence.
While the characteristics described have caused such structural members to be widely used for the erection of buildings, they are not without certain inherent disadvantages. Steel columns, beams and girders, for example, are quite bulky and considerable space is, therefore, required to accommodate them. Such structural members are also extremely heavy, and for both reasons they require extensive and frequently involved transportation arrangements to move them from their manufacturing site or storage location to their place of erection. In addition, the erection of traditional structural members typically requires heavy-duty cranes and large scale equipment in order to lift the members into place at the building site. The process of erection also necessitates the services of experienced labor, and involves welding and other relatively high-skill techniques.
A further significant disadvantage of construction utilizing standardized steel structural members lies in the fact that their manufacture can only be accomplished in large, capital-intensive rolling mills of the kind associated with steel manufacturing plants.
Furthermore, while some buildings have been fabricated from reinforced concrete and preformed sections, such construction requires extensive forming, and is often uneconomical as a result. In addition, the use of such methods in multi-structure buildings is limited for reasons that include the excessive weight entailed.
As a consequence of the preceding, therefore, construction of multi-story buildings by standard techniques is not only usually expensive, but it is sometimes impractical due to budgetary constraints. Furthermore, in many locations lacking a skilled work force or suitable construction equipment, or which are relatively remote, such construction is difficult from a practical point of view.
Notwithstanding the preceding, there is a widespread and continuing need for multi-story buildings, for example, up to about five stories in height, not only in urban areas in which standard building methods are possible, but in rural areas in which they are difficult, and in developing countries where both the necessary worker skills and sophisticated erection equipment are often either non-existent, or in short supply. Unfortunately, the latter areas are frequently those having the greatest need for schools, hospitals, and other public buildings of both the single and multi-story variety having superior strength and durabilty characteristics, that can be built using unskilled or semi-skilled labor, and that require only basic tools and equipment for their erection.
BRIEF DESCRIPTION OF THE INVENTION
In view of the preceding, therefore, it is a first aspect of this invention to provide building structures that can be fabricated from interlocking steel profiles.
A second aspect of this invention is to provide inexpensive, light-weight, high-strength structural members.
An additional aspect of this invention is to provide relatively light-weight steel profiles that can be "nested" together for transportation to building sites, thereby greatly reducing transportation problems.
Another aspect of this invention is to provide building structural members that can rapidly and easily be erected by relatively unskilled labor without extensive use of heavy-duty, specialized erection equipment.
A further aspect of this invention is to provide steel structural profiles that can be fabricated from relatively simple, roll-forming equipment.
An additional aspect of this invention is to provide open steel structural profiles that also serve as forms for concrete poured therein.
Yet an additional aspect of this invention is to provide a way in which to make strong but light-weight building frames available both in developed and relatively undeveloped areas.
Still another aspect of this invention is to furnish a way in which to make available composite steel and concrete structural members.
The foregoing and yet further aspects of the invention are provided by an elongated, hollow steel structural member useful for fabricating structures therefrom comprising a trough-like profile that includes a closed bottom; an open top; two sides; and wing-like flanges, said sides diverging as they extend upward from said bottom to said top; said flanges extending outward from said top parallel to said bottom, and said bottom having indentations extending into the interior of said profile.
The foregoing and further aspects of the invention are provided by a structural member for a building structure in which counterpart surfaces of two of the profiles of the preceding paragraph are joined to each other at right angles to form structural columns having a vertical section, and a horizontal section.
The foregoing and other aspects of the invention are provided by a column member for a building structure in which the vertical portions of two of the structural columns according to the preceding paragraph are positioned back-to-back with surfaces of their wing-like flanges adjacent to each other and connected together.
The foregoing and yet additional aspects of the invention are provided by a composite structural component comprising an elongated, hollow steel profile that includes: a closed bottom; an open top; two sides; and wing-like flanges, said sides diverging as they extend upward from said bottom to said top, said profile being provided with indentations extending into the interior of said profile, and said flanges extending outward from the top of at least one of said sides, parallel to said bottom, said profile being filled with concrete.
The foregoing and still other aspects of the invention are provided by skeletal framing of a building formed from interlocked structural components comprising vertical column members and horizontal beam members formed from composite structural components according to the preceding paragraph.
The foregoing and yet further aspects of the invention are provided by skeletal framing for a multi-story structure in which the lower ends of the vertical portions of structural column members according to the penultimate paragraph are positioned over the tops of others of said column members, and in axial alignment therewith, each of said upper columns resting on column support means spaced from the tops of the columns beneath by spacer bolts, said spacer bolts comprising: a bolt head; an upper, larger diameter threaded portion with a first nut engaged therewith; a lower, smaller diameter threaded portion with a second nut engaged therewith; and a shoulder between said larger diameter portion and said smaller diameter portion, wherein said support means is secured between said head and said first nut, and the column beneath is secured between said shoulder and said second nut, the distance between said shoulder and said first nut providing said spacing.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood when reference is had to the following drawings, in which like-numbers refer to like-parts, and in which:
FIG. 1A and FIG. 1B are isometric partial views of a structural frame for a building fabricated from the structural members of the invention.
FIG. 2 is an end view of structural beam member of the invention.
FIG. 2A is a partial front elevation of a structural member juncture showing the interconnection of structural beam members with a structural column member.
FIG. 3 is an isometric view of a structural member juncture showing the interconnection of a structural beam member with vertically aligned structural column members.
FIG. 4 shows a front elevation of a spacer bolt, including its associated nuts and washers.
FIG. 5 is an isometric view of a structural member junction showing the interconnection of two structural beam members with vertically aligned structural column members.
FIG. 6 is an isometric partial view of a structural frame for a building illustrating the use of double structural column members.
FIG. 7 is a top view of a structural member juncture showing the interconnection of a structural column member with structural beam members and spacer beam members.
FIG. 8 is an exploded front elevation view of a double structural column member with its associated structural beam members, floor panels, and shoulder U-bolts.
FIG. 9 is an isometric view of a structural member juncture showing the interconnection of vertically aligned double structural column members with two structural beam members.
FIG. 10 is an isometric view of a structural member showing the interconnection of a structural beam member, structural end beam members, and a structural column member, the structural beam member being shown with associated floor panels and shouldered U-bolts.
FIG. 11 is an isometric view of a lath screen jacket for a structural beam member of the invention.
FIG. 12 is an end view of a clad structural beam member fastened to deck panels with shouldered U-bolts.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1A and 1B are isometric partial views of a structural frame for a building fabricated from the structural members of the invention. In the Figures, structural beam members 14 are shown connected to single column members 16 comprising vertical portions connected by weld joints 22 to column shoulders 18. The vertical portion of the columns making up the first story of the structure are positioned on base plates 20 with the column shoulders 18 serving as supports for structural beam members 14 and as supports for further columns positioned in axial alignment thereon. In the interior of the building, spacer beams 28 are positioned between columns 16 to provide uniform distance between the spans 23. The ends of adjacent spans are interconnected by means of structure end-beam members 26, while floor panels 30 extend between the spans, supported on the edges of the beam members. Details of the structural member junctures circled by the dotted lines are to be seen in the Figures to which reference is had.
As previously indicated, the structure shown is well suited for use in structures at least up to about five stories in height, including particularly schools, hospitals, and the like. The individual structural members, including the beam members 14 and column members 16, may be nested together, loaded into trucks, and transported to the building site, the trucks' loads being dictated by the weight of the nested structural members, rather than by volume as in the case of ordinary I-beams and similar structural components. Once at the site, the structural profiles are simply bolted together to form the desired building frame.
When the frame has been completed, and the floor panels bolted into place, concrete is poured into the structural members, which act as concrete forms, and onto the deck panels, as will be described in greater detail in the following. With the exception of the spacer beam members 28, which are not filled with concrete, the structural members have open tops, which facilitate the insertion of reinforcing bars in cases where additional strength is required.
FIG. 2 is an end view of structural beam member of the invention showing the truncated, V-shaped cross-section of the structural members. As shown in the Figure, the beam member 14 includes beam wings 32 extending outward from the top of the beam which among other functions, support deck panels positioned thereon. The beam wings are parallel to the bottom 36 of the beam. In any given structure, the width of the bottom of the structural members, and the width of the open top will be the same, although the length of the sides 35 of the beam may vary, for example, as between structural members making up the column shoulders 18 and the vertical portions of the columns 17, as better seen in FIG. 2A.
Also shown in the Figure are rib indents 34, and boss or dimple indents 36 that extend into the interior of the beam profiles, anchoring the concrete to the profiles. The dimple indents in the bottom of the profiles provide the important function of preventing movement of the concrete in the beam when the beam is subjected to loading and unloading. Although not as important as the dimple indents in the bottom, the rib indents further prevent the concrete's movement under similar conditions. Although other dimple shapes and sizes may be used, round dimples are commonly employed having a diameter of from about 1 to 11/2 inches, and a height from about 1/16 to about 3/16 inch. Commonly, the dimples are positioned in transverse rows across the bottom of the member and spaced about 1 to 2 inches apart, measured from dimple-edge to dimple-edge, with the transverse rows being spaced about 1 to 3 inches apart. It will be understood, however, that different spacing, dimple sizes and shapes may also be employed without departing from the spirit of the invention.
While only one rib indent 34 is shown on each of the sides 35 of the structural member, more than that number can be used if desired. Although rib indents having different dimensions may be employed, typically, the rib indents will extend into the interior of the structural member from about 3/4 inch to 11/2 inch, and such indents will be from about 2 to 4 inches high.
Similarly, while beam members having different measurements may be employed, the wings of the beams will usually be from about 21/2 inches to 31/2 inches wide, and the bottom of the beam will be from about 7 inches to 9 inches wide, with the open top being from about 9 inches to 11 inches wide. The sides of the beams will normally range from about 11 inches to 17 inches high, based on their vertical dimension. As will be explained in the following, the structural members of the invention are advantageously made by the roll forming of steel sheet coils. When so fabricated, the width of the coil will normally determine the height of the sides, assuming the dimensions of the top and bottom of the structural member are maintained constant. In the case of a structural member with wings 3 inches wide, a bottom 8 inches wide and an open top 10 inches wide, for example, the vertical height of the sides will be about 163/4 inches when fabricated from a 48 inch coil; about 123/4 inches when made from a 40 inch coil; and approximately 83/4 inches when a 32 inch coil is used. While the beams can be made longer or shorter, ordinarily beams of from about 10 feet to about 32 feet long are convenient both from a structural and an erectional viewpoint.
The thickness of the metal from which the beams and columns are formed may be varied from about 1/16 to 3/16 inch, and will depend upon the structural requirements of the application contemplated.
With respect to the fabrication, a notable advantage of the structural members of the invention is that they can be fabricated by roll formers rather than by stamping processes. In fact, since it is important that the surfaces of adjacent members, for example, beam members resting in column shoulders, be characterized by a close fit, the roll forming procedure is of significant advantage since it allows more precise dimensions to be achieved. In forming the dimples 36, it will often be found desirable to use an eccentric press, for instance, of the 100 ton variety, provided with an appropriate die and a continuous feeder mechanism.
In some instances, particularly where greater strength is required, it has been found desirable to position reinforcing bars 37 in the structural profile members. This may be done by positioning the reinforcing bars on transverse supporting members 39 placed on the interior of the structural members. The fact that the structural members have an "open" top allows the positioning of the bars within the members to be readily accomplished. Thus, the steel/concrete composite structural members of the invention can be strengthened further if need be without increasing the thickness, and therefore the weight, of the profiles, a notable advantage of the invention. While only one tier of reinforcing bars is shown in the Figure, additional tiers may be employed if desired. Although such reinforcement is normally positioned in the lower 1/3 of the structural member, it may be positioned elsewhere if desired. A further advantage of the structural profiles contemplated by the invention is that they have open tops, facilitating placement of the reinforcement bars described.
FIG. 2A is a partial front elevation of a structural member juncture showing the interconnection of structural beam members with a structural column member. As shown, a vertical portion 17 of the column 16, having a shape similar to the transverse cross-section shown in FIG. 2, connected by welding to the horizontal column shoulder 18 by means better illustrated in others of the Figures. A structural beam member 14 is shown being supported by the shoulder 18 while a another structural beam 14a is attached to the vertical portion of the column by means of a beam flange 24 connected to the column by bolts, not shown. Indenting of the beams including both rib indents 34, and dimple indents 36 is illustrated.
The height of the vertical portion of the column 17 may be varied, but normally, will be from about 8 feet to 15 feet high, 11 feet being typical, and the column will have a shoulder length of from about 16 inches to 20 inches. Although not normally included, indenting of the column may be employed if desired.
FIG. 3 is an isometric view of a structural member juncture showing the interconnection of a structural beam member with vertically aligned structural column members. In the Figure, as in others of the Figures included herewith, indentation of the respective members has not been illustrated in the interest of simplification. As shown, two columns, 16 and 16a respectively, are held in axial alignment by means of spacer bolts 48, better seen in FIG. 4. The spacer bolts engage shoe flange 46 by means of its associated flange 44 about which the upper column 16a is positioned, being held by fastener bolts 50. A structural beam 14 rests in, and is supported by the column shoulder 18 connected by weld joint 22 to the vertical portion of the column 16. The spacer bolts 48 serve both to align the superimposed column 16a, as well as to fasten the columns together in a way that provides a gap between the columns of sufficient height to accommodate a concrete floor extending therebetween.
FIG. 4 shows a front elevation of a spacer bolt, including its associated nuts and washers. The Figure illustrates how the flange 44 of shoe 46, illustrated for example in FIG. 3, is held between washers 62 positioned below bolt head 64, and above larger nut 58, respectively. Between the larger diameter shank 52 of spacer bolt 48 and its smaller diameter shank 54 is a shoulder 56 which rests upon the shoulder wings of a column shoulder 18 when the spacer bolt is inserted through a hole in the wings. Smaller nut 60, threadably engaging smaller diameter shank 54 completes the assembly and bolts the two columns securely together.
By suitably fabricating the length of the larger diameter shank 52, the clearance between the aligned columns may be varied to accommodate whatever floor height is desired. Commonly, however, the height of the shank will be selected to accommodate a floor of from about 4 to 5 inches high.
FIG. 5 is an isometric view of a structural member juncture showing the interconnection of two structural beam members with vertically aligned structural column members. In this Figure, column 16 is connected to column 16a be means of spacer bolts 48 connecting the shoulder wings 38 of column shoulder 18 to the flange 44 of a single column shoe 46 about which column 16a is positioned. Again fastener bolts 50 attach the shoe to the column wings 40a. The vertical portion of the column 16 is connected to the column shoulder 18 by means of a weld joint 22, the shoulder acting as a support for the structural beam 14 enclosed therein and connected thereto by fastener bolts, not shown. Another structural beam member 14a is connected to the column wings 40 of the vertical portion of column 16 by means of fastener bolts 50 extending through a beam flange 24 connected to the beam 14a. The Figure illustrates the case in which a single column is employed for the structural member juncture, in contrast to a double column, as better seen in FIG. 9. In the case of the single column, one of the supported beams lies within the shoulder of the column, the other being bolted to the wings of the column's vertical portion. In the case of the double column, both beams lie in adjacent column shoulders.
FIG. 6 is an isometric partial view of a structural frame for a building illustrating the use of double structural column members. Shown in the Figure is a one story structure employing two single columns 16, held in such position, back-to-back, by fastener bolts, not shown, to form a double column 66. The double column rests on a double column base plate 68 and supports two structural beams 14 in the column shoulders 18. Two adjacent spans 23 are shown spaced apart by means of spacer beam members 28. Supported on the beams of the adjacent spans is floor paneling 30. The spacer beams 28 not only assist in correct spacing of the spans during the erection process, but helps to maintain that spacing and rigidify the structure even after its completion.
In the process of erection, the columns are set in place and the structural beams are positioned so to be supported by the columns, either by flanges or by column shoulders, as the case may be, and bolted together. Following such placement and interconnection, the concrete is poured in the beams and columns, and over floor panels fastened to the beam members, as will be described in more detail in the following. If desired, reinforcing bars may be positioned in the columns, as well as in the beams, to provide extra strength. After the concrete has set, and if desired, subsequent floors can be constructed by axially aligning columns on top of the first floor columns, supporting new beams therein, attaching floor paneling and proceeding generally as in the case of the first floor. Subsequent floors may be added in like fashion.
FIG. 7 is a top view of a structural column member with structural beam members and spacer beam members. The Figure illustrates a single column 16, including an attached column shoulder 18 with spacer beams 28 connected thereto by fastener bolts 50 passing through the column wings 40. On one side of the column a structural beam 14 is supported in column shoulder 18, while another structural beam 14a is connected to the column 16 by a beam flange 24. As previously related, although not filled with concrete, the spacer beams 28 provide spacing and additional rigidity to the spans both during and after their erection.
FIG. 8 is an exploded front elevation view of a double structural column member with its associated structural beam members, floor panels, and connecting shouldered U-bolts.
The Figure illustrates the use of a double column 66 comprising two single columns 16 held in a back-to-back position by means of fastener bolts 50. The construction is used where two long spans are to be erected adjacent to each other with no short span in between, although the double columns can be used elsewhere as well. As shown, two structural beams 14 and 14a are placed in the column shoulders 18 and 18a, respectively. Finally, a floor panel 30 is positioned on the shoulder wings 38 of the columns and fastened thereto by means of shouldered U-bolts 70, better seen in connection with FIG. 10. The floor panel 30 not only serves as a base and as a form for the concrete flooring, not shown, but provides reinforcing both to the floor and to the structure itself. If desired, reinforcing bar may be positioned in the concrete on top of the floor panel.
FIG. 9 is an isometric view of a structural member juncture showing the interconnection of vertically aligned double structural column members with two structural beam members. Again, the double columns 66 are formed from two single columns 16, the vertical portion 17 of each of which is connected by weld joints 22 to column shoulders 18. In axial alignment and superimposed over the lower double column is a double column shoe 72 attached to the column wings 40 of the lower double column by means of spacer bolts 48 extending from holes in the wings to holes in the double column shoe flange 74. Only one of the single column members 16a making up the upper double column is shown, fastened to the double column shoe 72 by means of fasteners 50. A structural beam 14a is also illustrated positioned in, and supported by one of the column shoulders 18.
Shoe 74 serves both to align the superimposed double columns with each other, as well as to reinforce the anchor point of the upper column. As previously indicated, where double columns are used, the structural beams forming part of the structural member juncture are supported by being placed in the column shoulders and secured there by fasteners, better seen in FIG. 10, rather than by a connection involving a beam flange 24, as illustrated in FIG. 5.
FIG. 10 is an isometric view of a structural member showing the interconnection of a structural beam member, structural end beam members, and a structural column member, the structural beam member being shown with associated floor panels and shouldered U-bolts. The U-bolts serve the important function of assuring that the beam members and floor panels attached thereto "work" together in an integrated relationship. In FIG. 10, a column 16 including a vertical portion 17 and a column shoulder 18, and fastened together by weld joint 22 are shown with structural end beams 26 attached to the wings of the column by means of fasteners 50. A structural beam 14 is supported in column shoulder 18 and bolted thereto by fastener bolts 50. Attached to the beam wings 32 by means of shouldered U-bolts 70 are floor panels 30. The concrete 77 for filling structural beam 14 and forming the flooring is also illustrated. While the structural end beams 26 are not portrayed with concrete therein, anchor bolt 78 designed to help anchor concrete placed therein is illustrated.
It will be observed that the end beams 26 of the Figure have a beam wing 32 only on one side thereof. This permits the opposite side of the structural end beam to form a flush surface with the open side of the vertical portion 17 of column 16, permitting the outside facade of the building to lie substantially in a single plane. Such construction permits the outside of the building to be finished in a pleasing fashion with no discordant protrusions extending therefrom.
While end beams 26 are shown without indents extending into the interior thereof to stabilize the concrete included therein, they may be so furnished if desired.
The number of fasteners 50 connecting the column shoulder 18 and structural beam 14 together will be determined by engineering stress calculations, based upon the anticipated stress on the juncture. The fasteners are shown extending substantially into the interior of the structural beam, an expedient that allows them to serve as concrete anchors, as well as fasteners.
While the horizontal portions of the structural member profiles contemplated by the invention may be filled with concrete, which is held therein by gravity during the setting process, in order to fill the vertical portions 17 of the column 16, temporary plywood facing may be fastened over the open portion thereof by means of clips snapped over the plywood and wings of the column, thereby allowing concrete to be poured and retained within the column. After the concrete has set, the clips and plywood facing may be removed.
FIG. 11 is an isometric view of a lath screen jacket for a structural beam member of the invention. The lath screen 80, which is attached as better seen in connection with FIG. 12, allows structural members to be fireproofed by serving to hold concrete sprayed or otherwise applied thereon. It also facilitates covering the outside of the structural members with decorative plaster or other mastics where that is desirable.
FIG. 12 is an end view of a clad structural beam member fastened to deck panels with shouldered U-bolts. As shown, lath screening 80 is fastened to the outside of a structural beam 40 by means of a shouldered U-bolt 70. Applied to the outside of the lath screening 80 is a layer of lath coating 82 which may be concrete, plaster, or other desired mastic material.
The U-bolts are similar in operation to the spacer bolts 48 in that they include a larger diameter shank 84, and a smaller diameter shank 86, with a shoulder 90 formed at the juncture of the two. This enables the smaller diameter portion of the bolt 86 to extend through the floor panel 30 and beam wing 32 while the larger diameter shank 84 is retained above the floor paneling by virtue of the shoulder 90. Thus the insertion of the bolt as described automatically positions the height of the bolt, permitting it to serve as a stabilizing anchor for concrete poured around it, as well as a means for fastening the floor panel and structural beam together.
While in accordance with the patent statutes, a preferred embodiment and best mode has been presented, the scope of the invention is not limited thereto, but rather is measured by the scope of the attached claims. | Structural members for building structures comprise indented, truncated, V-shaped profiles which include flanges extending horizontally from the open tops thereof. Structural beam members comprise open-ended, elongated members, while structural column members are fabricated by joining counterpart surfaces of two of such profiles together at right angles. The structural members are nested together for transportation to building sites, where they are bolted together and floors formed by fastening corrugated panels to the beam flanges. Concrete is thereafter poured into the open profiles, and onto the deck panels to provide a floored framework for a building structure. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a ceramic capacitor and method for manufacturing same; and, more particularly, to a ceramic capacitor having prolonged lifetime by using a precise control of a dielectric layer composition and a manufacturing method therefor.
BACKGROUND OF THE INVENTION
[0002] Generally, a ceramic capacitor includes a chip-shaped sintered body and a pair of electrodes formed at two opposite sides thereof. In case of a multi-layer ceramic capacitor, the sintered body is generally made of alternately laminated dielectric layers and internal electrodes. Every two neighboring internal electrodes face each other through a dielectric layer disposed therebetween, and are electrically coupled to different external electrodes, respectively.
[0003] The dielectric layer is formed of a reduction-resistant dielectric ceramic, which includes ceramic grain primarily composed of BaTiO 3 , and an additive having a glass component serving to combine the ceramic grains. The internal electrodes are made of sintered conductive paste primarily composed of, e.g., Ni metal powder. Sintering as defined herein represents a process in which individual particles are densified through modification and bonding below melting point thereof to have a poly-crystalline structure in a shape of mass.
[0004] The sintered body is made by performing removal of binder from alternately laminated ceramic green sheets and internal electrode patterns, sintering in a non-oxidizing atmosphere at a high temperature of about 1200˜1300° C., and thereafter re-oxidizing under a mild oxidation condition.
[0005] If a ratio of Ba/Ti(A/B) of BaTiO 3 contained in the dielectric layers is equal to or less than 1.000 and sintering is performed in a reducing atmosphere, the sintered product does not function as a capacitor, since the constituents of the dielectric ceramic become semi-conductive during sintering and thus insulating properties thereof is deteriorated. To improve reduction-resistant properties of the dielectric ceramic, a ratio A/B of BaTiO 3 is required to be greater than 1.000. For making A/B greater than 1.000, it has been proposed to put an A-site component such as barium, strontium, and calcium greater than a stoichiometric ratio.
[0006] However, when sintering the dielectric ceramic having thus enhanced reduction-resistant characteristics, the A-site component of the perovskite crystal structure diffuses to grain boundaries so that the ratio A/B of ceramic grains becomes lowered. Therefore, reduction-resistance of the dielectric ceramic is deteriorated and oxygen deficiencies increase, resulting in a lifetime, i.e., a reliability, of a ceramic capacitor to be degraded.
SUMMARY OF THE INVENTION
[0007] It is, therefore, an object of the present invention to provide a ceramic capacitor and a method for the manufacture thereof, which has a prolonged lifetime and high reliability, wherein an A-site component of the perovskite crystal structure is prevented from diffusing into grain boundaries and thus the reduction of the ratio A/B in ceramic grains is effectively suppressed and the reduction resistance thereof is guaranteed.
[0008] In accordance with one aspect of the present invention, there is provided a ceramic capacitor having at least one dielectric layer and at least two electrodes having the dielectric layer therebetween, wherein the dielectric layer is formed of a dielectric ceramic having a sintered ceramic grain of a perovskite crystal structure in a form of ABO 3 , a ratio A/B of an outer portion of the ceramic grain is greater than that of an inner portion of the ceramic grain.
[0009] In such structure, the A-site component of the perovskite crystal structure will not be diffused to grain boundaries and reduction-resistance of the outer portion of a ceramic grain can be improved. Accordingly, the ceramic capacitor in accordance with the present invention has an improved reduction resistant dielectric layer, which gives rise to prolonged lifetime, and improved electric characteristics such as insulating resistance.
[0010] Herein, a dielectric ceramic of the present invention is preferably BaTiO 3 or SrTiO 3 based ceramic. However, other alternative dielectric ceramic may also be used if it is composed of sintered ceramic grains having the perovskite crystal structure.
[0011] The drawing of the invention shows ceramic grains, outer portions thereof, inner portions thereof, and grain boundaries of a sintered body. The outer portion of a ceramic grain indicates a portion of the ceramic grain from the outer surface toward the center thereof up to about 10 nm in depth and the inner portion of a ceramic grain represents a portion thereof inside the outer portion. The outer portion of a ceramic grain does not refer to a part of the grain boundary but a portion inside of the ceramic grain. A ratio of A/B, e.g., of Ba x Ti y O 3 , denotes molar ratio x/y of Ba and Ti.
[0012] In the perovskite crystal structure of the present invention, a ratio A/B of the outer portions of ceramic grains composing a sintered ceramic body is greater than that of the center portions thereof. In such a structure, an A-site component of the perovskite structure would not diffuse to grain boundaries. The ratio A/B of the outer portions of the ceramic grains is preferably to be within a range of about 1.000<A/B≦1.015. If the ratio A/B is equal to or lower than about 1.000, reduction-resistance is reduced and required IR(insulation resistance) lifetime is not achieved, thereby deteriorating the reliability. On the other hand, if the ratio A/B is greater than about 1.015, required sintered features and electrical characteristics or required growth of grain and electrical characteristics cannot be achieved. However, within such range of 1.000<A/B≦1.015, required electrical properties can be achieved.
[0013] It is also preferable that an amount of an A-site component ranging from about 0.05 to 0.1 mole per 100 moles of a primary component forming the ceramic grain is included in an additive containing a glass component to be used in combining ceramic grains. If the A-site component is included less than about 0.05 mole, the A-site component diffuses from the outer portions of the ceramic grains into the grain boundaries and the ratio A/B at the outer portions is lowered, which reduces reduction-resistance, thereby deteriorating the reliability. If the A-site component is included more than about 0.1 mole, the A-site component becomes a surplus and as a result the ratio A/B of the ceramic grains in the outer portions exceeds 1.015, thereby making it impossible to get the required growth of grain and electrical properties. On the other hand, if the A-site component is included within a range from about 0.05 to 0.1 mole, the diffusion of the A-site component from the ceramic grains into the grain boundaries is suppressed and the ratio A/B of ceramic grains is not allowed to be lowered, which yields the ratio A/B of the outer portions to be greater than that of the inner portion and also the ratio A/B of the outer portions to be within the range of about 1.000<A/B≦1.015, thereby enabling the required electrical properties to be obtained.
[0014] In accordance with another aspect of the invention, there is provided a method for manufacturing a ceramic capacitor including the steps of making unsintered ceramic powder, forming ceramic green sheets by mixing the uncalcined ceramic powder and an organic binder, printing internal electrodes on the ceramic green sheets to provide electrode printed green sheets, laminating the electrode printed green sheets, cutting the laminated ceramic green sheets according to the printed internal electrodes pattern to provide chip-shaped laminated bodies, and sintering the chip-shaped laminated bodies, wherein the unsintered ceramic powder includes a primary component of a perovskite crystal structure in a form of ABO 3 and an additive containing an A-site component of the perovskite crystal structure.
[0015] The unsintered ceramic powder is e.g., BaTiO 3 and SrTiO 3 family, but other alternative ceramic powder that can form a sintered ceramic body having perovskite crystal structure may be used.
[0016] Further, as an additive having, e.g., SiO 2 , Li 2 O, B 2 O 3 or a combination thereof as a main component can be used, but other alternative may be included in the additive.
[0017] It is preferable for an amount of the additive to be ranged from about 0.1 to 1.0 part by weight with respect to 100 moles of a primary component forming the ceramic grains. If the amount of the additive is less than about 0.1 part by weight, a required growth of grain and electrical properties cannot be obtained, whereas if the amount of the additive is greater than 1.0 part by weight, a growth of grain is hard to control for obtaining the required electrical properties or excessive growth of grains may occur, resulting in degraded reliability. However, the amount of additive ranging from about 0.1 to 1.0 part by weight makes it possible to obtain the required electrical properties.
[0018] Further, one or more components selected from the group consisting of barium, calcium, and strontium may be used as the A-site component included in the additive, but other alternative material may also be used.
[0019] It is also preferable that an amount of an A-site component ranging from about 0.05 to 0.1 mole per 100 moles of a primary component forming the ceramic grain is included in an additive containing a glass component to be used in combining the ceramic grains. If the A-site component is included less than about 0.05 mole, the A-site component diffuses from the outer portions of the ceramic grains into the grain boundaries and the ratio A/B at the outer portions is lowered, which reduces reduction-resistance, thereby deteriorating the reliability. If the A-site component is included more than about 0.1 mole, the A-site component becomes a surplus and as a result the ratio A/B of the ceramic grains in the outer portions exceeds 1.015, thereby making it impossible to get the required growth of grain and electrical properties. On the other hand, if the A-site component is included within a range from about 0.05 to 0.1 mole, the diffusion of the A-site component from the ceramic grains into the grain boundaries is suppressed and the ratio A/B of ceramic grains is not allowed to be lowered, which yields the ratio A/B of the outer portions to be greater than that of the inner portion and also the ratio A/B of the outer portions to be within the range of about 1.000<A/B<1.015, thereby enabling the required electrical properties to be obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The above and other objects and features of the present invention will become apparent from the following description of preferred embodiments given in conjunction with the accompanying drawing, which schematically shows ceramic grains 1 , outer portions thereof 2 , inner portions thereof 5 , and grain boundaries 4 of a sintered body 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
[0021] A-site components having a molar ratio of Ba:Ca=0.90:0.10 and B-site components having a molar ratio of Ti:Zr=0.850:0.150 were calcined for forming a primary component Ba 1-x Ca x Ti 1-y Zr y O 3 .
[0022] Next, with respect to 100 moles of the primary component Ba 1-x Ca x Ti 1-y Zr y O 3 , 1.0 mole of Mn and 1.0 mole of Ho were added thereto as minor additives and then mixed and stirred for 15 hours in a ball mill.
[0023] Tetraethoxysilane was slowly added to 100 Ml of ethanol by using a dropping pipette so that 0.7 part by weight of SiO 2 was present in the solution with respect to 100 moles of the primary component and stirred at room temperature for 15 minutes. Further, barium acetate was weighed so that about 0 to 0.12 mole of barium was present with respect to 100 moles of the primary component(not including SiO 2 powder, Mn and Ho) and fully dissolved in ethylene glycol. Above-obtained solution was added to the tetraethoxysilane solution slowly and stirred at room temperature for 15 minutes for obtaining sol.
[0024] Next, the above-obtained sol was added to the BaCaTiZrO 3 slurry, and the mixture was stirred for 30 minutes in a ball mill and dried to obtain various types of unsintered ceramic powders in which about 0 to 0.12 mole of barium was present with respect to 100 moles of the primary component.
[0025] Next, by using the unsintered ceramic powder, ceramic slurry was obtained, from which ceramic green sheets, each having a thickness of about 5 μm, were obtained. Thereafter, internal electrodes were printed on the ceramic green sheets and 10 ceramic green sheets were laminated, followed by removing binder therefrom, and sintering at high temperature, consequently obtaining various ceramic capacitors.
[0026] Next, a ratio A/B of outer portions, i.e., portions from surface to 10 nm in depth toward center, of the ceramic grains forming dielectric layers of the ceramic capacitors and a ratio A/B of inner portions of the ceramic grains were examined, respectively, wherein the ratio A/B of inner portions were sampled from points about 10 nm below the outer portions (i.e., about 20 nm below the surfaces of the ceramic grains). The result of the examination is described in test specimen numbers 1 to 10 of Table 1. In addition, an IR lifetime of the ceramic capacitor is also described.
[0027] The ratio A/B of the outer portions and inner portions of ceramic grains were tested by spot quantitative analysis by using a TEM-EDX method for 50 ceramic grains, wherein 10 spots for each of the outer portion and inner portion of every grain were examined, and 4 significant figures(rounded up to the third floating point) were measured and averaged. The IR lifetime of the ceramic capacitor was defined as the duration of time at which an order of resistance was changed when a voltage of 20V/μM was applied at a temperature of 200° C. This is equally applied to the following EXAMPLES 2 and 3.
[0028] As seen in test specimen numbers 4 to 9 of Table 1, barium contained in the additive in an amount ranging from about 0.05 to 0.1 mole yielded the ratio A/B of the outer portions of the ceramic grains that ranged from 1.000 to 1.015 and satisfied required lifetime characteristics(IR lifetime over 2 hours). On the other hand, when the amount of barium contained in the additive was less than about 0.05 mole as in the test specimen numbers 1 to 3, the ratio A/B of the outer portions of the ceramic grains became no more than 1.000 and could not satisfy required lifetime. In addition, when the amount of barium contained in the additive was more than about 0.1 mole as in the test specimen number 10, the ratio A/B of the outer portions of the ceramic grains became greater than 1.015, so that a required sintering, electrical properties or growth of grain could not be obtained.
EXAMPLE 2
[0029] A-site components having a molar ratio of Ba:Ca=0.95:0.05 and B-site components having a molar ratio of Ti:Zr=0.920:0.080 were calcined for forming a primary component Ba 1-x Ca x Ti 1-y Zr y O 3 .
[0030] Next, with respect to 100 moles of the primary component Ba 1-x Ca x Ti 1-y Zr y O 3 , 1.0 mole of Mn and 1.5 moles of Ho were added thereto as minor additives and then mixed and stirred for 15 hours in a ball mill.
[0031] And, tetraethoxysilane was slowly added to 100 Ml of ethanol by using a dropping pipette so that about 0.9 part by weight of SiO 2 was present in the solution with respect to 100 moles of the primary component and stirred at room temperature for about 15 minutes. Further, barium acetate was weighed so that about 0 to 0.12 mole of barium was present with respect to 100 moles of the primary component and fully dissolved in ethylene glycol. Above-obtained solution was slowly added to the tetraethoxysilane solution and stirred at room temperature for 15 minutes for obtaining sol.
[0032] Next, the above-obtained sol was added to the BaCaTiZrO 3 slurry and the mixture was stirred for 30 minutes in a ball mill and dried to obtain various types of unsintered ceramic powders in which about 0 to 0.12 mole of barium was present with respect to 100 moles of the primary component.
[0033] Next, by using the unsintered ceramic powder, ceramic slurry was obtained, from which ceramic green sheets, each having a thickness of about 5 μm, were obtained. Thereafter, internal electrodes were printed on the ceramic green sheets and 10 ceramic green sheets were laminated, followed by removing binder therefrom, and sintering at high temperature, consequently obtaining various ceramic capacitors.
[0034] Next, a ratio A/B of outer portions, i.e., portions from surface to 10 nm in depth toward center, of the ceramic grains forming dielectric layers of the ceramic capacitors and a ratio A/B of inner portions of the ceramic grains were examined, respectively, wherein the ratio A/B of inner portions were sampled from points about 10 nm below the outer portions (i.e., about 20 nm below the surfaces of the ceramic grains). The result of the examination is described in test specimen numbers 11 to 20 of Table 1. In addition, an IR lifetime of the ceramic capacitor is also described.
[0035] As seen in test specimen numbers 14 to 19 of Table 1, barium contained in the additive in an amount ranging from about 0.05 to 0.1 mole yielded the ratio A/B of the outer portions of the ceramic grains that ranged from 1.000 to 1.015 and satisfied required lifetime characteristics. On the other hand, when the amount of barium contained in the additive was less than about 0.05 mole as in the test specimen numbers 11 to 13, the ratio A/B of the outer portions of the ceramic grains became no more than 1.000 and could not satisfy required lifetime. In addition, when the amount of barium contained in the additive was more than about 0.1 mole as in the test specimen number 20, the ratio A/B of the outer portions of the ceramic grains became greater than 1.015, so that a required sintering, electrical properties or growth of grain could not be obtained.
EXAMPLE 3
[0036] A-site components having a molar ratio of Ba:Ca=0.90:0.10 and B-site components having a molar ratio of Ti:Zr=0.850:0.150 were calcined for forming a primary component Ba 1-x Ca x Ti 1-y Zr y O 3 .
[0037] Next, with respect to 100 moles of the primary component Ba 1-x Ca x Ti 1-y Zr y O 3 , 1.0 mole of Mn and 1.0 mole of Ho were added thereto as minor additives and then mixed and stirred for 15 hours in a ball mill.
[0038] And, tetraethoxysilane was slowly added to 100 Ml of ethanol by using a dropping pipette so that about 0.05 to 1.30 part by weight of SiO 2 was present in the solution with respect to 100 moles of the primary component and stirred at room temperature for about 15 minutes. Further, barium acetate was weighed so that about 0.07 mole of barium was present with respect to 100 moles of the primary component and fully dissolved in ethylene glycol. Above-obtained solution was slowly added to the tetraethoxysilane solution and stirred at room temperature for 15 minutes for obtaining sol.
[0039] Next, the above-obtained sol was added to the BaCaTiZrO 3 slurry and the mixture was stirred for 30 minutes in a ball mill and dried to obtain various types of unsintered ceramic powders in which about 0.05 to 4.00 part by weight of the additive including SiO 2 was present.
[0040] Next, by using the unsintered ceramic powder, ceramic slurry was obtained, from which ceramic green sheets, each having a thickness of about 5 μm, were obtained. Thereafter, internal electrodes were printed on the ceramic green sheets and 10 ceramic green sheets were laminated, followed by removing binder therefrom, and sintering at high temperature, consequently obtaining various ceramic capacitors.
[0041] Next, a ratio A/B of outer portions, i.e., portions from surface to 10 nm in depth toward center, of the ceramic grains forming dielectric layers of the ceramic capacitors and a ratio A/B of inner portions of the ceramic grains were examined, respectively, wherein the ratio A/B of inner portions were sampled from points about 10 nm below the outer portions (i.e., about 20 nm below the surfaces of the ceramic grains). The result of the examination is described in test specimen numbers 21 to 28 of Table 1. In addition, an IR lifetime of the ceramic capacitor is also described.
[0042] As shown in test specimen numbers 22 to 26 of Table 1, an amount of additive ranging from about 0.1 to 1.0 part by weight satisfies required lifetime of the capacitor. On the other hand, when the amount of the additive less than 0.1 part by weight with respect to 100 moles of the primary component was added, as shown in test specimen number 21, sintered characteristics were deteriorated so that a required growth of grain and electrical properties could not be obtained. When the amount of additive exceeded about 1.0 part by weight, as shown in specimen numbers 27 and 28, controlling the growth of grain became difficult, i.e., resulting in an excess growth of grain, thereby deteriorating the reliability of the ceramic capacitor.
TABLE 1 Primary Material A-site B-site Minor IR Component Component Additive Additive A/B Ratio Life No. Ba Ca Sr Ti Zr Mn Ho S 1 O 2 Ba Outer Inner time *1 0.90 0.10 — 0.850 0.150 1.0 1.0 0.7 0.00 0.927 1.000 0.32 *2 ″ ″ — ″ ″ ″ ″ ″ 0.02 0.994 1.000 0.54 *3 ″ ″ — ″ ″ ″ ″ ″ 0.04 0.999 1.000 0.98 4 ″ ″ — ″ ″ ″ ″ ″ 0.05 1.001 1.000 2.62 5 ″ ″ — ″ ″ ″ ″ ″ 0.06 1.002 1.000 3.55 6 ″ ″ — ″ ″ ″ ″ ″ 0.07 1.006 1.000 5.10 7 ″ ″ — ″ ″ ″ ″ ″ 0.08 1.009 1.000 4.61 8 ″ ″ — ″ ″ ″ ″ ″ 0.09 1.012 1.000 3.98 9 ″ ″ — ″ ″ ″ ″ ″ 0.10 1.015 1.000 2.53 *10 ″ ″ — ″ ″ ″ ″ ″ 0.12 1.020 1.000 1.98 *11 0.95 0.05 — 0.920 0.080 1.0 1.5 0.9 0.00 0.929 1.000 0.08 *12 ″ ″ — ″ ″ ″ ″ ″ 0.02 0.950 1.000 0.09 *13 ″ ″ — ″ ″ ″ ″ ″ 0.04 0.999 1.000 0.10 14 ″ ″ — ″ ″ ″ ″ ″ 0.05 1.001 1.000 2.01 15 ″ ″ — ″ ″ ″ ″ ″ 0.06 1.003 1.000 3.64 16 ″ ″ — ″ ″ ″ ″ ″ 0.07 1.006 1.000 6.51 17 ″ ″ — ″ ″ ″ ″ ″ 0.08 1.010 1.000 6.54 18 ″ ″ — ″ ″ ″ ″ ″ 0.09 1.013 1.000 4.41 19 ″ ″ — ″ ″ ″ ″ ″ 0.10 1.014 1.000 2.53 *20 ″ ″ — ″ ″ ″ ″ ″ 0.12 1.017 1.000 1.97 21 — 0.90 0.10 0.850 0.150 1.0 1.0 0.05 0.07 1.004 1.000 0.08 22 ″ ″ — ″ ″ ″ ″ ″ 0.10 1.003 1.000 2.12 23 ″ ″ — ″ ″ ″ ″ ″ 0.30 1.006 1.000 3.04 24 ″ ″ — ″ ″ ″ ″ ″ 0.50 1.005 1.000 3.70 25 ″ ″ — ″ ″ ″ ″ ″ 0.70 1.006 1.000 5.10 26 ″ ″ — ″ ″ ″ ″ ″ 1.00 1.005 1.000 4.11 *27 ″ ″ — ″ ″ ″ ″ ″ 1.10 1.001 1.000 1.98 *28 ″ ″ — ″ ″ ″ ″ ″ 1.30 0.999 1.000 0.70 29 ″ 0.05 0.05 ″ ″ ″ ″ 0.90 0.06 1.002 1.000 3.50 *30 ″ 0.10 — ″ ″ ″ ″ 0.7 0.07 0.999 1.000 0.08 *31 0.95 0.05 — 0.920 0.080 ″ 1.5 0.9 ″ 0.999 1.000 0.09 *32 0.90 0.10 — 0.850 0.150 ″ 1.0 0.50 ″ 0.999 1.000 0.10
COMPARATIVE EXAMPLE
[0043] A-site components having a molar ratio of Ba:Ca=0.90:0.10 and B-site components having a molar ratio of Ti:Zr=0.850:0.150 were calcined to obtain the primary component Ba 1-x Ca x Ti 1-y Zr y O 3 , and then 1.0 mole of Mn and 1.0 mole of Ho serving as minor additives and BaCO 3 and SiO 2 functioning as an additive containing glass components were added for 100 moles of the primary component Ba 1-x Ca x Ti 1-y Zr y O 3 , which were then mixed and stirred for 15.5 hours in a ball mill to obtain unsintered ceramic powder.
[0044] Next, ceramic slurry was formed by using the thus obtained unsintered ceramic powder, which was subsequently used in forming ceramic capacitors as in EXAMPLE 1. A ratio A/B of outer portions, i.e., portions from surface to 10 nm depth toward center of the ceramic grains forming dielectric layers of the ceramic capacitor and a ratio A/B of inner portions thereof were examined, respectively, wherein the ratio A/B of inner portions were sampled from points about 10 nm below the outer portions (i.e., about 20 nm below the surfaces of the ceramic grains). The result of the examination is described in Table 1 in test specimen numbers 30 to 32. In addition, an IR lifetime of the ceramic capacitors is also described in Table 1 in test specimen numbers 30 to 32.
[0045] Besides EXAMPLES 1 to 3, employing strontium as an A-site component(test specimen number 29) and glass containing lithium and boron as an additive resulted in achieving the same results.
[0046] In the present invention, by putting an A-site component in an additive, its diffusion from the perovskite structured grains into grain boundaries is prevented and a ratio A/B of an outer portion of a ceramic grain greater than that of an inner portion thereof is realized. In case of the ratio A/B of the outer portions of the ceramic grains ranging from about 1.000 to 1.015, the ratio A/B of the inner portions may take on a different value other than 1.000 as was the case in Table 1. Accordingly, reduction-resistance is improved and the reliability of the product, such as insulating resistance or lifetime can be enhanced.
[0047] While the invention has been shown and described with respect to the preferred embodiments, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims. | A ceramic capacitor has at least one dielectric layer and at least two electrodes having the dielectric layers therebetween. The dielectric layer includes a sintered body of ceramic grains containing a primary component of a perovskite crystal structure in a form of ABO 3 and a ratio A/B of outer portions of the ceramic grains is greater than that of an inner portions thereof. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of memories and more specifically of ROMs.
[0003] 2. Discussion of the Related Art
[0004] Conventionally, in a ROM, storage elements or memory points are arranged at the intersection of rows and columns, each memory point being likely to memorize a binary state, that is, a 0 or a 1. Thus, each memory point is a single-bit point.
[0005] To reduce the size of memories, it has been provided that each memory point, instead of being able to be in one or the other of two states, is likely to provide a richer information, characteristic for example of one or the other of three or four states. Preferably, for memory management reasons, it would be preferred for each memory point to be able to memorize an integral number of bits, that is, a number of data equal to an integral power of 2. Each memory point would for example correspond to a transistor, the conduction level of which would be greater or smaller when controlled to be in the on state. For this purpose, it may be envisaged to provide, at the level of each memory point, transistors of larger or smaller size, or again to provide transistors with a floating gate, the gate of which is more or less precharged. However, none of these solutions has been crowned with industrial success in standard CMOS technology, most likely because all these solutions imply relatively complex technological operations and require comparing a voltage or current level with several distinct thresholds. This operation is always relatively complex and risks suffering from a lack of reliability if the component characteristics drift.
SUMMARY OF THE INVENTION
[0006] Thus, an object of the present invention is to enable storage in a simple memory point of several data, that is, an information of several bits, or multibit information.
[0007] Another object of the present invention is to provide an array of such memory points in which the memory points are all identical.
[0008] Another object of the present invention is to provide such a memory point array in which the read operations are binary and reliable.
[0009] Another object of the present invention is to provide such a memory point array which is particularly easy to form and which takes up little room on an integrated circuit.
[0010] To achieve these objects, the present invention provides a ROM including a set of memory points arranged in rows and columns, in which each memory point, formed of a single controllable switch, memorizes an N-bit information, with N>2. Each column includes 2 N conductive lines; each of the two main terminals of each memory point is connected to one of said conductive lines, each information value being associated with a specific assembly of 2 N connections from among the set of the 2 2N possible connections; and each of N read means is provided to apply a precharge voltage to a chosen group of 2 N−1 first lines, connect the 2 N−1 other lines to a reference voltage, select a memory point, read the voltages from the first lines, combine the obtained results to provide an indication of the value of one of the bits of the information contained in the selected memory point.
[0011] According to an embodiment of the present invention, each switch is a MOS transistor, two adjacent transistors of a same column having a common source/drain region.
[0012] According to an embodiment of the present invention, the gates of the MOS transistors of a same row are interconnected.
[0013] The foregoing objects, features and advantages of the present invention, will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 shows a column of memory points of the connection position coding type;
[0015] [0015]FIG. 2 shows an embodiment of a two-bit memory point column according to the present invention;
[0016] [0016]FIGS. 3A and 3B show read circuits adapted to the memory column of FIG. 2;
[0017] [0017]FIG. 4 shows an embodiment of a set of two-bit memory point columns according to the present invention;
[0018] [0018]FIG. 5 shows an embodiment of a three-bit memory point column according to the present invention;
[0019] [0019]FIGS. 6A, 6B and 6 C show read circuits adapted to the memory column of FIG. 5; and
[0020] [0020]FIG. 7 shows an embodiment of a set of three-bit memory columns according to the present invention.
DETAILED DESCRIPTION
[0021] One of the bases of the present invention has been for the inventor to consider and classify the various types of existing memory cells to search whether one of the cells could be transformed into a multibit cell.
[0022] The most current memory cells are cells in which, at a crossing point, a memorized information materializes as the presence or the absence of a transistor, or more generally as the presence of an active or inactive transistor. An active transistor is a transistor which turns on when a signal is applied to its control terminal, generally, its gate, since memories are generally designed based on MOS transistors. An inactive transistor is a transistor which remains off while the signal applied on its gate is enough to turn on a corresponding active transistor. Such an inactive transistor is generally made like an active transistor, by skipping or adding one or several manufacturing steps so that it is not functional. It can be said that such conventional memories are memories with a coding by the presence or the absence of a transistor.
[0023] A second type of memory point has been described in U.S. Pat. No. 5,917,224 of L. Zangara, sold to the applicant. The architecture of a memory point column of this second type is shown in FIG. 1. This column includes a chain of transistors T, two adjacent transistors having confounded source-drain regions. To each column are associated two lines A and B between which, in the reading, it is attempted to determine whether there is or not a conduction. Generally, one of these lines is assigned to a reference voltage, the other line is precharged, and, after the end of the precharge, the potential difference between the two lines is read while one of memory points T is addressed All the memory points are identical active transistors but each transistor has its main terminals connected either to the same line or to two different lines. If both terminals are connected to the same line and this transistor is addressed, the precharged line will remain at the precharge voltage, which characterizes a first state. If the two terminals of the addressed transistor are connected to different lines, this transistor short-circuits the two lines and the voltage of the precharged line drops, which characterizes a second state. It can be said that this second type of memory is a connection position coding memory.
[0024] The present invention provides a modification of this second type of memory to make it a multibit memory. The present invention will first be described in the case where a memory point enables storing a three-bit information, which will result in a generalization of the present invention.
[0025] Two-Bit Memory Point
[0026] [0026]FIG. 2 illustrates an embodiment of a two-bit memory point memory according to an embodiment of the present invention. Each column of the memory includes a chain of transistors T 1 associated with four (2 2 ) lines A, B, C, D. Each column is associated with a read circuit such as illustrated in FIGS. 3A and 3B. For two adjacent transistors of a same column, the drain of one transistor corresponds to the source of the other. Each transistor has its drain connected to one of lines A, B, C, D and its source connected to one of lines A, B, C, D (possibly the same line). All transistors are identical and are active transistors
[0027] In read mode, one of the column transistors is selected and the read circuit is successively placed in the configuration illustrated in FIG. 3A, then in the configuration illustrated in FIG. 3B. This switching from one configuration to the other may be performed by any known switching means. Read circuits associated with storage means could also be simultaneously used.
[0028] In the configuration of FIG. 3A, two of the lines, A and C, are connected to a reference voltage, which will be called the ground for simplification, but which must only be different from a precharge voltage mentioned hereafter. The other two lines, B and D, are likely to be precharged, then connected to an AND gate 10 , via respective read amplifiers A 1 and A 2 . Thus, if the column transistor that receives a control signal has its terminals connected to the same line, to line B and to line D or to line A and to line C, this transistor will connect none of lines B and D to ground. These lines will remain at the precharge voltage, both amplifiers A 1 and A 2 will provide a signal in the high state (1), and the AND gate 10 will output a 1. However, if the considered transistor connects line B or line D to line A or to line C, a 0 will be detected. This corresponds to the reading of a first bit of the considered memory point.
[0029] In a second read phase, to read the second bit, the modified read circuit as shown in FIG. 3B, in which lines A and D are grounded, and lines B and C are likely to be precharged, then “read”, may be used. It the considered transistor T 1 has its main terminals connected to the same line, to lines A and D or to lines B and C, lines B and C will not be discharged. However, if the considered transistor has one of its terminals connected to line B or C and the other one of its terminals connected to line A or D, line B or C will discharge. In the first case, a 1 will be detected at the output of AND gate 10 , and in the second case, a 0 will be detected.
[0030] Based on these considerations, and considering the specific read circuits illustrated in FIGS. 3A and 3B, it can be seen that for each memory point, data 00, 01, 10, and 11 may be coded in one of the four ways indicated in the following table 1.
TABLE 1 Data Drain/source connections of the MOS transistor 00 AB BA CD DC 01 AD BC CB DA 10 AC BD CA DB 11 AA BB CC DD
[0031] For the completeness of the table, it has for example been indicated that datum 00 could be created by connection AB or BA and by connection CD or DC. These are in fact symmetrical connections.
[0032] It should be noted, comparing this table with the read circuits of FIGS. 3A and 3B, that these circuits effectively decode the indicated two-bit data for the indicated connections. As an example, the coding corresponding to each of the column transistors, successively 10, 01, 10, 00, 11, 10 and 00 for the read mode illustrated in FIGS. 3A and 3B, has been indicated in FIG. 2.
[0033] Generally, from the time that a mode for reading the two bits has been chosen, by assigning a reference line (here, line A) then by first “reading” two of lines B, C, D (here, lines B and D), then reading two other lines out of B, C, D (here, lines B and C), a transistor coding table can be constructed. It is important that, for each transistor, a connection to any one of the lines and to another chosen line can be provided to perform any chosen coding given that two adjacent transistors have a common terminal and thus that, once a transistor has been programmed, the connection of one of the terminals of the immediately adjacent transistor is predetermined.
[0034] Since one of lines A, B, C and D, here line A, always is at the reference voltage, two adjacent columns can share a common line. This is shown in FIG. 4 in which seven successive rows i+3 to i−3 and four successive columns j−1 to j+2 have been illustrated. Column j−1 includes four lines D j − 1 , C j − 1 , B j − 1 , and A j − 1 and column j includes four successive lines A j , B j , C j , and D j . Lines A j − 1 and A j form one and the same line. Similarly, for columns j+1 and j+2, line A j+1 and line A j+2 are one.
[0035] Various alterations and modifications will occur to those skilled in the art. Each memory point has been illustrated in the drawing as being a MOS transistor. Generally, it may be any structure forming a controllable switch and the various types of controllable switches known in the art may be used.
[0036] An important advantage of the present invention is the fact that each memorized bit couple is detected by two successive binary state read operations. Upon each reading, a high or low level is detected, rather than various intermediary levels.
[0037] Three-Bit Memory Point
[0038] [0038]FIG. 5 illustrates a column of a memory according to the present invention in which each memory point is likely to memorize three data bits. Each column includes a chain of transistors T 2 associated with eight (2 3 ) lines A, B, C, D, E, F, G, H. Each transistor has its drain connected to one of lines A, B, C, D, E, F, G, H and its source connected to one of lines A, B, C, D, E, F, G, H (possibly the same).
[0039] The reading of such a memory point is performed by successively using read circuits such as illustrated in FIGS. 6A, 6B, and 6 C. In each read circuit, four lines are grounded and four lines are prechargeable and connected to read amplifiers All, A 12 , A 13 , and A 14 having their outputs connected to an AND gate 20 . The read circuits can be distinguished in that in each circuit, four lines different from those of the preceding circuit are connected to the read amplifiers. In practice, this can be achieved by appropriate switching circuits. These read circuits are successively used to read the first, second, and third bits memorized in each memory point. It should be understood, by analogy with the two-bit circuit, that:
[0040] for the circuit for reading the first bit shown in FIG. 6A, the output will be at 1 if the terminals of the considered memory point are connected between lines A, C, E and G or between lines B, D, F et H or to the same line; and the output will be at 0 if the connections of the involved memory point are arranged between any one of lines B, D, F and H and any one of lines A, C, E and G;
[0041] for the circuit for reading the second bit shown in FIG. 6B, the output will be at 1 if the considered memory point has its terminals connected between one of lines A, D, E, or H or between one of lines B, C, F or G or to two lines or to the same line; and the output will be at 0 if the connections of the involved memory point are arranged between any one of lines B, C, F, and G and any one of lines A, D, E and H; and
[0042] for the circuit for reading the third bit shown in FIG. 6C, the output will be at 1 if the memory point has its terminals connected between lines A, B, G or H or between lines C, D, E or F or to the same line; and the output will be at 0 if the memory point is connected between one of lines C, D, E, F and one of lines A, B, G or H.
[0043] This corresponds to the following table 2.
TABLE 2 Data Drain/source connections of the MOS transistor 000 AF BE CH DG EB FA GD HC 001 AB BA CD DC EF FE GH HG 010 AD BC CB DA EH FG GF HE 011 AH BG CF DE ED FC GB HA 100 AC BD CA DB EG FH GE HF 101 AG BH CE DF EC FD GA HB 110 AE BF CG DH EA FB GC HD 111 AA BB CC DD EE FF GG HH
[0044] It should be noted that, in the read circuits of the three-bit cell, as for the two-bit cell, a line (line A) is constantly grounded. This line may be common to two neighboring cell columns. This is shown in FIG. 7 where it can be seen that among lines A to H of columns j−1 and j, lines A j and A j−1 form one and the same line.
[0045] Multi-Bit Memory Point
[0046] What has been described previously generalizes to N-bit memory points. For this purpose, each column will include 2 N lines and the memory points will have their terminals connected to one of these 2 N lines. N read circuits will be provided, selectively connected to 2 N−1 different lines among the 2 N lines. Based on these connections, those skilled in the art will readily determine a coding table corresponding to above tables 1 and 2.
[0047] The present invention is likely to have various alterations, modifications, and improvement which will readily occur to those skilled in the art. Especially, according to the choices made for the read cell connections, a corresponding table enabling identification of N bits per memory point associated with 2 N lines may each time be deduced.
[0048] In a practical embodiment, those skilled in the art will be able to manufacture the illustrated circuit in various manners, for example, by providing the various lines forming each column in various metallization levels and by providing connections (vias) between the various metallization levels. Each transistor has been indicated to be connected to a column formed of several lines. Terms “column” and “row” are interchangeable, “column” not necessarily implying that the corresponding lines are vertical.
[0049] Although each memory point has been described as being a MOS transistor with its drain or source region common to the source or drain region of the adjacent MOS transistor of the same column, any switchable switch may be used.
[0050] Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and the scope of the present invention. Accordingly, the foregoing description is by way of example only and is not intended to be limiting. The present invention is limited only as defined in the following claims and the equivalents thereto. | A ROM including a set of memory points arranged in rows and columns, in which each memory point, formed of a single controllable switch, memorizes an N-bit information, with N>2. Each column includes 2 N conductive lines; each of the two main terminals of each memory point is connected to one of said conductive lines, each information value being associated with a specific assembly of 2 N connections from among the set of the 2 2N possible connections; and each of N read means is provided to apply a precharge voltage to a chosen group of 2 N−1 first lines, connecting the 2 N−1 other lines to a reference voltage, select a memory point, read the voltages from the first lines, combine the obtained results to provide an indication of the value of one of the bits of the information contained in the selected memory point. | 6 |
FIELD OF THE INVENTION
The present invention relates generally to container apparatus and methods, and more specifically to methods and apparatus for in situ mixing of components prior to use.
BACKGROUND OF THE INVENTION
It is often desirable or necessary to store two or more components of a product separately and to mix the components shortly before use or application. In some cases, the components may react together and thus need to be stored separately, prior to use. In some cases, these components may be of a medical preparation, a food or beverage, a chemical product, a building product or the like.
In the medical field, it is also particularly desirable to mix components in single use batches, to assure consistency in the delivery of the combined components. Compositions comprising at least two of anesthetics, pain killers, antibiotics and antiseptics need to be mixed quickly in emergency medicine, for example. Orthopedic mixtures such as bone fillers and bone cements need to be mixed immediately before use, as do medical adhesives, dental adhesives and the like.
There is therefore a need to provide apparatus and methods to perform in-situ mixing of two or more components in a hygienic, sterile manner, prior to application to a patient. Likewise, many other food/beverage/chemical mixtures need to be mixed in such apparatus prior to use.
The storage and mixing apparatus should preferably store the components separately prior to mixing. Thereafter, using a simple mechanism, mixing should be relatively quick, and the apparatus should be relatively cheap.
Several prior art patent publications in the field include:
US Patent Application Publication No. US2003222102 describes a cap device for bottles, which is capable of mixing an additive contained therein with a material contained in a bottle to prepare a mixture in accordance with a simple rotating action of the cap device relative to the bottle, performed by a user, thus allowing the user to easily prepare the mixture just before taking or using the mixture. The cap device has a cap body tightened to an externally threaded mouth of the bottle, with a funnel part integrally formed in the cap body to discharge the additive from the cap body into the bottle through a lower end thereof. A cap cover is assembled with the cap body to cover an open upper end of the cap body while defining a cavity inside both the cap body and the cap cover to contain the additive in the cavity. The cap device also has a valve means for opening or closing the lower end of the funnel part of the cap body in accordance with the rotating action of the cap body relative to the externally threaded mouth of the bottle.
U.S. Pat. No. 5,743,312 describes an apparatus for combining liquid or solid components stored in containers includes a cylindrical hollow body for receiving end closures of the containers and at least one cannula for penetrating the end closures. The cannula is mounted in a cannula holder movable in the hollow body, and retainer bridges connect the cannula holder to an inner wall surface of the hollow body. The retainer bridges fracture after the cannula penetrates the end closure in the first container so that the cannula moves toward the second container to penetrate the closure in the second container. Also disclosed is a system including the apparatus, two containers, and outer packaging enclosing the containers and the hollow body.
U.S. Pat. No. 7,018,089 discloses a double syringe apparatus and method for mixing two components.
US Patent Application Publication No. US2009180923A relates to a self-mixing container with a releasable internal vessel and its usage, wherein said self-mixing container comprises a container body, a double-walled external cap and an internal vessel, and through a corresponding production line, assembling of the self-mixing container with a releasable internal vessel will be realized. The invention makes it possible to pack and seal in a cold filling process at least two different materials in one and the same container body respectively. When in use, at least two kinds of materials are mixed and formulated in one and the same container body in a rapid and automatic way, by means of relative movement of the screw-threads by which the container body, the double-walled external cap and the internal vessel are coupled with each other, and engagement of the ratchet and the pawls, without the structure of the container body being damaged, so that initial fresh active components in the materials sealed therein are preserved, and rapid formulation is achieved. Furthermore, the structure is simple, durable and has a low fabrication cost, and it can be used without great effort or time, especially can be used conveniently when carried on, and it can be broadly applied to pharmaceutical, food and beverage, chemical, farm chemical, disinfectants, or fire-fighting equipments field.
US Patent Application Publication No. US2010034574 describes a dispensing device, including inner and outer compartments for housing two different cosmetic liquid materials therein, the outer compartment secured to a cap by threading; a spring biased valve for blocking both openings of the inner and outer compartments when the device is in an inoperative position; and an outlet assembly partially fastened in the valve. An individual may unfasten and remove the cap from the device to unblock the valve, and squeeze both the outer and the inner compartments to push the cosmetic liquid materials to mix in the outlet assembly prior to dispensing out of the device.
It is therefore still desirable to provide improved storage and mixing apparatus, which are relatively inexpensive to produce, yet should provide complete and reliable isolation of the components to be mixed prior to use. The apparatus should be suitable for both liquid-powder and liquid-liquid mixes and should be relatively simple to use. The apparatus should further provide precise and accurate delivery of the mixed compositions. At least some of these objectives will be met by the inventions described herein below.
SUMMARY OF THE INVENTION
It is an object of some aspects of the present invention to provide storage and mixing apparatus for in-situ mixing of at least two components prior to use of a resultant mixture.
In some embodiments of the present invention, improved methods and apparatus are provided for in-situ mixing of at least two components prior to use of a resultant mixture.
In other embodiments of the present invention, a method and system is described for providing a syringe apparatus and method for in-situ mixing of at least two components prior to use of a resultant mixture.
There is thus provided according to an embodiment of the present invention, a multi-compartment apparatus for in-situ mixing of a plurality of components before use, the apparatus including;
a. an outer container including a first product; b. an inner container including a second product, wherein the inner container is adapted to release the second product into the first product thereby forming a mixture; and c. an openable aperture portion, in fluid communication with the outer container, typically including a filter, adapted to filter the mixture prior to release via the aperture.
According to some embodiments of the present invention, the first product is a first liquid.
Furthermore, according to some embodiments of the present invention, the inner container is disposed in the first liquid.
Additionally, according to some embodiments of the present invention, the second product includes a second liquid.
According to some additional embodiments of the present invention, the outer container includes at least one flexible portion.
According to some yet further embodiments of the present invention, the at least one flexible portion may be manipulated so as to break the inner container to release the second product into the first liquid thereby forming the mixture.
Furthermore, according to some embodiments of the present invention, the apparatus is a syringe.
According to some additional embodiments of the present invention, the openable aperture further includes a removable lid.
Additionally, according to some embodiments of the present invention, upon removal of the removable lid, the filtered mixture is adapted to be released from the apparatus.
Additionally, according to some embodiments of the present invention, the multi-compartment apparatus further includes a second inner containing adapted to house a third product. The third product may be a liquid or flowable solid.
There is thus provided according to another embodiment of the present invention, a method for multi-product storage and mixing in-situ before use, the method including;
a. providing a first and second product in the apparatus as described herein; b. releasing the second product into the first product thereby forming a mixture; and optionally, c. filtering the mixture to form a filtrate; and d. applying at least one of the filtrate and the mixture to a destination site.
Additionally, according to some embodiments of the present invention, the filtrate is a medical product.
There is thus provided according to another embodiment of the present invention, a multi-compartment kit for in-situ mixing of a plurality of components before use, the kit including;
a) an apparatus as described herein; and b) instructions on how to use the apparatus.
The present invention will be more fully understood from the following detailed description of the preferred embodiments thereof, taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in connection with certain preferred embodiments with reference to the following illustrative figures so that it may be more fully understood.
With specific reference now to the figures in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.
In the drawings:
FIG. 1 is a simplified pictorial illustration of a multi-compartment apparatus for in-situ mixing of a plurality of components before use, in accordance with an embodiment of the present invention;
FIG. 2 is a simplified flow chart of a method for in-situ mixing of a plurality of components using the apparatus of FIG. 1 , in accordance with an embodiment of the present invention;
FIG. 3 is a simplified pictorial illustration of another multi-compartment apparatus, in accordance with an embodiment of the present invention;
FIG. 4 is a simplified pictorial illustration of another multi-compartment apparatus, in accordance with an embodiment of the present invention;
FIG. 5 is a simplified pictorial illustration of a multi-compartment syringe apparatus, in accordance with an embodiment of the present invention;
FIG. 6 is a simplified flow chart of a method for in-situ mixing of a plurality of components using the apparatus of FIG. 5 , in accordance with an embodiment of the present invention;
FIG. 7 is a simplified pictorial illustration of another multi-compartment apparatus, in accordance with an embodiment of the present invention;
FIG. 8 is a simplified flow chart of a method for in-situ mixing of a plurality of components using the apparatus of FIG. 7 , in accordance with an embodiment of the present invention; and
FIG. 9 is a simplified pictorial illustration of another multi-compartment apparatus, in accordance with an embodiment of the present invention.
In all the figures similar reference numerals identify similar parts.
DETAILED DESCRIPTION OF THE INVENTION
In the detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that these are specific embodiments and that the present invention may be practiced also in different ways that embody the characterizing features of the invention as described and claimed herein.
Reference is now made to FIG. 1 , which is a simplified pictorial illustration of a multi-compartment apparatus 100 for in-situ mixing of a plurality of components before use, shown in three different positions A, B and C, respectively in accordance with an embodiment of the present invention.
Apparatus 100 comprises an external container 102 , made, at least in some parts of a deformable material and contains a first liquid 106 . An internal container 104 is disposed in the first liquid. The internal container comprises a second liquid 108 . External container 102 typically comprises air 110 in an air portion 118 . The apparatus comprises an upper portion 112 above the air portion. The upper portion comprises a filter, which allows passage of liquids from the air portion to an aperture 119 , but does not allow solids to exit at aperture 119 after lid/screw cap 116 has been removed.
According to some embodiments, apparatus 100 has a flexible region 117 of made of more flexible material than the other regions 115 .
According to some embodiments, regions 115 and region 117 are made of the same material of the same thickness. The material may be suitable formulations of polyethylene, polyurethane, polypropylene, polyamide or combinations thereof. According to one embodiment, the external container is made of a clear molded plastic. In some cases, coloring components or dyes will be added to the material of the outer container, if the first and/or second liquid is light sensitive, by methods well known in the art.
According to some embodiments, regions 115 and region 117 are made of the same material, but the flexible region is of a lesser thickness.
According to some embodiments, external container 102 is made of a deformable polymeric material, such as a plastic polymer or polymer blend.
As is seen in FIG. 1B , external container 102 may be bent over by pressing on two other regions 115 thereby breaking internal container 104 , which is made of a stiffer, less flexible material than the external container, thereby breaking internal container 104 into pieces and releasing second liquid 108 into first liquid 106 thereby forming a mixture 130 ( FIG. 1C ). According to one embodiment, the internal container may be a sealed frangible glass vial. According to some further embodiments, the internal container may be made of a material, which may be glass, a glass substitute, a fragile or rigid polymer, a polymer blend or combinations thereof.
Alternatively, the user can press on a flexible region and break the internal container.
Reference is now made to FIG. 2 , which is a simplified flow chart 200 of a method for in-situ mixing of a plurality of components using the apparatus of FIG. 1 , in accordance with an embodiment of the present invention.
In a first breaking step 202 , the user breaks the inner container (or ampoule) by deforming the outer container from the upper and lower portions 115 or by pressing in on flexible portion 117 .
In a mixing step, as shown in FIG. 1B , inner container 104 is broken into pieces 120 and thereby releases second liquid 108 into first liquid 106 thereby forming a first mixture 130 . The user may additionally shake the apparatus to ensure enhanced mixing.
In an opening step 206 , the user opens lid 116 (which may be a screw cap, cork, bung, lid or any other suitable lid).
In an application step 208 , the mixture passes through filter 114 to ensure that no pieces 120 exit from aperture 119 . The liquid mixture is then applied to the target site. This may be an external body site, a piece of furniture, it may be eaten/drunk if appropriate, or applied to the required destination site. It should be understood that the mixture may be a suspension, a liquid-gas fluid or any other liquid-like mixture.
Reference is now made to FIG. 3 , which is a simplified pictorial illustration of another multi-compartment apparatus 300 , in accordance with an embodiment of the present invention. Apparatus 300 comprises a netting 326 or filter disposed within an outer container 302 . The netting 326 or filter is suitably disposed adjacent to an upper portion 312 of the apparatus to ensure adequate catching of pieces 120 formed upon breaking of inner container 304 , in addition to a filter 314 disposed in the upper portion 312 .
As was shown in FIG. 1A , in apparatus 100 , the inner container was not attached to any part of the outer container. In contrast, in FIG. 4 , there is seen a simplified pictorial illustration of another multi-compartment apparatus 400 , in accordance with an embodiment of the present invention.
Apparatus 400 comprises attaching means 410 for affixing an inner container 404 , comprising a second liquid 408 , inside an outer container 402 containing a first liquid 406 . The attaching means is constructed and configured to prevent the breakage of the inner container before its intended use.
Reference is now made to FIG. 5 , which is a simplified pictorial illustration of a multi-compartment syringe apparatus 100 , in accordance with an embodiment of the present invention.
Multi-compartment syringe apparatus 500 is constructed and configured to enable hygienic and preferably sterile, in-situ mixing of a plurality of components before use.
According to some embodiments, apparatus 500 is for medical use for providing a medicament mixture comprising a first liquid 506 and a second liquid 508 after forming the mixture.
Multi-compartment syringe apparatus 500 comprises a plunger 530 housing a second container 504 (similar or identical to internal container 104 of FIG. 1 , which contains a second liquid 508 . The plunger comprises a handle section 532 , an upper section 534 and a lower section 536 . Plunger 530 is made of a similar or identical material to external container 102 ( FIG. 1 ) and may also have flexible portions therein (not shown).
Multi-compartment syringe apparatus 500 further comprises a plunger receiving section 510 , made out of a material similar or identical to external container 102 ( FIG. 1 ), which comprises air 512 , a filter 514 disposed below the air and above a first container 502 housing a first liquid 506 . The multi-compartment syringe apparatus 500 further comprises a conical section 542 and hollow needle portion 540 . Section 510 is not sealed, thereby allowing air 512 to penetrate in and out of section 510 , depending on the situation of piston/filter 514 . Filter/piston 514 is connected to plunger 530 . The filter allows liquid passage only from first container 502 into plunger receiving section 510 .
It should be noted that the surface of second container 504 is unfolded, thereby upon breaking the container, its entire content (second product) is mixed with the first product.
Reference is now made to FIG. 6 , which is a simplified flow chart 600 of a method for in-situ mixing of a plurality of components, prior to application using the apparatus of FIG. 5 , in accordance with an embodiment of the present invention.
In a breaking step 602 , scheme (A) in FIG. 5 , the user breaks the inner container 504 (or ampoule) by deforming the plunger 530 such as by pressing in on flexible portion 517 . This releases the second liquid 508 into the plunger. The result of this operation is illustrated in scheme (B) in FIG. 5 . Reference numeral 508 ′ denotes the spilled content 508 of container 504 . Reference numeral 504 ′ denotes the broken inner container.
In an inserting step 604 , while holding syringe apparatus 500 vertically such that needle 540 turns down, the plunger is pulled out and thereby forcing the second liquid 508 ′ to pass through the filter into first container 502 , yet retaining any pieces of the broken ampoule within the plunger.
In a mixing step 606 , the second liquid that has been received in first container 502 is mixed with a first liquid 506 forming a mixture ( 507 in FIG. 5 ).
In an injecting step 608 (scheme (D) in FIG. 5 ), the mixture is injected from the first container via the conical section and needle into the patient.
Alternatively, the mixture may be applied via needle 540 to any other suitable destination site.
Reference is now made to FIG. 7 , which is a simplified pictorial illustration of another multi-compartment apparatus 700 , in accordance with an embodiment of the present invention.
Apparatus 700 houses a solid particulate product 760 within a lower section 780 . The solid particulate matter is kept dry and separate from a first liquid 706 by means of a membrane 750 . The first liquid is contained within a first container 702 above the lower section of the apparatus. The first container may be constructed of a material similar or identical to first container 102 of FIG. 1 . The apparatus also comprises a lid 716 , a filter 714 disposed in an upper portion 712 thereof.
The apparatus may also comprise an air portion 790 comprising air 710 .
A second container 704 is suspended in the first liquid. The second container comprises a second liquid 708 and a sharp pointed end section 770 .
FIG. 8 is a simplified flow chart 800 of a method for in-situ mixing of a plurality of components using the apparatus of FIG. 7 , in accordance with an embodiment of the present invention.
In a membrane breaking step 802 , the user pushed pointed end section into membrane 750 by, for example, pressing on the flexible section or by squeezing the first container.
Once the membrane is broken, the particulate powder product 760 is released into the first liquid, thereby forming a first mixture (not shown). This first mixing step 804 may additionally require shaking of the apparatus, in some cases.
In a second optional breaking step 806 , the user breaks the second container 704 by, for example pressing on the flexible regions or bending the first container.
In a second mixing step 808 , the second liquid and first mixture are mixed by diffusion and/or by shaking thereby forming a second mixture.
In a mixture application step 810 , the lid is removed and the first or second mixture (depending on the previous steps) is filtered via filter 714 upon release to a destination site or container or person.
According to one embodiment, the first liquid is water, the second liquid is milk and the particulate powder is a drink powder, such as frieze-dried coffee or tea and/or sugar and/or artificial sweetener. The second mixture is thus for example, a cold coffee drink. It should be understood that the apparatus may be heated by microwave to supply a hot drink.
Reference is now made to FIG. 9 , which is a simplified pictorial illustration of a multi-compartment apparatus 900 for housing three liquids, in accordance with an embodiment of the present invention.
Apparatus 900 comprises a lid 916 (and filter (not shown)) a first container 902 containing a first fluid 906 . Container 902 comprises two sections 920 and 930 with a narrow connecting element 970 enabling fluid connection between the two sections 920 , 930 . Section 920 comprises first ampoule 904 containing a second liquid 908 .
Section 930 comprises a second ampoule 960 containing a third liquid 962 . Ampoules 960 and 904 may be broken to release the third and second liquid into the first liquid.
Alternatively, one or more of the ampoules may contain a powder or gel or suspension. Thus, various mixtures may be made in-situ, prior to application to one or more destination sites.
The following examples are meant to provide exemplary illustrations of the present invention, which are not intended to be limiting.
EXAMPLES
Example 1
In emergency care, it is often necessary to provide a painkiller and at least one of a) an antibiotic; b) a drug and a c) vaccine. The painkillers, antibiotics, drugs and vaccines are nearly always stored separately. For example, a paramedic may need to provide a painkiller, such as lidocaine and an anti-tetanus vaccine, which can be painful. Rather than inject the patient twice, he can use the multi-compartment syringe apparatus 500 of FIG. 5 hereinabove and the method of FIG. 6 , in which the lidocaine preparation is second liquid 508 and the anti-tetanus vaccine is first liquid 506 .
The dosages used will be in accordance to the patient's weight, age, gender as is current practice by medical practitioners in the art.
The patient can thus be vaccinated and provided with a painkiller in the form of a mixture simultaneously.
Example 2
In emergency care, it is often necessary to provide a painkiller and at least one of a) an antibiotic; b) a drug and a c) vaccine. The painkillers, antibiotics, drugs and vaccines are nearly always stored separately. For example, a paramedic may need to provide a painkiller, such as lidocaine and an anti-coagulant, such as heparin. Rather than inject the patient twice, he can use the multi-compartment syringe apparatus 500 of FIG. 5 hereinabove and the method of FIG. 6 , in which the lidocaine preparation is second liquid 508 and the heparin solution is first liquid 506 .
In many other examples for medical applications, the user can use apparatus 100 of FIG. 1 comprising one medical component in the inner compartment 104 and a second medical component in the outer compartment 102 . It should be further understood that the apparatus shown in FIGS. 3 , 5 , 7 and 9 may all be used and applied to various different medical applications.
The patient can thus be provided with an anti-coagulant and provided with a painkiller in the form of a mixture simultaneously. The dosages used will be in accordance to the patient's weight, age, gender as is current practice by medical practitioners in the art.
Many other examples in the medical field are apparent to a person skilled in the art and the example is not meant to be limiting.
Example 3
Various glues and adhesives are provided in two separate tubes, such as Epoxy or polyepoxide, which is a thermosetting polymer formed from reaction of an epoxide “resin” with polyamine “hardener”. Epoxy has a wide range of applications, including fiber-reinforced plastic materials and general purpose adhesives. Apparatus 100 may be used to house an epoxy 106 and the polyamine 108 may be housed in an inner ampoule 104 . Using the method of FIG. 2 , the mixed epoxy may be applied to a target site, such as for bonding two pieces of metal.
Example 4
Apparatus 700 in FIG. 7 may be used to prepare coffee. According to one embodiment, the first liquid 706 is water, the second liquid 708 is milk and the particulate powder 760 is a drink powder, such as frieze-dried coffee or tea and/or sugar and/or artificial sweetener. The second mixture, produced using the method of FIG. 8 is thus for example, a cold coffee drink. It should be understood that the apparatus may be heated by microwave to supply a hot drink.
Example 5
A sportsperson may wish to drink during his/her sporting activity, such as cycling, swimming and the like. He may use the apparatus of the present invention, such as, but not limited to apparatus 100 as shown in FIG. 1 . The apparatus may be a flexible or non-flexible bottle of any suitable size, such as 300 ml, 500 ml 1 liter and 1.5 liter. The outer compartment may comprise an energy gel, such as GU Energy Gel and the inner compartment an isotonic drink such as, but limited to GATORADE.
Example 6
The apparatus of the present invention shown in the figures may be used for keeping two or more beverage components stored separately, which can be mixed shortly before drinking For example, an alcoholic beverage such as Bacardi with coca cola, or vodka with energy drinks, or other kinds of cocktails. These are stored separately before use.
There are drinks without alcohol that usually contains more than one component. For example, one may wish to store soda water and tomato juice separately and mix them before use. Numerous other examples of multi-component drinks mixes may be stored separately using the apparatus of the present invention, and can then be hygienically prepared before use.
This example applies to a person who goes on a trip or on a nature hike or trek and wants to take with him his favorite drink. Applying the apparatus and methods of the present invention, this may be performed easily, whether the apparatus is made of glass, plastic or any other suitable material.
The references cited herein teach many principles that are applicable to the present invention. Therefore the full contents of these publications are incorporated by reference herein where appropriate for teachings of additional or alternative details, features and/or technical background.
It is to be understood that the invention is not limited in its application to the details set forth in the description contained herein or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Those skilled in the art will readily appreciate that various modifications and changes can be applied to the embodiments of the invention as hereinbefore described without departing from its scope, defined in and by the appended claims. | A multi-compartment syringe apparatus ( 500 ) for in-situ mixing of a plurality of products before use, the apparatus comprising: a tube; a hollowed flexible plunger ( 530 ); a one way filter piston ( 514 ), connected to the plunger ( 530 ), the piston confining a first compartment ( 502 ) at a side of a needle ( 540 ) of the apparatus, and a second compartment ( 510 ) at a side of the plunger, wherein the filter allowing passage of content only form the first compartment to the second compartment ( 510 ); a first product ( 506 ), stored in the first compartment ( 502 ); a second product ( 508 ), stored in a first breakable container ( 504 ) disposed in the plunger ( 530 ); thereby the second product ( 508 ) mixes with the first product ( 506 ); and the mixed products are then pushed out of the apparatus, through the needle ( 540 ). | 0 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority from U.S. Patent Application No. 60/621,379, filed on Oct. 22, 2004, the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to light emitting diode (“LED”) display devices, and more particularly to LED displays that are touch-input enabled, and methods for using the same.
BACKGROUND INFORMATION
[0003] Light emitting diodes (“LEDs”) are compact inexpensive solid-state devices which produce light when a suitable electric current is applied. They are extensively used as display indicators for electronic and computing devices. They are also widely used in large arrays to display graphics and text information in raster form.
[0004] Operating an array of LEDs to display graphical data is typically performed by connecting them in a passive-matrix configuration and driving them column by column in a time-multiplexed manner. During each column-scan period, row drivers are selectively enabled or disabled, causing the LEDs at those row/column intersections to emit light, in accordance with the desired image output. This column-scan process occurs rapidly enough, so that the individual LED emission pulses appear continuous, and the image is coherent. This arrangement and method reduces complexity and drive electronics enough to make arrays of a useful size at all practical.
[0005] Most LEDs can also operate as photodiodes, or light detectors, as well. Though they typically designed for only their emitting, and not their detecting role, most can function effectively in either role.
[0006] The use of LEDs in a bidirectional manner is known, e.g., in LED copier/scanner heads, as described in U.S. Pat. No. 4,424,524 to Daniele, and U.S. Pat. No. 5,424,855 to Nakamura.
[0007] Furthermore, it is possible to utilize the same set of LEDs for both display and sensing purposes simultaneously, by rapidly multiplexing these functions in time. This is possible without sacrificing the display capabilities, if the sensing is done fast enough to be beyond the scope of human perception.
[0008] U.S. Pat. No. 4,692,739 to Dorn describes the use of LEDs in this manner to create a touch sensing display. The features described in this publication include an LED array that has been configured for simultaneously emitting and detecting light, and registers touches by detecting the attenuation of background illumination when a finger covers one or more LEDs. However, this occlusion-based approach may be prone to false triggering by shadows. It also may require the presence of a stable external illumination source. Finally it does not apply to passive-matrix configurations, and hence is not scalable in practice to large arrays.
[0009] Touch sensing mechanisms have also been described that operate by employing active emitter/detector pairs, and sensing fingers and objects through the reflection of light, as described in U.S. Pat. No. 3,621,268 to Friedrich. However, this approach likely needs the addition of a large number of dedicated photo-detectors, resulting in increased cost and complexity in component layout and in wiring. Furthermore, such arrangement may still be prone to false triggers due to external illumination.
OBJECTS AND SUMMARY OF THE INVENTION
[0010] It is one of the objects of the present invention to improve the accuracy of a touch sensor of the kind that uses an LED array in a bidirectional manner.
[0011] Another one of the objects of the present invention is to eliminate the need for any additional illumination, external or internal, for a sensor of this kind.
[0012] Still another object of the present invention is to eliminate the need for any additional opto-electronic elements for a sensor of this kind.
[0013] Still another object of the present invention is to be scalable in practice to large implementations.
[0014] An exemplary embodiment of the present invention utilizes a matrix array of LEDs equipped with both the constant-current drivers necessary to drive them to emit light, and with the appropriate sense-amplifiers necessary to measure flux levels photodiodes. These drivers and amplifiers may be configured in parallel, so that each LED within a column can be dynamically configured to be driven or sensed.
[0015] Conventionally, touch sensing of the screen can be performed with such LED array by detecting the occlusion of light. However, optical touch sensing can also be accomplished by reflection or scattering. While touch sensing by occlusion requires illumination from behind the subject (from the point of view of the sensor), the other two techniques require the subject to be illuminated from the front.
[0016] An exemplary embodiment of the present invention can be provided which operates the LED display in such a way as to enable the array itself to act as the illumination source necessary for reflective or scattering optical touch sensing.
[0017] In a display array that consists of discrete, individually mounted LEDs, the exemplary embodiment of the method according to the present invention may provide alternate LEDs within a column are operated as emitters, while the remaining LEDs are operated as detectors. Light from the emitting elements may be potentially reflected or scattered by the presence of a finger, and is subsequently received and registered by the detecting elements. To cover all the elements in the column, an exemplary procedure according to the present invention may be performed again with the emitting/sensing roles of the LEDs interchanged.
[0018] When the array consists of multi-chip LEDs with individually addressable electrodes, as can be the case in multi-color displays, the illumination provided for touch sensing can also be generated by operating, e.g., only one of the chips within each LED package as an emitter, while an alternate chip operates as a detector. In this exemplary configuration according to one exemplary embodiment of the present invention, the spatial interleaving of LED function may not be needed, and both lighting and sensing can be performed at all pixels simultaneously.
[0019] As the next exemplary step, all elements can be operated as detectors, and a photometric measurement is taken at all points without any additional illumination supplied. In this manner, the device can obtain, for each element, two photometric readings, one with active illumination, and one without. Control logic thresholds both readings with established ranges, and determines at each pixel whether a finger is in contact.
[0020] Because the illumination used for active optical sensing can come from the LED array itself, the need for any additional or ambient light source is eliminated or at least reduced. Also, because the light sought for sensing purposes comes from only the device itself, the signal thresholds used for resolving the presence of a finger can be much more narrowly defined, thus producing more accurate results. Because the light emitted during the scan process is spatially localized to the area being actively sensed, sensing accuracy is again improved.
[0021] Because the LEDs themselves are used as the photodetecting element, no additional opto-electronic components are necessary.
[0022] Because a sense-amplifier is required only for each row in the matrix, the invention is feasible for larger scales.
[0023] The exemplary process of touch sensing can thus be driven very quickly, and performed such that momentary lighting and blanking of LEDs is negligibly perceptible.
[0024] Accordingly, an exemplary embodiment of an apparatus according to the present invention is provided. This exemplary apparatus can be provided for displaying graphical data and simultaneously (e.g., multiple) sensing touch information. The apparatus may include a plurality of light emitting diodes (“LEDs”) arranged in a matrix-array as at least one column and/or at least one row. The apparatus may also have a first arrangement configured to operate at least one first individual one of the LEDs within the column(s)/row(s) to emit light, and a second arrangement configured to, approximately simultaneously with the operation of the first arrangement, operate second individual ones of the LEDs within the column(s)/row(s) to detect the light. The LEDs may be organic LEDs and/or individually addressable multi-chip LEDs.
[0025] The first arrangement and/or the second arrangement may be configured to operate at least one individual chip within the respective one of the LEDs. At least one of the emitting chips can have an emissive wavelength which is at most the same as a wavelength of a respective detecting chip. The first arrangement and/or the second arrangement are capable of generating an illumination from a subset of the LEDs, and wherein the second arrangement is configured to measure the light from the illumination which is reflected and/or scattered back. The subset may include every second one of the LEDs in a scan row of the columns and/or a scan column of the rows, and the detected subset may include the remaining ones of the LEDs.
[0026] The LED can have emitter/detector roles which are interchangeable, and the first arrangement and/or the second arrangement measure(s) light responses of the LEDs from which the light is detected. All of the LEDs may be operated as detectors; and the first arrangement and/or the second arrangement can measure light responses of the LEDs that are without an illumination.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a schematic diagram of an exemplary embodiment of an apparatus according to the present invention where a display matrix is composed of individual LEDs;
[0028] FIG. 2 is a schematic diagram of alternative analog acquisition methods according to an exemplary embodiment of the present invention;
[0029] FIG. 3 is a schematic diagram of the apparatus according to one exemplary embodiment of the present invention during a sensing scan sequence, where even row-drivers are enabled, and signal paths are highlighted;
[0030] FIG. 4 is a schematic diagram of the apparatus according to one exemplary embodiment of the present invention during a sensing scan sequence, where odd row-drivers are enabled, and signal paths are highlighted;
[0031] FIG. 5 is a schematic diagram of the apparatus according to one exemplary embodiment of the present invention during a sensing scan sequence, where all row-drivers are disabled, and signal paths are highlighted;
[0032] FIG. 6 is a pictorial diagram illustrating the overall touch sensing function using an exemplary embodiment of the present invention;
[0033] FIG. 7 is a detailed pictorial diagram illustrating a finger being sensed, through the light from an emitting LED entering the finger, being scattered within the finger, and exiting at a sensing LED using the exemplary embodiment of the apparatus according to the present invention;
[0034] FIG. 8 is a schematic diagram of the apparatus according to one exemplary embodiment of the present invention where the display matrix is composed of multi-chip LEDs;
[0035] FIG. 9 is a detailed pictorial diagram illustrating the light paths involved when a finger is being sensed by a multi-chip LED according to the present invention;
[0036] FIG. 10 is a timing diagram illustrating the touch sensing operation of the circuit provided in FIG. 1 in accordance with one exemplary embodiment of the present invention;
[0037] FIG. 11 is a flowchart of an exemplary embodiment of a touch sensing procedure in accordance with the present invention which is performed by the circuit in FIG. 8 .
[0038] FIG. 12 is a timing diagram illustrating the touch sensing operation of the circuit provided in FIG. 1 in accordance with another exemplary embodiment of the present invention; and
[0039] FIG. 13 is a an exemplary flowchart of another exemplary embodiment of the touch sensing procedure in accordance with the present invention which is the circuit in FIG. 8 .
[0040] Throughout the figures, the same reference numerals and characters, unless otherwise stated, are used to denote like features, elements, components or portions of the illustrated embodiments. Moreover, while the present invention will now be described in detail with reference to the figures, it is done so in connection with the illustrative embodiments.
DETAILED DESCRIPTION
[0041] Exemplary embodiments of the present invention will be described with reference to the attached drawings. These drawings illustrate the invention but do not restrict its scope, which should be determined solely from the appended claims.
[0042] For example, FIG. 1 shows an exemplary embodiment of an arrangement according to the present invention which includes an array of individual LEDs 100 that are connected in a matrix row/column configuration as is typical for arrays designed for display purposes. For example, all LED anodes for a given row are connected together to constant-current unipolar row source drivers 101 . Similarly, the cathodes for all the LEDs in a given column are connected together to unipolar column sink drivers 102 . These drivers can be MOSFETs. Under the control of a controller 103 , the array 100 can display graphical information by sequentially enabling each of the column drivers in turn, while row drivers can be enabled or disabled according to the desired output image.
[0043] In addition to the row drivers, each row can also be equipped with a row sense-amplifier, thus forming a series of amplifiers. The amplifier may allow the output from an LED to be acquired when it is operating as a photodiode. For example, the arrangement of FIG. 1 can include a current-to-voltage (I-V) converter stage (e.g., an FET-input operational amplifier 104 with a negative feedback resistor 105 ), also known as a transimpedance amplifier. The voltage outputs from the I-V converters can be directed into a multiple-channel analog-digital converter (ADC) 106 . The ADC can supply digital values for any channel to the controller 103 .
[0044] When the controller 103 completes a full column scan of the array for the purposes of displaying output, the controller 103 may then performs a different scanning procedure for an exemplary touch sensing functionality.
[0045] The scanning procedure may be performed sequentially, e.g., one column at a time. Referring to FIG. 3 , a single column-driver 300 can be enabled, while the even-numbered row-drivers 301 may be enabled. This causes the even-numbered LEDs 301 in the column 302 to act as emitters, and produce light. The odd-numbered LEDs in the column 303 however do not produce light to be instead utilized as detectors, and complete circuits through the respective row's sense-amplifier 304 .
[0046] As shown in FIGS. 6, 7 and 9 , if a finger 700 is in contact with the column, light may enter the fingers at points of contact with certain emitting elements 701 , which subsequently gets scattered about within an inside portion 702 of the finger 700 , and which finally may exit at points of contact with the detecting elements of the column 703 .
[0047] After a short delay (e.g., a microsecond) to allow the amplifiers values to settle, the ADC 106 can perform a conversion for each odd-numbered input channel, and the results are stored by the controller 103 into its memory. The signals from the even-numbered sense-amplifiers can be ignored. Referring to FIG. 4 , the exemplary process can then be repeated for this column with the emitters and detector roles exchanged. For example, the odd-numbered row-drivers 400 may be enabled, while the even-numbered row-drivers can be disabled. This may cause the odd-numbered LEDs in the column 401 to light, and allow the even-numbered LEDs 402 to act as detectors. After a short delay, the ADC 106 performs a conversion for each even-numbered channel input, and the values are stored into memory of the controller 103 .
[0048] Referring to FIG. 5 , the row-drivers can be disabled for all rows, and all LEDs in the column may be utilized as detectors. After another short delay, a further set of conversions by the ADC 106 for all channel-inputs is performed and stored. The column-driver for the column is finally disabled. The above-described exemplary procedure is then repeated for the next column until it has been executed on all columns in the array. The total time to execute this sensing sequence may be so short in duration that users will not perceive these LED strobes as anything but a small increase in the display's black level, if at all. Furthermore, the sense sequence does not have to be executed after every display scan.
[0049] For example, when all columns have been scanned in this manner, the controller 103 acquired photometric information for every element in the array under two conditions—while neighboring LEDs are lit, and dark. The controller 103 determines or computes whether touch has occurred for each element by examining these values. If the light levels for both the lit and dark conditions each fall within their respective predetermined ranges, a touch may be registered. Appropriate values for these ranges can be determined in an initial calibration process which executes the sensing sequence, and monitors the raw photometric values acquired.
[0050] The exemplary device according to the present invention may be optimized to detect scattering by a finger, but if desired the threshold values can also be made to trigger based on other modes of operation, such as by reflection. This may be preferable if the LED emission is of a wavelength that does not appreciably penetrate a finger. In order for this exemplary device to be able to sense touch, the distance between LEDs in the array should be shorter than half of the minimum feature size to be detected. For an individual finger tip, 6 mm pitch packing of the common T-1¾/LED package is sufficient.
[0000] Multi-Chip Exemplar Embodiment
[0051] LEDs also can be manufactured so that several chips are tightly contained within a single package, while having separate electrodes, so that each chip is individually electrically controllable. These multi-chip LEDs are generally constructed with chips of differing wavelengths, so that they can function as a multi-color light source. Examples may be a bi-color LED consisting of a red and green chip, or a full-color LED consisting of a red, a green, and a blue chip. Multi-chip LEDs can also contain several chips of identical wavelength, so that optical power output is increased.
[0052] For example, a matrix of multi-chip LEDs can be operated to sense touch in the manner described above, by applying the procedure to only one chip out of each LED. However, having multiple chips per pixel invites a reflective technique that requires fewer steps. This second embodiment of the invention will now be described.
[0053] Referring to FIG. 8 , an array of three-chip red-green-blue LEDs 800 may be connected in a matrix row/column configuration 800 , which is similar to the configuration of another exemplary embodiment of the present invention shown in FIG. 1 . Each LED 801 may have a common cathode, and likely three (3) separate anodes. Instead of a single row-driver for each row, three may be provided, e.g., one for the anode of each red, green, and blue chip 802 . The common-cathodes for all the LEDs in a given column may be connected together to sink-drivers 803 . Each row may have one row-sense amplifier, which may be attached to the red anode bus of the amplifier 804 .
[0054] The scanning procedure may be performed sequentially, e.g., one column at a time. A single column-driver may be enabled 805 . All blue row-drivers 806 can be enabled, while all red and green row-drivers can be disabled. This causes only the blue chips in the LEDs in the column 807 to act as emitters, and produce light. The red chips may be utilized as detectors through each row's sense-amplifier 804 . If a finger is in contact with one of the LEDs in such column, light may be reflected off the finger 700 , and be received by the red chips as shown in FIG. 9 . After a short delay (e.g., a microsecond) to allow the amplifiers' values to settle, the ADC 106 can perform a conversion for every input channel, and the results may be stored by memory of the controller 106 . The blue row-drivers are then disabled, and another set of conversions may be performed without any illumination. The column-driver for the column can then be disabled. The above-described procedure may then be repeated for the next column, until it has been executed on all columns in the matrix. A touch by the finger 700 is registered to be at those pixels where the photometric data is within predetermined range of values.
[0055] According to one exemplary experiment in accordance with the present invention, LEDs likely respond as photodetectors significantly to wavelengths similar to or shorter to their own emission wavelength. This result facilitates a choice in color for the emitter and detector chips used in the above procedures. If the LEDs are composed of identical color chips, then the responses are perfectly matched.
[0056] This exemplary scanning procedure can be modified so that it is repeated with the green chips in place of the blue chips. This allows for greater accuracy, as both color reflectance measurements can be used together to identify a finger touch. The green rows can also be outfitted with row-sense amplifiers, to allow blue-to-green measurements. In general, every combination of emitter/detector chip pair where the emitter is of a shorter wavelength than that of the detector, can be utilized, so long as the detector color is equipped with a sense-amplifier.
[0057] In order for this exemplary embodiment of the apparatus according to the present invention to be able to register contact, the distance between LEDs in the array can be of the same order as the feature size to be detected. LEDs can also be fabricated with, e.g., semiconducting organic compounds, e.g., organic LEDs (“OLEDs”), and they can be manufactured in arrays on sheets in very high pixel densities, both monochrome and multicolor, using simple printing methods. Either embodiment described above is directly suitable for touch-enabling these OLED displays.
[0058] Data acquisition of the output from LEDs used as detectors has been described herein above using a current-voltage converter and ADC. However, this exemplary procedure in accordance with the present invention can be replaced by several other conventional techniques. These include, are not limited to, the use of a current-voltage converter along with a simple voltage comparator 200 as shown in FIG. 2 , whose threshold level is dynamically set by a digital-to-analog converter (DAC) 201 , or whose threshold level is set by a manually trimmable voltage reference 202 . LED photodetectors can also be obtained by taking advantage of the LED's inherent parasitic capacitance, and monitoring the voltage resulting from the discharge of this capacitance, or measuring the time it takes for this voltage to reach a certain threshold.
[0059] The exemplary techniques described herein above can also be modified such that the sense-amplifiers are placed on LED anodes columns instead, along with appropriate changes to effect a column-oriented device. This allows operation of the analog circuit components (e.g. transimpedance amplifiers, ADC) without a bipolar power supply.
[0060] FIG. 11 shows a flow diagram of an exemplary embodiment of a touch sensing procedure in accordance with the present invention which can be performed by the circuit provided in FIG. 8 . In particular, a normal display scan sequence can be initiated in step 900 . The column count (i) can be set to 0 in step 905 . Then, in step 910 , the column i is enabled, and in step 915 , even rows are enabled. The odd rows are sampled in step 920 , and the odd rows are enabled in step 925 . Further, in step 930 , the even rows are sampled, and then all rows are disabled in step 935 . In step 940 , all rows are sampled, and in step 945 , the column count (i) is increased by 1. In step 950 , it is determined whether a predetermined column limit (m) has been reached. If not, the process returns to step 910 , and otherwise, the process returns to step 900 .
[0061] FIG. 10 shows a timing diagram of the results provided by the procedure of FIG. 11 providing the results of the touch sensing operation of the circuit in accordance with one exemplary embodiment of the present invention;
[0062] FIG. 13 shows a flow diagram of another exemplary embodiment of the touch sensing procedure in accordance with the present invention which can be performed by the circuit provided in FIG. 8 . In particular, a normal display scan sequence can be initiated in step 1000 . The column count (i) can be set to 0 in step 1005 . Then, in step 1010 , the column i is enabled, and in step 1015 , blue rows are enabled. The red rows are sampled in step 1020 , and then all rows are disabled in step 1025 . In step 1030 , red rows are sampled, and in step 1035 , the column count (i) is increased by 1. In step 1040 , it is determined whether a predetermined column limit (m) has been reached. If not, the process returns to step 1010 , and otherwise, the process returns to step 1000 .
[0063] FIG. 12 shows a timing diagram of the results provided by the procedure of FIG. 13 providing the results of the touch sensing operation of the circuit in accordance with one exemplary embodiment of the present invention;
[0064] The foregoing merely illustrates the principles of the invention. Various modifications and alterations to the described embodiments will be apparent to those skilled in the art in view of the teachings herein. It will thus be appreciated that those skilled in the art will be able to devise numerous systems and methods which, although not explicitly shown or described herein, embody the principles of the invention and are thus within the spirit and scope of the invention. All publications and patents cited above are incorporated herein by reference in their entireties. | Apparatus and method for both displaying graphical output and for sensing, e.g., multi-touch input are provided. A light-emitting diode (“LED”) matrix-array may be configured to both emit and sense light. The array may be driven in such a way so as to enable the array itself to act as the illumination source preferable for either reflective or scattering optical touch sensing. The need for additional opto-electronic components, or an external illumination source, is thus eliminated or at least reduced, and sensing accuracy is likely improved. Additionally, the method is practical for large dimensions. | 7 |
This invention claims the benefit of priority to U.S. Provisional patent application 60/419,181 filed Oct. 17, 2002.
FIELD OF THE INVENTION
This invention relates to quarter-wave films, in particular to methods and devices for widening the bandwidth of a quarter-wave film.
BACKGROUND AND PRIOR ART
Reflective and transflective liquid crystal displays (LCDs) have been widely used in personal information display for its low power consumption and light weight. In most reflective and transflective direct-view display devices, a broadband quarter-wave retardation film is needed in order to obtain a good dark state. As shown in FIG. 1 , the conventional broadband quarter-wave film laminates a chromatic half-wave film and a chromatic quarter-wave film at specific angles. See for example, S. Pancharatnam, Proceedings of the Indian Academy of Science , Section A, Vol. 41, p.130, (1955); and T. H Yoon, G. D. Lee and J. C. Kim, Opt. Lett ., Vol.25(20), p. 1547, (2000). The fabrication processes of the prior art are relatively simple, however, its spectral bandwidth is insufficient.
There is a need to improve broadband technology to meet the intended purpose of making displays and delivery of personal information more effective. The broadband quarter-wave film of the present invention can be used in personal information tools and would further increase the contrast ratio and also serve as a reflective LCD when the twisted film is replaced by a liquid crystal cell.
SUMMARY OF THE INVENTION
The first objective of the present invention is to provide a quarter-wave film and method of forming a quarter-wave film having a wide bandwidth.
The second objective of the present invention is to provide a reflective liquid crystal display (LCD) using a chromatic half-wave film.
The third objective of the present invention is to provide a broadband circular polarizer comprising a linear polarizer, a chromatic half-wave film, and a twisted nematic liquid crystal (TN-LC).
The fourth objective of the present invention is to provide a broadband quarter-wave film that improves the functioning and results of personal information displays and tools.
Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments, which are illustrated, schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a prior art broadband quarter-wave film.
FIG. 2 shows a perspective view of a preferred embodiment of the novel broadband quarter-wave film of the present invention.
FIG. 3 shows the configuration to verify the broadband quarter-wave film conditions in the present invention.
FIG. 4 a is a graph of the relationship between 4θ−2β, φ and dΔn/λ 0 to make Eq.(2) equal to 0 with a positive twist angle (i.e., left handedness).
FIG. 4 b is a graph of the relationship between 4θ−2β, φ and dΔn/λ 0 to make Eq.(2) equal to 0 with a negative twist angle (i.e., right handedness).
FIG. 5 shows the twist angles and retardation values of the TN-LC films that satisfy the quarter-wave film conditions.
FIG. 6 shows the wavelength-dependent refractive indices and birefringence of MLC 9100-000. Squares and circles are experimental results at T=23° C. and the lines are fitting results using Cauchy formula.
FIG. 7 a is a graph of the angles of chromatic half-wave film and polarizer that satisfy the broadband quarter-wave retardation film conditions for positive twist (i.e., left handedness) TN-LC. This configuration forms a broadband right-handed circular polarizer.
FIG. 7 b is a graph of the angles of chromatic half-wave film and polarizer that satisfy the broadband quarter-wave retardation film conditions for positive twist (i.e., left handedness) TN-LC. This configuration forms a broadband left-handed circular polarizer.
FIG. 7 c is a graph of the angles of chromatic half-wave film and polarizer that satisfy the broadband quarter-wave retardation film conditions for negative twist (i.e., right handedness) TN-LC. This configuration forms a broadband left-handed circular polarizer.
FIG. 7 d is a graph of the angles of chromatic half-wave film and polarizer that satisfy the broadband quarter-wave retardation film conditions for negative twist (i.e., right handedness) TN-LC. This configuration forms a broadband right-handed circular polarizer.
FIG. 8 shows a graph of the relationship between central wavelength λ 0 and 4θ−2β.
FIG. 9 shows the spectrum of normalized reflectance. The lines from solid to dash denote the cases of different 4θ−2β, from −90° to 0° with a step increment of 10°. The solid line represents the result of the prior art.
FIG. 10 shows the ellipticity angle of this invention. The lines from solid to dash denote the cases of different 4θ−2β, from −90° to 0° with a step increment of 10°. The solid line represents the result of the prior art.
FIG. 11 a shows the effect of film thickness error on normalized reflectance for prior art.
FIG. 11 b shows the effect of film thickness error on normalized reflectance for one embodiment of this invention at 4θ−2β=−40°, dΔn/λ 0 =0.278, φ=38.3°, β=−50°, and θ=−35°.
FIG. 12 shows the electro-optical curve of a reflective LCD incorporating the present invention, d=1.54 μm, φ=38.3°, β=−50° and θ=−35°.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
A preferred embodiment of the subject invention encompasses an improved quarter-wave film exhibiting a much wider bandwidth than that of the prior art depicted in FIG. 1 .
The quarter-wave film device of the present invention can be a quarter-wave film with a broadband wavelength, a broadband circular polarizer or when appropriately modified, a reflective liquid crystal display (LCD).
One embodiment of the novel quarter-wave film device that functions with a broadband wavelength is a combination of a chromatic half-wave film and a twisted nematic liquid crystal (TN-LC) polymeric film.
A second embodiment of the novel quarter-wave film device that functions as a broadband circular polarizer is a combination of a linear polarizer, a chromatic half-wave film, and a TN-LC polymeric film.
The first and second embodiments described above can be fabricated by having one side of the TN-LC film laminated to one side of the chromatic half-wave film, and when a linear polarizer is laminated to the other side of the chromatic half-wave film, the combination of chromatic half-wave film and TN-LC film forms a quarter-wave film with a broadband wavelength. The twist sense of the TN-LC film can be left-handed or right-handed. The twist angle is larger than 0 degree and less than approximately 80 degrees. Retardation (dΔn) values of the TN-LC film are in a range that is larger than approximately 0.1λ and less than approximately 1.0λ.
When the twist sense of the TN-LC film is left-handed, the twist angle of 4θ−2β is larger than approximately −90°+m×180° and less that approximately 0°+m×180°, wherein θ is the angle between optical axis of chromatic half-wave film and top liquid crystal director, β is the angle between transmission axis of linear polarizer and top liquid crystal director, and m is an integer.
When the twist sense of the TN-LC film is right-handed, the twist angle of 4θ−2β is larger than approximately 0°+m×180° and less than approximately 90°+m×180°, wherein θ is the angle between optical axis of chromatic half-wave film and top liquid crystal director, β is the angle between transmission axis of linear polarizer and top liquid crystal director, and m is an integer.
A third embodiment of the novel quarter-wave film device functions as a reflective liquid crystal display (LCD) and combines a polarizer, a chromatic half-wave film, a first substrate and a second substrate, a TN-LC layer, and a reflector. The reflector can be implemented at the inner side or at the outer side of the second substrate. The polarizer means is laminated to one side of the chromatic half-wave film, and one side of the TN-LC cell is laminated to the other side of the chromatic half-wave film, and the reflector is coated either inner or outer side of the TN-LC cell.
The twist angle of the TN-LC layer is larger than approximately 0 degrees and less than approximately 80 degrees, and the twist sense can be left-handed or right-handed, in the reflective liquid crystal display device.
The retardation (dΔn) values and angle measurements for the angle of 4θ−2β for the reflective LCD device are the same as for embodiments one and two above.
FIG. 2 illuminates the design of the present invention. The basic components of the broadband quarter-wave film device of the present invention consist of a chromatic half-wave film and a twisted-nematic liquid crystal polymeric film at specific angles.
In FIG. 3 , a reflector is added below the TN-LC film to verify that the combination of a chromatic half-wave film and a TN-LC film functions as a broadband quarter-wave film. As shown in FIG. 3 , after passing through the polarizer, the unpolarized incident light becomes linearly polarized. When these optical components are properly arranged, the linearly polarized light, after passing through the chromatic half-wave film and the TN-LC film, becomes circularly polarized. This circularly polarized light is then reflected back by the reflector. The reflected light passes through the TN-LC film and chromatic half-wave film the second time and becomes linearly polarized with its axis orthogonal to the polarizer. As a result, the light is blocked by the polarizer resulting in a dark state. That means the combined half-wave film and the TN LC film functions as a quarter-wave film.
According to the configuration shown in FIG. 3 , the normalized reflectance R is obtained using Jones matrix method:
R = ( cos β sin β ) · M Film · M LC ref · M LC i n · M Film · ( cos β sin β ) 2 ( 1 )
where M Film is the Jones matrix of the half-wave film and M LC ref and M LC in are the Jones matrices of the TN-LC for the reflected light and the incident light, respectively. And β is the angle between the polarizer and the top LC director.
At the central wavelength λ 0 , the phase retardation of the chromatic half-wave film is π and hence the normalized reflectance is:
R = [ 2 ( Γ 2 · sin X X ) 2 - 1 ] 2 + { Γ · sin X X [ cos X cos ( 4 θ - 2 β ) + ϕ sin X X sin ( 4 θ - 2 β ) ] } 2 ( 2 )
where Γ=2πdΔn/λ 0 , X=√{square root over (φ 2 +(Γ/2) 2 )}; d is thickness of TN-LC layer, birefringence of liquid crystal material, φ is twist angle of TN-LC layer. To make the combined chromatic half-wave film and TN-LC film in FIG. 3 function as a quarter-wave film, the normalized reflectance in equation (Eq.)(2) is set to 0. Under such circumstance, the relationship between 4θ−2β, φ and dΔn/λ 0 is obtained, as shown in FIG. 4 . From FIG. 4 , for a given 4θ−2β, it is possible to find a group of parameters (φ, dΔn/λ 0 ) of the TN-LC film to satisfy R=0. That means a group of parameters (φ, dΔn/λ 0 ) of the TN-LC film can always be found to make the combined chromatic half-wave film and TN-LC film in FIG. 3 function as a quarter-wave film.
It should be noted that there are first order and higher order quarter-wave films. FIG. 5 shows the twist angles and retardation values of the TN-LC films that satisfy the first, the second and the third order conditions. However, the second and the third order conditions are not suitable for broadband quarter-wave retardation films since they have larger color dispersion. Therefore, the design of the first order broadband quarter-wave film is a priority.
In order to realize broadband quarter-wave retardation condition, it is necessary to properly set the direction of the optical axis of the chromatic half-wave film with respect to the polarizer. Since the properties of a broadband quarter-wave film depends on the material color dispersion, the liquid crystal material chosen is MLC9100-000 (from Merck& Co., Inc.); it is assumed that the color dispersion of the chromatic half-wave film matches that of the LC material employed. The wavelength dependent refractive indices are approximated by Cauchy formula:
n e , o = A e , o + B e , o λ 2 ( 3 )
where the subscripts denote the extraordinary (e) and ordinary (o) rays, respectively. FIG. 6 shows the wavelength dependent refractive indices of MLC 9100-000 at T˜23° C.; these parameters are used in the following simulations.
After taking the material color dispersion into consideration, the angles between the chromatic half-wave film and the linear polarizer are obtained and this satisfies the broadband quarter-wave film condition. Results are shown in FIG. 7 . FIGS. 7 a and 7 b are the cases of positive twist (left-handedness) TN-LC, while FIGS. 7 c and 7 d are the cases of negative twist (right-handedness) TN-LC. In fact, the two conditions with 4θ−2β=−90° as plotted in FIGS. 7 a and 7 b , and the two conditions with 4θ−2β=90° as plotted in FIGS. 7 c , 7 d are exactly the cases for the above-mentioned prior art, where the twist angle φ=0° and phase retardation dΔn/λ=0.25.
As long as the twist angle (φ) of the TN-LC layer is non-zero, the combination of the chromatic half-wave film and the TN-LC film is equivalent to a quarter-wave film at two different wavelengths. Therefore, the central wavelength λ 0 is adjusted to get the desired bandwidth. For LCD applications, the peaks of the three primary colors occur at 460 nm, 550 nm and 630 nm wavelengths. To obtain a balanced white, the ratio of green/red/blue should be close to 60/30/10.
FIG. 8 shows the central wavelength λ 0 selection for different 4θ−2β. This central wavelength selection is also dependent on the color dispersion of chromatic half-wave film and TN-LC film. The variation of central wavelength means changing the thickness of chromatic half-wave film and TN-LC film. It should be pointed out here that each 4θ−2β has a corresponding set of φ and dΔn/λ 0 as shown in FIGS. 4 a and 4 b and a corresponding set of θ and β as shown in FIGS. 7 a , 7 b , 7 c and 7 d . For instance, if 4θ−2β=−30° is choosen from FIG. 7 a , then θ=−30° and β=45° are found. Note that although the calculated 4θ−2β is actually −210°, it is equivalent to −30° because of the 180° periodicity of 4θ−2β in Eq. (2). In FIG. 4 a , the LC twist angle is φ˜45° and retardation (dΔn) value ˜0.29λ 0 .
The normalized reflectance spectrum of the structure shown in FIG. 3 is plotted in FIG. 9 , which shows that with the increase of 4θ−2β from −90° to 0°, the two wavelengths at which normalized reflectance equals to 0 are separated farther and farther. Here the solid line represents the prior art. Only one wavelength exists at which normalized reflectance is 0. However, in the present invention with non-zero twist angle, there exist two different wavelengths at which the normalized reflectance is 0.
FIG. 10 shows the ellipticity angle of the present invention. In the prior art, when twist angle is 0°, there is only one wavelength at which the ellipticity angle is 45°, while in the present invention with non-zero twist angle, there are two different wavelengths at which the ellipticity angle is 45°. Therefore, the present invention exhibits a wider bandwidth than the prior art.
The film thickness tolerance is an important factor affecting manufacturing yield. FIGS. 11 a and 11 b plot the effect of the TN-LC film thickness tolerance on the normalized reflectance for the prior art and present invention, respectively. From FIG. 11 a , the prior art has a better dark state in the green band, but a narrower bandwidth if the film thickness is within ±1% of the optimal value. Beyond 2%, the present invention results are compatible with the prior art; however, the bandwidth of the present invention is wider.
In addition to the broadband quarter-wave film, the present invention can also be used as a reflective LCD. The principle is similar to that shown in FIG. 3 except replacing the TN-LC film by a TN-LC cell. Such a display is a normally black mode. When no voltage is applied to the cell, a broadband dark state is achieved. When a voltage is applied to the TN-LC cell, the liquid crystal is reoriented perpendicularly to the substrates and hence a white state is obtained. FIG. 12 shows the voltage-dependent reflectance curve of a reflective LCD incorporating this invention. The parameters used are d=1.54 μm, φ=38.3°, β=−50° and θ=−35°.
The major difference between the reflective display of the present invention and the prior art is that a half-wave film rather than a quarter-wave film is employed. The twist angle of the LC cell is φ=38.3° and retardation, dΔn=132.4 nm.
The major advantages of the present invention over the prior art is the wider bandwidth and better thickness tolerance The wider bandwidth improves the contrast ratio of a reflective display while a larger film thickness tolerance improves the manufacturing yield.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended. | A quarter-wave film having a wide bandwidth is invented. A preferred device configuration includes a chromatic half-wave film adjacent to a twisted nematic liquid crystal (TN-LC) film. When a linear polarizer is attached to the side of chromatic half-wave film and the angles of all the optical components are properly set, the combination of chromatic half-wave film and TN-LC film behaves as a broadband quarter-wave film. Based on this idea, a broadband circular polarizer is invented if the linear polarizer, the chromatic half-wave film and the TN-LC film are combined together. In addition, this idea can also be applied to reflective liquid crystal display devices, which include a linear polarizer, a chromatic half-wave film, a TN-LC cell and a reflector. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a cancer screening method, and in particular, to a cancer screening method using methylated DNA as the biomarker.
[0003] 2. Description of the Prior Art
[0004] Cervical cancer has been one of the main causes of death in females worldwide and in Taiwan. Based on the statistical survey by the World Health Organization (WHO) in 2002, cervical cancer was the second major disease responsible for the death of women worldwide, second to breast cancer. Regular cervical cancer screening is the best way to prevent cervical cancer. Conventional cervical cancer screening includes two approaches: the most commonly used Pap smear, and human papilloma virus testing (HPV testing). Pap smear consists of sampling secreta from cervix uteri, examining under microscope whether there is cancerous pathological change in the exfoliated epithelial cell, so as to detect cervical cancer early. HPV testing, on the other hand, relies on the detection of human papilloma virus (HPV) DNA.
[0005] There are, however, many undesired properties of Pap smear. For one, it requires sampling by a physician, and analysis by a medical examiner/pathologist, which is a high cost of manpower that poses difficulty on promoting the test in many developing countries. Also, Pap smear has a high false negative rate which delays diagnosis and proper treatment prior to cancerous pathological change. As for HPV testing, although it is highly sensitive, it tends to create a high false positive rate, which not only leaves patients worry in vain, but also wastes much medical resources in examinations follow up to those false positive patients. Accordingly, one of the important topics in promoting cervical cancer examination relies on increasing the accuracy and convenience of cervical cancer examination method.
[0006] Infection with oncogenic human papilloma virus (HPV) is the most significant risk factor in the etiology of cervical cancer. E6/E7 oncoprotein encoded by “high-risk” HPV types has been shown to interact with the tumor-suppressor gene p53/pRB, causing abnormal cell-cycle regulation (zur Hausen 2000). HPV DNA could be detected in virtually all cases of cervical cancers (Walboomers, Jacobs et al. 1999). However, HPV infection is necessary but not sufficient to cause cervical cancer. About 60% of LSIL (low-grade squamous intraepithelial lesion) regress, 30% persists, 5-10% progress to high-grade SIL (HSIL, or High-grade squamous intraepithelial lesion) and only less than 1% becomes cervical cancer (Syrjanen, Vayrynen et al. 1985; Syrjanen 1996). Persistence of HPV infection and viral load may be detrimental accounting the development of HSIL and cancer (Ylitalo, Sorensen et al. 2000). However, the molecular mechanism of cervical carcinogenesis remains illusive.
[0007] Other factors, such as environmental and genetic alterations, may also play a decisive role in malignant conversion of cervical keratinocytes (Magnusson, Sparen et al. 1999; Ylitalo, Sorensen et al. 1999). Despite initiation by HPV, genetic changes with resultant genomic instability has long been recognized as an important mechanism for cervical carcinogenesis. Cytogenetic studies have revealed non-random chromosomal changes in cervical cancers (Mitra, Rao et al. 1994; Atkin and Baker 1997; Harris, Lu et al. 2003). Several molecular genetic studies have identified a few frequent loss of heterozygosity (LOH) sites, suggesting the involvement of tumor suppressor genes (TSGs) in the development of cervical cancer. (Mitra, Murty et al. 1994; Mullokandov, Kholodilov et al. 1996; Rader, Kamarasova et al. 1996; Kersemaekers, Hermans et al. 1998; Mitra 1999).
[0008] Genomic deletions have long been considered to be an important factor in tumorigenesis. For a long time, we have been accustomed to the idea that the coding potential of the genome lies within the arrangement of the four A, T, G, C bases. The two-hit theory proposed as early as in 1970s indicates concomitant mutations or deletions of some homologous tumor suppressor genes may cause or predispose to cancer development (Knudson, Hethcote et al. 1975; Knudson 2001). However, additional information that affects phenotype can be stored in the modified base 5-methylcytosine. 5-Methylcytosine is found in mammals in the context of the palindromic sequence 5′-CpG-3′. Most CpG dinucleotide pairs are methylated in mammalian cells except some areas called “CpG island.” CpG islands are GC- and CpG-rich areas of approximately 1 kb, usually located in the vicinity of genes and often found near the promoter of widely expressed genes (Bird 1986; Larsen, Gundersen et al. 1992). Cytosine methylation occurs after DNA synthesis, by enzymatic transfer of a methyl group from the methyl donor S-adenosylmethionine to the carbon-5 position of cytosine. The enzymatic reaction is performed by DNA methyltransferases (DNMTs)(Laird 2003). DNMT1 is the main enzyme in mammals, and is responsible for the post-replicative restoration of hemi-methylated sites to full methylation, referred to as maintenance methylation, whereas DNMT3A and DNMT3B are thought to be involved primarily in methylating new sites, a process called de novo methylation (Okano, Bell et al. 1999; Robert, Morin et al. 2003).
[0009] Loss of methylation at CpG dinucleotides, i.e., general hypomethylation, was the first epigenetic abnormalities identified in cancer cells (Feinberg and Vogelstein 1983; Cheah, Wallace et al. 1984). However, during the past few years, it has become increasing apparent that site-specific hypermethylation, e.g., some tumor suppressor genes, is associated with loss of function which may provide selective advantages during carcinogenesis (Jones and Baylin 2002; Feinberg and Tycko 2004). Dense methylation of CpG islands at promoter regions can trigger chromatin remodeling through histone modifications with subsequent gene silencing (Geiman and Robertson 2002; Egger, Liang et al. 2004). Therefore, in addition to chromosomal deletions or genetic mutations, epigenetic silencing of tumor suppressor genes by promoter hypermethylation is commonly seen in human cancer (Baylin, Herman et al. 1998; Jones and Laird 1999; Baylin and Herman 2000).
[0010] Epidemiologic studies have recently shown the correlation of serum folate level, a major source of methyl group, with the infection and clearance of HPV (Piyathilake, Henao et al. 2004). Genetic polymorphisms of enzymes in the metabolism of methyl cycle were also reported to be associated with the development of cervical intraepithelial lesions (Henao, Piyathilake et al. 2004). As the concept of epigenetics evolves, studies exploring the association between DNA methylation and cervical cancer are also booming. Studies of DNA methylation in cervical cancer are accumulating, which showed the potential of using methylation as markers in cervical screening (Feng, Balasubramanian et al. 2005). With the nature of the interface between genetics and environment, the prevalence of methylation in tumor suppressor genes varies in different genes and different populations. The concept of methylator phenotypes with different disease behaviors was proposed with controversy. The methylator phenotype of cervical cancer and its interaction with HPV genotypes still remains unknown. The extent to which adenocarcinoma can be analogue to squamous cell carcinoma in terms of methylation patterns has never been investigated. What genes are specifically methylated in cervical cancer and how many genes are required to achieve clinical application will remain a blossoming issue in the coming future. The excavation of genes with higher contribution component to cervical carcinogenesis may shed light on the promise of using DNA methylation as a diagnostic marker as well as the development of a novel therapeutic intervention through epigenetic modulation.
SUMMARY OF THE INVENTION
[0011] The invention provides a cancer diagnostic method. The method uses the degree of methylation of a specific gene as the index to diagnose whether there is presence of cancer. The cancer diagnostic method according to the invention is applicable on the detection of cervical cancer. In addition to be the first line screening for cervical cancer, the cancer diagnostic method according to the invention can be used as the second line screening for cervical cancer in combination with or as an assistant to HPV testing in order to achieve a more accurate screening result for cervical cancer. Furthermore, the cancer diagnostic method according to the invention is capable of detecting other cancer types such as ovarian cancer, liver cancer and the like, to facilitate the diagnosis of other abnormal specimens.
[0012] In using the cancer diagnostic method according to the invention on the detection of cervical cancer, it exhibits a sensitivity and specificity higher than those of the Pap smear and HPV testing.
[0013] Accordingly, the invention provides a method for the diagnosis of cancer, characterized in that it comprises of detecting the methylation state of the target gene in the cell of the test specimen as a screening index to determine the existence of cancer, the method comprising the following steps:
[0014] step 1: providing a test specimen;
[0015] step 2: detecting the methylation state of the CpG sequence in at least one target gene within the genomic DNA of the test specimen, wherein the target genes is consisted of SOX1, PAX1, LMX1A, NKX6-1, WT1 and ONECUT1; and
[0016] step 3: determining whether there is cancer or cancerous pathological change in the specimen based on the presence or absence of the methylation state in the target gene.
[0017] The test specimens may be a cervical smear, ascites, blood, urine, feces, sputum, oral mucosa cell, gastric juice, bile, cervical epithelial cell and the like.
[0018] Method for detecting the methylation state of the CpG sequence in the target gene may be a methylation-specific PCR (MSP), quantitative methylation-specific PCR (QMSP), bisulfite sequencing (BS), microarrays, mass spectrometer, denaturing high-performance liquid chromatography (DHPLC), and pyrosequencing.
[0019] The target gene SOX1 has a nucleotide sequence as depicted in SEQ ID No: 1.
[0020] The target gene PAX1 has a nucleotide sequence as depicted in SEQ ID No: 2.
[0021] The target gene LMX1A has a nucleotide sequence as depicted in SEQ ID No: 3.
[0022] The target gene NKX6-1 has a nucleotide sequence as depicted in SEQ ID No: 4.
[0023] The target gene WT1 has a nucleotide sequence as depicted in SEQ ID No: 5.
[0024] The target gene ONECUT1 has a nucleotide sequence as depicted in SEQ ID No: 6.
[0025] The invention provides a method for screening cervical cancer, characterized in that it comprises of detecting the methylation state of the target gene in the cell of the test specimen as a screening index to determine the existence of the cervical cancer, the method comprising the following steps:
[0026] step 1: providing a test specimen;
[0027] step 2: detecting the methylation state of the CpG sequence in at least one target gene within the genomic DNA of the test specimen, wherein the target genes is consisted of SOX1, PAX1, LMX1A, NKX6-1, WT1 and ONECUT1; and
[0028] step 3: determining whether there is cervical cancer or cancerous pathological change in the specimen based on the presence or absence of the methylation state in the target gene.
[0029] The test specimens may be a cervical smear, blood, urine, cervical epithelial cell and the like.
[0030] In one embodiment, the test specimen is a cervical smear.
[0031] In one embodiment, the test specimen is a cervical cell specimen exhibiting a positive HPV testing.
[0032] Method for detecting the methylation state of the CpG sequence in the target gene may be a methylation-specific PCR (MSP), quantitative methylation-specific PCR (QMSP), bisulfite sequencing (BS), microarrays, mass spectrometer, denaturing high-performance liquid chromatography (DHPLC), and pyrosequencing.
[0033] The target gene SOX1 has a nucleotide sequence as depicted in SEQ ID No: 1.
[0034] The target gene PAX1 has a nucleotide sequence as depicted in SEQ ID No: 2.
[0035] The target gene LMX1A has a nucleotide sequence as depicted in SEQ ID No: 3.
[0036] The target gene NKX6-1 has a nucleotide sequence as depicted in SEQ ID No: 4.
[0037] The target gene WT1 has a nucleotide sequence as depicted in SEQ ID No: 5.
[0038] The target gene ONECUT1 has a nucleotide sequence as depicted in SEQ ID No: 6.
[0039] The invention provides further a method for screening ovarian cancer, characterized in that it comprises of detecting the methylation state of the target gene in the cell of the test specimen as a screening index to determine the existence of ovarian cancer, the method comprising following steps:
[0040] step 1: providing a test specimen;
[0041] step 2: detecting the methylation state of the CpG sequence in at least one target gene within the genomic DNA of the test specimen, wherein the target genes is consisted of SOX1, PAX1, and LMX1A; and
[0042] step 3: determining whether there is an ovarian cancer or cancerous pathological change in the specimen based on the presence or absence of the methylation state in the target gene.
[0043] The test specimens may be an ascites, blood, urine and the like.
[0044] Method for detecting the methylation state of the CpG sequence in the target gene may be a methylation-specific PCR (MSP), quantitative methylation-specific PCR (QMSP), bisulfite sequencing (BS), microarrays, mass spectrometer, denaturing high-performance liquid chromatography (DHPLC), and pyrosequencing.
[0045] The target gene SOX1 has a nucleotide sequence as depicted in SEQ ID No: 1.
[0046] The target gene PAX1 has a nucleotide sequence as depicted in SEQ ID No: 2.
[0047] The target gene LMX1A has a nucleotide sequence as depicted in SEQ ID No: 3.
[0048] The invention provides further a method screening liver cancer, characterized in that it comprises of detecting the methylation state of the target gene in the cell of the test specimen as a screening index to determine the existence of liver cancer, the method comprising following steps:
[0049] step 1: providing a test specimen;
[0050] step 2: detecting the methylation state of the CpG sequence in at least one target gene within the genomic DNA of the test specimen, wherein the target genes is consisted of SOX1, and NKX6-1; and
[0051] step 3: determining whether there is a liver cancer or cancerous pathological change in the specimen based on the presence or absence of the methylation state in the target gene.
[0052] The test specimens may be an ascites, blood, urine, feces, gastric juice, bile, and the like.
[0053] Method for detecting the methylation state of the CpG sequence in the target gene may be a methylation-specific PCR (MSP), quantitative methylation-specific PCR (QMSP), bisulfite sequencing (BS), microarrays, mass spectrometer, denaturing high-performance liquid chromatography (DHPLC), and pyrosequencing.
[0054] The target gene SOX1 has a nucleotide sequence as depicted in SEQ ID No: 1.
[0055] The target gene NKX6-1 has a nucleotide sequence as depicted in SEQ ID No: 4.
[0056] These features and advantages of the present invention will be fully understood and appreciated from the following detailed description of the accompanying Drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0057] FIG. 1 shows the analysis of CpG sequences in various target gene used in the cancer screening method according to the invention, wherein CpG sequences in various genes are marked with , positions occupied by synthetic fragments of MSP primers in various MSP genes are marked with , and positions occupied by synthetic fragments of bisulfite-sequenced primer in various genes are marked with .
[0058] FIG. 2 shows results of methylation-specific PCR (MSP) analysis of various target genes used in the cancer screening method according to the invention, in mixed cervical cancer tissue specimens (a mixture of 30 specimens) as well as in mixed normal cervical smear specimens (a mixture of 10 specimens): the first column, mixed normal cervical smear specimens (a mixture of 10 specimens); the second column mixed cervical cancer tissue specimens (a mixture of 30 specimens); the third column, negative control; the fourth column, positive control; and the fifth column, blank control (water).
[0059] FIG. 3 shows results of methylation-specific PCR (MSP) analysis of various target genes used in the cancer screening method according to the invention, in individual cervical cancer tissue specimens as well as in individual normal cervical smear specimens: T1, T2, T3 and T4 represent 4 individual cervical cancer tissue specimens, while N1, N2, N3 and N4 represent 4 normal specimens; entries labeled with U indicate results from the methylation-specific PCR (MSP) conducted with MSP primers (U) that can recognize specifically the non-methylated gene sequences; while entries labeled with M indicate results from the methylation-specific PCR (MSP) conducted with MSP primers (M) that can recognize specifically the methylated gene sequences.
[0060] FIG. 4A shows results of methylation-specific PCR (MSP) analysis conducted with various target genes used in the cancer screening method according to the invention in non-5′-aza-2′-deoxycytidine-treated HeLacervical cancer cell line (AZC−, the first and second columns), as well as in 5′-aza-2′-deoxycytidine-treated HeLacervical cancer cell line (AZC+, the third and fourth columns); entries labeled with U indicate results from the methylation-specific PCR (MSP) conducted with MSP primers (U) that can recognize specifically the non-methylated gene sequences; while entries labeled with M indicate results from the methylation-specific PCR (MSP) conducted with MSP primers (M) that can recognize specifically the methylated gene sequences.
[0061] FIG. 4B shows results of RT-PCR analysis conducted with various target genes used in the cancer screening method according to the invention in non-5′-aza-2′-deoxycytidine-treated HeLacervical cancer cell line (AZC−, the fifth column), as well as in 5′-aza-2′-deoxycytidine-treated HeLacervical cancer cell line (AZC+, the sixth column).
[0062] FIG. 5A shows results of bisulfite sequencing (BS) analysis conducted with various target genes used in the cancer screening method according to the invention in non-5′-aza-2′-deoxycytidine-treated HeLacervical cancer cell line.
[0063] FIG. 5B shows results of bisulfite sequencing (BS) analysis conducted with various target genes used in the cancer screening method according to the invention in 5′-aza-2′-deoxycytidine-treated HeLacervical cancer cell line.
[0064] FIG. 6A shows results of bisulfite sequencing (BS) analysis conducted with various target genes used in the cancer screening method according to the invention in the cervical squamous cell carcinoma (SCC).
[0065] FIG. 6B shows results of bisulfite sequencing (BS) analysis conducted with various target genes used in the cancer screening method according to the invention in the normal specimen.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
EXAMPLE 1
Materials and Methods
1. Tissue Specimens
[0066] Cervical tissue specimens were obtained from patients with normal uterine cervixes (n=45) and patients with LSIL (n=45), HSIL (n=58), and invasive squamous cell carcinoma (SCC; n=109) of the uterine cervix. The patients were diagnosed, treated, and tissue banked at the Tri-Service General Hospital, Taipei, Taiwan, since 1993. For diagnostic purposes, cytological, histological, and clinical data for all patients were reviewed by a panel of colposcopists, cytologists, and pathologists. All patients were examined and treated using a standard hospital protocol for cervical neoplasia. Controls were recruited from healthy women who underwent routine Pap screening during the same period. Informed consent was obtained from all patients and control subjects. Exclusion criteria included pregnancy, chronic or acute viral infection, a history of cervical neoplasia, skin or genital warts, an immune-compromised state, the presence of other cancers, and past surgery of the uterine cervix. The study was approved by the Institutional Review Board of the Tri-Service General Hospital.
[0067] The tissue specimens also include a series of ovarian tumor samples, which were obtained from the tumor bank of Tri-Service General Hospital, and the ovarian samples include benign ovarian samples (n=36), borderline ovarian tumors (n=6), and malignancy ovarian tumors (n=122).
[0068] In addition, the liver samples used in the study includes normal liver samples (n=13), chronic hepatitis (n=15), cirrhosis of the liver (n=40), and hepatocellular carcinoma (HCC, n=54). All the liver samples were from the tumor bank of Tri-Service General Hospital.
2. Preparation of Genomic DNA
[0069] Genomic DNA was extracted from specimens using Qiagene DNA Extraction Kits. The concentration of DNA was determined using the PicoGreen fluorescence absorption method, and DNA quality was verified using agarose gel electrophoresis.
3. Differential Methylation Hybridization (DMH) Using CpG Island Microarrays
[0070] Differential Methylation Hybridization (DMH) was performed according to Yan et al. Pooled DNA from 30 cancer tissues and 10 normal cervical swabs were used for comparison. DNA was digested using MseI, ligated to linkers, and sequentially digested with methylation-sensitive restriction enzymes (HpaII and BstUI). The digested linker-ligated DNA was used as a template for polymerase chain reaction (PCR) amplification (20 cycles) and coupled to fluorescence dyes (Cy3: pooled normal cervical sample; Cy5: pooled cervical cancer sample) before hybridizing to the CpG island microarray containing 8,640 CpG island tags (University of Toronto). The identity of selected CpG islands (CGIs) was obtained from the CGI database (http://derlab.med.utoronto.ca/CpGIslands/). The microarray data were analyzed using the circular-features mode of GenePix 6.0 software. Spots representing repetitive clones were flagged and unacceptable features were removed by filtering. Loci with ratios >2.0 were accepted as hypermethylated in the pooled cervical cancer sample.
4. Bisulfite Modification, Methylation-Specific PCR (MS-PCR), and Bisulfite Sequencing
[0071] A DNA modification kit (Chemicon, Ternecula, Calif.) was used according to the manufacturer's recommendations to convert 1 μg aliquots of genomic DNA with sodium bisulfite to preserve the methylated cytosines. The final precipitate was eluted with 70 μl of prewarmed (55° C.) TE buffer for MS-PCR.
[0072] MS-PCR was performed according to Herman et al. (1996). In short, 1 μl of modified DNA was amplified using MS-PCR primers (table 1) that specifically recognized either the unmethylated or the methylated gene sequences present in the bisulfite-converted DNA. Methylation-specific PCR was done in a total volume of 25 μl containing 1 μl of modified template DNA, 1.5 pmol of each primer, 0.2 mmol/L deoxynucleotide triphosphates, and 1 unit of Gold Taq DNA polymerase (Applied Biosystems, Foster City, Calif.). MS-PCR reactions were subjected to an initial incubation at 95° C. for 5 min, followed by 35 cycles of 95° C. for 30 s, and annealing at the appropriate temperature for 30 s and at 72° C. for 30 s. The final extension was done at 72° C. for 5 min.
[0000]
TABLE 1
The sequences of MS-PCR primers
Gene
Primer
Sequence
SOX1
M
Forward (F′)
5′ CGTTTTTTTTTTTTCGTTATTGGC 3′
(SEQ ID No: 7)
Reverse (R′)
5′ CCTACGCTCGATCCTCAACG 3′
(SEQ ID No: 8)
U
Forward (F′)
5′ TGTTTTTTTTTTTTTGTTATTGGTG 3′
(SEQ ID No: 9)
Reverse (R′)
5′ CCTACACTCAATCCTCAACAAC 3′
(SEQ ID No: 10)
LMX1A
M
Forward (F′)
5′ TTTAGAAGCGGGCGGGAC 3′
(SEQ ID No: 11)
Reverse (R′)
5′ CCGAATCCAAACACGCG 3′
(SEQ ID No: 12)
U
Forward (F′)
5′ GAGTTTAGAAGTGGGTGGGATG 3′
(SEQ ID No: 13)
Reverse (R′)
5′ CAACCAAATCCAAACACACAAAAC 3′
(SEQ ID No: 14)
ONECUT1
M
Forward (F′)
5′ TTGTAGCGGCGGTTTTAGGTC 3′
(SEQ ID No: 15)
Reverse (R′)
5′ GCCAAACCCTTAACGTCCCG 3′
(SEQ ID No: 16)
U
Forward (F′)
5′ GATTGTAGTGGTGGTTTTAGGTTG 3′
(SEQ ID No: 17)
Reverse (R′)
5′ CACCAAACCCTTAACATCCCAATAC 3′
(SEQ ID No: 18)
PAX1
M
Forward (F′)
5′ TATTTTGGGTTTGGGGTCGC 3′
(SEQ ID No: 19)
Reverse (R′)
5′ CCCGAAAACCGAAAACCG 3′
(SEQ ID No: 20)
U
Forward (F′)
5′ GTTTATTTTGGGTTTGGGGTTGTG 3′
(SEQ ID No: 21)
Reverse (R′)
5′ CACCCAAAAACCAAAAACCAC 3′
(SEQ ID No: 22)
NKX6.1
M
Forward (F′)
5′ CGTGGTCGTGGGATGTTAGC 3′
(SEQ ID No: 23)
Reverse (R′)
5′ ACAAACAACGAAAAATACGCG 3′
(SEQ ID No: 24)
U
Forward (F′)
5′ GTGTGGTTGTGGGATGTTAGTG 3′
(SEQ ID No: 25)
Reverse (R′)
5′ CAACAAACAACAAAAAATACACAAC 3′
(SEQ ID No: 26)
WT1
M
Forward (F′)
5′ TGTTGAGTGAATGGAGCGGTC 3′
(SEQ ID No: 27)
Reverse (R′)
5′ CGAAAAACCCCCGAATATAAACG 3′
(SEQ ID No: 28)
U
Forward (F′)
5′ GTTGTTGAGTGAATGGAGTGGTTG 3′
(SEQ ID No: 29)
Reverse (R′)
5′ AATTACAAAAAACCCCCAAATATAAACAC 3′
(SEQ ID No: 30)
M: The primers can specifically recognize the methylated gene sequences present in the bisulfite-converted DNA.
U: The primers can specifically recognize the unmethylated gene sequences present in the bisulfite-converted DNA.
[0073] Normal DNA from human peripheral blood was modified with sodium bisulfite and used as a control for the unmethylated promoter sequence. Normal human DNA was treated with SssI methyltransferase (New England Biolabs, Beverly, Mass.) to generate a positive control for methylated alleles. Amplification products were visualized on 2.5% agarose gel containing ethidium bromide and illuminated under UV light. All MS-PCR data were derived from at least two independent modifications of DNA. The absence of signal in duplicate experiments was scored as negative methylation. Bisulfite-treated genomic DNA was amplified using primers (table 2) and amplified PCR product was purified and cloned into pCR4-TOPO vectors (Invitrogen, Carlsbad, Calif.). Bisulfite sequencing was performed on at least five individual clones using the 377 automatic sequencer (Applied Biosystems, Foster City, Calif.).
[0000] TABLE 2 The sequences of Bisulfite sequencing primers Gene Primer Sequence Sox1 Forward (F′) 5′ GTTGTTTTYGGGTTTTTTTTTGGTTG 3′ (SEQ ID No: 31) Reverse (R′) 5′ ATTTCTCCTAATACACAAACCACTTACC 3′ (SEQ ID No: 32) LMX1A Forward (F′) 5′ TAGTTATTGGGAGAGAGTTYGTTTATTAG 3′ (SEQ ID No: 33) Reverse (R′) 5′ CTACCCCAAATCRAAAAAAAACAC 3′ (SEQ ID No: 34) ONECUT1 Forward (F′) 5′ GAGTTTATTTAAGTAAGGGAGG 3′ (SEQ ID No: 35) Reverse (R′) 5′ CAACTTAAACCATAACTCTATTACTATTAC 3′ (SEQ ID No: 36) PAX1 BS1 Forward (F′) 5′ GTGTTTTGGGAGGGGGTAGTAG 3′ (SEQ ID No: 37) Reverse (R′) 5′ CCCTCCCRAACCCTACCTATC 3′ (SEQ ID No: 38) BS2 Forward (F′) 5′ GATAGAAGGAGGGGGTAGAGTT 3′ (SEQ ID No: 39) Reverse (R′) 5′ TACTACCCCCTCCCAAAACAC 3′ (SEQ ID No: 40) NKX6.1 BS1 Forward (F′) 5′ GGTATTTTTGGTTTAGTTGGTAGTT 3′ (SEQ ID No: 41) Reverse (R′) 5′ AATACCCTCCATTACCCCCACC 3′ (SEQ ID No: 42) BS2 Forward (F′) 5′ GGTGGGGGTAATGGAGGGTATT 3′ (SEQ ID No: 43) Reverse (R′) 5′ CCTAAATTATAAATACCCAAAAAC 3′ (SEQ ID No: 44) WT1 Forward (F′) 5′ GTGTTGGGTTGAAGAGGAGGGTGT 3′ (SEQ ID No: 45) Reverse (R′) 5′ ATCCTACAACAAAAAAAAATCCAAAATC 3′ (SEQ ID No: 46)
5. Re-Expression of Methylated Genes by 5′-aza-2′-Deoxycytidine Treatment in Cancer Cell Lines
[0074] The methylation status of candidate genes was tested in HeLa cervical cancer cell line using MS-PCR. Re-expression of methylated genes in cervical cancer cell lines after treatment with 10 μM of 5′-aza-2′-deoxycytidine (AZC) (Sigma Chemical Co.) for four days was assessed by RT-PCR. Total RNA was extracted using a Qiagen RNeasy kit (Qiagen, Valencia, Calif.). An additional DNase I digestion procedure (Qiagen) was included in the isolation of RNA to remove DNA contamination. One microgram of total RNA from each sample was subjected to cDNA synthesis using Superscript II reverse transcriptase and random hexamer (Invitrogen). The cDNA that was generated was used for PCR amplification with the reagents in the PCR master mix reagents kit (Applied Biosystems) as recommended by the manufacturer. The reactions were carried out in a thermal cycler (GeneAmp 2400 PE, Applied Biosystems). The primers and conditions for the PCR are listed in Table 3.
[0000]
TABLE 3
The sequences of MSP primers for RT-PCR
Gene
Primer
Sequence
SOX1
Forward (F′)
5′ AGACCTAGATGCCAACAATTGG 3′
(SEQ ID No: 47)
Reverse (R′)
5′ GCACCACTACGACTTAGTCCG 3′
(SEQ ID No: 48)
LMX1A
Forward (F′)
5′ GCTGCTTCTGCTGCTGTGTCT 3′
(SEQ ID No: 49)
Reverse (R′)
5′ ACGTTTGGGGCGCTTATGGTC 3′
(SEQ ID No: 50)
ONECUT1
Forward (F′)
5′ CAAACCCTGGAGCAAACTCAA 3′
(SEQ ID No: 51)
Reverse (R′)
5′ TGTGTTGCCTCTATCCTTCCC 3′
(SEQ ID No: 52)
PAX1
Forward (F′)
5′ CCTACGCTGCCCTACAACCACATC 3′
(SEQ ID No: 53)
Reverse (R′)
5′ TCACGCCGGCCCAGTCTTCCATCT 3′
(SEQ ID No: 54)
NKX6.1
Forward (F′)
5′ CACACGAGACCCACTTTTTCC 3′
(SEQ ID No: 55)
Reverse (R′)
5′ CCCAACGAATAGGCCAAACG 3′
(SEQ ID No: 56)
WT1
Forward (F′)
5′ GCTGTCCCACTTACAGATGCA 3′
(SEQ ID No: 57)
Reverse (R′)
5′ TCAAAGCGCCAGCTGGAGTTT 3′
(SEQ ID No: 58)
6. HPV Detection
[0075] The presence of HPV DNA in SCC was detected by L1 consensus PCR followed by a reverse line blot (Gravitt, et al., 1998; Lai, et al., 2005). DNA sequencing was used to verify novel HPV types that exceeded the detection spectrum of the hybridization procedure.
7. Statistical Analysis
[0076] Data analysis was carried out using statistical package SAS version 9.1. Associations between the methylation of genes and clinical parameters, including HPV status, were analyzed using a X 2 test and Fisher's exact test, wherever appropriate. Odds ratios (ORs) and 95% confidence intervals (95% CI) were calculated and adjusted for age and HPV infection using a logistic regression model. The alpha level of statistical significance was set at p=0.05. The sensitivity and specificity using HPV and methylation markers for the diagnosis of cervical lesions were calculated. The 95% CI was estimated using the BINOMIAL option in the EXACT statement.
EXAMPLE 2
Identification of Methylated Genes in Invasive Squamous Cell Carcinoma of the Cervix
[0077] Differential methylation hybridization (DMH) was carried out by means of CpG island microarrays to screen out the highly methylated gene in cervical squamous cell carcinoma (SCC). The result from CpG island microarrays revealed that there were 216 points exhibited differential methylation between cervical cancer tissue specimens and normal cervical smears, of which, after taking off those having overlapped sequences, 26 gene promoter domain CpG islands (promoter CGIs).
[0078] Sequencing and analysis were carried out on these gene promoter and 6 genes were selected. These genes included: SOX1 (SEQ ID No: 1), PAX1 (SEQ ID No: 2), LMX1A (SEQ ID No: 3), NKX6-1 (SEQ ID No: 4), WT1 (SEQ ID No: 5) and ONECUT1 (SEQ ID No: 6). Their detailed information were shown in Table 4. All of these 6 genes are important transcription factors in the development course, of which, SOX1, PAX1, LMX1A, NKX6-1, and WT1 were vital for the development of brain, roof plate, extremities, pancreatic island and urogenital organ, respectively, while ONECUT1 is important for the performance of hepatic and pancreatic genes. However, little correlation between these genes and cancer has been disclosed so far.
[0000]
TABLE 4
Characteristics of methylated genes in cervical cancer that were
identified using a CpG island microarray
Chromosomal
Gene
UniGene
location
Full name
Known molecular function
SOX1
NM_005986
13q34
Sex
DNA binding
determining
Transcription factor activity
region Y-box 1
PAX1
NM_006192
20p11.2
Paired box
DNA binding
gene 1
LMX1A
NM_177398
1q22-q23
LIM
Transcription factor activity
homeobox
Zinc ion binding
transcription
factor 1 alpha
NKX6-1
NM_006168
4q21.2-q22
NK6
Transcription factor activity
transcription
factor related
locus 1
ONECUT1
NM_004498
15q21.1-q21.2
One cut
Transcription factor activity
domain family
Transcriptional activator
member 1
activity
WT1
NM_024426
11p13
Wilm's tumor 1
Transcription factor activity
Zinc ion binding
[0079] CpG sequence analysis was carried out over about 500 bp nucleotides before and after each gene transcription initiation point (+1). As shown in FIG. 1 , various genes containing CpG sequence are marked with . MSP primer (as shown in Table 1) and bisulfite sequencing (BS) primer (as shown in Table 2) were designed with respect to each gene. Positions occupied by fragments synthesized during methylation-specific PCR (MSP) and bisulfite sequencing (BS) over various genes are shown also in FIG. 1 .
[0080] Then, methylation-specific PCR (MSP) analysis were carried out on mixed cervical cancer tissue specimens (a mixture of 30 specimens) as well as on mixed normal cervical smear specimens (a mixture of 10 specimens) in order to confirm whether the methylation phenomena of these 6 genes were different in different tissue specimens. As indicated from results shown in FIG. 2 , these 6 genes exhibited methylation in mixed cervical cancer tissue specimens (as shown at column 2 in FIG. 2 ), while no methylation was occurred in mixed normal cervical smear specimens (as shown at column 1 in FIG. 2 ). Further testing was carried out with individual cervical cancer tissue specimen. Methylation-specific PCR (MSP) was performed on 4 cervical cancer tissue specimens (T1, T2, T3, T4) and 4 normal specimens (N1, N2, N3, N4), respectively, with MSP primer (U) that could recognize specifically non-methylated gene sequence as well as with MSP primer (M) that could recognize specifically methylated gene sequence. Results shown in FIG. 3 revealed that all of these 6 genes exhibited methylation in individual cervical cancer tissue specimen (as shown at columns 1, 3, 5, and 7 in FIG. 3 ), while no methylation could be detected in normal specimens with these same genes (as shown at columns 9, 11, 13, and 15 in FIG. 3 ). Based on the above-described results, these 6 genes were used as the methylation indicator genes for screening cervical cancer.
EXAMPLE 3
Association of DNA Methylation and Gene Expression in HeLa Cervical Cancer Cell Line
[0081] In order to confirm whether the expression of cervical cancer methylation indicator gene is regulated through DNA methylation, HeLa cervical cancer cell line was treated with 10 μM of DNA methyltransferase inhibitor, 5′-aza-2′-deoxycytidine (AZC) (Sigma Chemical Co.), for 4 days, following by checking the demethylation by the 6 gene promoters described above by means of methylation-specific PCR (MSP) carried out with MSP primer (U) that could recognize specifically non-methylated gene sequence, as well as with MSP primer (M) that could recognize specifically methylated gene sequence, respectively. Results as shown in FIG. 4A indicated that among non-5′-aza-2′-deoxycytidine (AZC)-treated HeLa cervical cancer cell lines (AZC−), 6 gene promoters exhibited methylated conditions (as shown at column 1 in FIG. 4A ), and no non-methylated gene was detected (as shown at column 2 in FIG. 4A ). On the other hand, after treated with 5′-aza-2′-deoxycytidine for 4 days, non-methylated target gene could be detected in HeLa cervical cancer cell lines (AZC+) (as shown at column 4 in FIG. 4A ), indicating that through treated with methyltransferase inhibitor, 5′-aza-2′-deoxycytidine (AZC), the above-described 6 target genes had been demethylated partially.
[0082] Next, expressions of these 6 genes in HeLa cervical cancer cell line were analyzed through RT-PCR. Results shown in FIG. 4B indicated that in cell lines treated with 5′-aza-2′-deoxycytidine (AZC), mRNA of these 6 target genes could be detected (as shown at column 6 in FIG. 4B ), while in those cell lines that had not been treated with 5′-aza-2′-deoxycytidine (AZC), no mRNA of any one target gene could be detected (as shown at column 5 in FIG. 4B ). It is evident from these results that gene expression of these 6 target genes in cervical cancer cell could be modified actually through DNA methylation. As gene had been methylated, its expression could be inhibited, whereas after demethylated, the target gene could be re-expressed.
[0083] Furthermore, bisulfite sequencing (BS) was used to analyze whether the target gene in HeLa cervical cancer cell line exhibited hypermethylation condition. Results shown in FIG. 5 indicated that the number of hypermethylated target gene specimens in cell lines that had not been treated with 5′-aza-2′-deoxycytidine(AZC) ( FIG. 5A ) is higher than that in cell lines that had been treated with 5′-aza-2′-deoxycytidine (AZC) ( FIG. 5B ). Furthermore, cervical squamous cell carcinoma (SCC) and normal specimens were analyzed by means of bisulfite sequencing (BS) analysis. Results shown in FIG. 6 indicated that the number of hypermethylated target gene specimens in cervical squamous cell carcinoma (SCC) specimens ( FIG. 6A ) is considerably higher than that in normal specimens ( FIG. 6B ).
EXAMPLE 4
Methylation Analysis of Genes in Clinical Cervical Samples
[0084] The mean ages of patients with normal cervix and with LSIL, HSIL and SCC were 51.0±11.3, 39.7±9.6, 46.4±14.4 and 53.3±10.9 years, respectively (p<0.05). As shown in Table 5, the positive rate of high risk HPV DNA is 21.4%, 47.7%, 59.3% and 88.9% in normal, LSIL, HSIL and SCC, respectively (p<0.05). Patients with HPV infection showed significantly higher risk of the full spectrum of cervical lesions (OR: 3.1, 95% CI: 1.1-8.3; OR: 5.2, 95% CI: 2.1-13.0; OR: 29.9, 95% CI: 11.5-77.7 for LSIL, HSIL and SCC, respectively). All six genes (SOX1, PAX1, LMX1A, NKX6-1, WT1, and ONECUT1) showed frequent methylation in SCC (81.5%, 94.4%, 89.9%, 80.4%, 77.8%, and 20.4%, respectively), which was significantly greater than the methylation frequencies of their normnal counterparts (2.2%, 0%, 6.7%, 11.9%, 11.1% and 0%, respectively; p≦0.001).
[0085] The methylation frequency of NKX6-1 was 53.3% in LSIL, 55.1% in HSIL, and 80.4% in SCC. Patients with methylations of NKX6-1 showed higher risks of SCC (OR: 29.8, 95% CI: 10.4-85.2). The methylation frequency of PAX1 was 2.3% in LSIL, 42.1% in HSIL, and 94.4% in SCC. Patients with methylations of PAX1 showed higher risks of HSIL and SCC (OR: >999.9, 95% CI:<0.1→999.9; OR:>999.9, 95% CI:<0.1→999.9, respectively).
[0086] The methylation rates of SOX1, LMX1A, and ONECUT1 were low in precancerous lesions, but increased substantially between HSIL and SCC (9.3% vs. 81.5%, 16% vs. 89.9%, and 7.4% vs. 20.4%, respectively). Patients with methylations of SOX1, LMX1A and ONECUT1 showed higher risks of SCC (OR: 200.2, 95% CI: 25.8-999.9; OR: 124.5, 95% CI: 33.0-470.1; OR: 7.3, 95% CI: 2.0-25.9, respectively). WT1 exhibited a severity-dependent increase in methylation frequency (11.1% in nornal, 20.0% in LSIL, 42.1% in HSIL, and 77.8% in SCC). Patients with methylations of WT1 showed higher risks of HSIL and SCC (OR: 6.7, 95% CI: 2.2-19.8; OR: 27.9, 95% CI: 9.8-78.9, respectively).
EXAMPLE 5
Diagnostic Performance of DNA Methylation Markers
[0087] The sensitivities and specificities of HPV and DNA methylations were determined to assess their usefulness as biomarkers for diagnosis of high-grade cervical lesions and invasive cervical cancer. As shown in Table 6, the sensitivity and specificity for the diagnosis of SCC using HPV testing were 83.1% and 85.5%, respectively (95% CI: 77.6-88.5 and 79.6-91.4, respectively). SOX1, PAX1, LMX1A, NKX6-1, and WT1 methylations had high sensitivities (77.8%-94.4%) and specificities (88.1%-100%) for diagnosis of SCC.
[0088] When combined parallel testing (CPT) was applied for HPV and each methylation marker, which means that either one being positive was counted as positive, the sensitivities and specificities were in the ranges of 97.2%-98.2% and 66.7%-79.5%, respectively. When combined sequential testing (CST) was applied for HPV and each methylation marker, which means testing for HPV first with methylation detection following for HPV (+) patients, the sensitivities were in the ranges of 69.4%-85.0%. All the specificities were 100%.
[0089] When HSIL and SCC were present, the sensitivity and specificity for the diagnosis of HSIL/SCC using HPV testing were 75.0% (95% CI 70.2-79.8) and 85.5% (95% CI 79.6-91.4), respectively. The sensitivities and specificities of SOX1, PAX1, LMX1A, NKX6-1 and WT1 methylations were in the ranges of 57.4%-76.2% and 88.1%-100%, respectively. Using CPT for HPV and each methylation marker, the sensitivities could be improved to 85.8%-94.9%. Using CST for HPV and each methylation marker, all the specificities were 100%. When CPT was done using HPV and the methylations of SOX1, PAX1 and LMX1A, the sensitivities could be 100% for SCC and 93.4% for HSIL/SCC. PAX1 conferred the best performance when used alone with sensitivities of 94.4% (95% CI 90.0-98.8) and 76.2% (95% CI 69.7-82.7) for SCC and HSIL/SCC, respectively. The specificities were both 100%.
[0000]
TABLE 5
Clinical relevance of DNA methylations in the full spectrum of cervical neoplasias
Clinical status/
genes
SOX1
PAX1
LMX1A
NKX6-1
WT1
ONECUT1
HPV
Normal
1/45
0/41
3/45
5/42
5/45
0/45
9/42
(n = 45)
(2.2%)
(0%)
(6.7%)
(11.9%)
(11.1%)
(0%)
(21.4%)
LSIL
2/45
1/44
6/45
24/45
9/45
3/45
21/44
(n = 45)
(4.4%)
(2.3%)
(13.3%)
(53.3%)
(20.0%)
(6.7%)
(47.7%)
OR
2.0
—
2.2
8.5
2.0
—
3.3
(95% CI)
(0.2-23.4)
—
(0.5-9.2)
(2.8-25.5)
(0.6-6.5)
—
(1.3-8.6)
OR*
3.1
—
2.2
9.6
2.7
—
3.1
(95% CI)
(0.3-36.7)
—
(0.5-9.7)
(3.1-30.4)
(0.8-9.3)
—
(1.1-8.3)
HSIL
5/54
24/57
8/50
27/49
24/57
4/54
32/54
(n = 58)
(9.3%)
(42.1%)
(16.0%)
(55.1%)
(42.1%)
(7.4%)
(59.3%)
OR
4.5
>999.9
2.7
9.1
5.8
2.3
5.3
(95% CI)
(0.5-39.9)
(<0.1->999.9)
(0.6-10.7)
(3.1-27.0)
(2.0-16.9)
(0.5-10.8)
(2.1-13.3)
OR*
5.1
>999.9
2.7
9.6
6.7
2.3
5.2
(95% CI)
(0.6-45.9)
(<0.1->999.9)
(0.7-10.9)
(3.2-29.1)
(2.2-19.8)
(0.5-10.8)
(2.1-13.0)
SCC
88/108
101/107
98/109
86/107
84/108
22/108
96/108
(n = 109)
(81.5%)
(94.4%)
(89.9%)
(80.4%)
(77.8%)
(20.4%)
(88.9%)
OR
193.5
>999.9
124.7
30.3
28.0
7.4
29.3
(95% CI)
(25.2-1000)
(<0.1->999.9)
(33.1-469.9)
(10.6-86.5)
(10.0-78.8)
(2.1-25.7)
(11.3-75.8)
OR*
200.2
>999.9
124.5
29.8
27.9
7.3
29.9
(95% CI)
(25.8-999.9)
(<0.1->999.9)
(33.0-470.1)
(10.4-85.2)
(9.8-78.9)
(2.0-25.9)
(11.5-77.7)
Probability
p < 0.0001
p < 0.0001
p < 0.0001
p < 0.0001
p < 0.0001
p = 0.001
p < 0.0001
*adjusted for age and HPV infection
[0000]
TABLE 6
The sensitivities and specificities of HPV testing and DNA methylations
for high-grade cervical lesions and invasive cervical cancer.
SCC
HSIL/SCC
Sensitivity
Specificity
Sensitivity
Specificity
Biomarker
Test
OR
(95% CI)
OR
(95% CI)
OR
(95% CI)
OR
(95% CI)
HPV
alone
83.1
(77.6-88.5)
85.5
(79.6-91.4)
75.0
(70.2-79.8)
85.5
(79.6-91.4)
SOX1
alone
81.5
(74.2-88.8)
97.6
(93.0-100.0)
57.4
(49.8-65.0)
97.6
(93.0-100.0)
CPT
98.1
(95.6-100.0)
76.2
(63.3-89.1)
85.8
(80.4-91.2)
76.2
(63.3-89.1)
CST
72.2
(63.8-80.7)
100.0
(100.0-100.0)
50.6
(42.9-58.3)
100.0
(100.0-100.0)
PAX1
alone
94.4
(90.0-98.8)
100.0
(100.0-100.0)
76.2
(69.7-82.7)
100.0
(100.0-100.0)
CPT
98.1
(95.6-100.0)
79.5
(66.8-92.2)
89.6
(85.0-94.3)
79.5
(66.8-92.2)
CST
85.0
(78.3-91.8)
100.0
(100.0-100.0)
65.2
(58.0-72.5)
100.0
(100.0-100.0)
LMX1A
alone
89.9
(84.3-95.6)
92.9
(85.1-100.0)
66.7
(59.3-74.0)
92.9
(85.1-100.0)
CPT
98.2
(95.7-100.0)
71.4
(57.8-85.1)
89.3
(84.5-94.1)
71.4
(57.8-85.1)
CST
80.7
(73.3-88.1)
100.0
(100.0-100.0)
58.5
(50.8-66.2)
100.0
(100.0-100.0)
NKX6-1
alone
80.4
(72.9-87.9)
90.0
(80.7-99.3)
72.4
(65.4-79.5)
90.0
(80.7-99.3)
CPT
98.1
(95.6-100.0)
70.0
(55.8-84.2)
94.9
(91.4-98.3)
70.0
(55.8-84.2)
CST
71.0
(62.4-79.6)
100.0
(100.0-100.0)
59.0
(51.3-66.7)
100.0
(100.0-100.0)
WT1
alone
77.8
(69.9-85.6)
88.1
(78.3-97.9)
65.5
(58.2-72.7)
88.1
(78.3-97.9)
CPT
97.2
(94.1-100.0)
66.7
(52.4-80.9)
90.3
(85.8-94.8)
66.7
(52.4-80.9)
CST
69.4
(60.8-78.1)
100.0
(100.0-100.0)
53.9
(46.3-61.5)
100.0
(100.0-100.0)
HPV
CPT
100.0
(100.0-100.0)
69.2
(54.8-83.7)
93.4
(89.4-97.3)
69.2
(54.8-83.7)
+SOX1
+PAX1
+LMX1A
EXAMPLE 6
Methylation Analysis of Genes in Ovarian Samples
[0090] MS-PCR was performed to analyze the methylation status of the target genes in ovarian samples. As shown in Table 7, the promoters of SOX1, PAX1, and LMX1A were methylated neither in benign ovarian samples nor in borderline ovarian tumors. However, the methylation frequency of these 3 genes, SOX1, PAX1, and LMX1A, was significantly greater in malignancy ovarian tumors. The methylation frequency of SOX1, PAX1, and LMX1A was 55.7%, 49.2%, and 32.8%, respectively.
[0000]
TABLE 7
Clinical relevance of DNA methylations in ovarian samples
Clinical status/genes
SOX1
PAX1
LMX1A
Benign (n = 36)
0/36 (0.0)
0/36 (0.0)
0/36 (0.0)
Borderline (n = 6)
0/6 (0.0)
0/36 (0.0)
0/36 (0.0)
Malignancy (n = 122)
68/54 (55.7)
60/122 (49.2)
40/122 (32.8)
Probability
p < 0.0001
p < 0.0001
p < 0.0001
EXAMPLE 7
Methylation Analysis of Genes in Liver Samples
[0091] MS-PCR was performed to analyze the methylation status of the target genes in liver samples. As shown in Table 8, the methylation frequency of SOX1 was significantly greater in abnormal liver samples than in normal liver samples, and the frequency was 7.7%, 33.3%, 27.5%, and 53.7% in normal liver samples, chronic hepatitis, cirrhosis of the liver, and hepatocellular carcinoma (HCC) respectively. Moreover, the methylation frequency of NKX6-1 was significantly greater in hepatocellular carcinoma (HCC) (57%) than in normal liver samples (10%).
[0000]
TABLE 8
Clinical relevance of DNA methylations in liver samples
Clinical status/genes
SOX1
NKX6-1
Normal liver (n = 13)
1/13 (7.7)
1/10 (10)
Chronic Hepatitis (n = 15)
5/15 (33.3)
—
Cirrhosis (n = 40)
11/40 (27.5)
—
HCC (n = 54)
29/54 (53.7)
12/21 (57)
Probability
P = 0.005
P < 0.05
[0092] Many changes and modifications in the above described embodiment of the invention can, of course, be carried out without departing from the scope thereof. Accordingly, to promote the progress in science and the useful arts, the invention is disclosed and is intended to be limited only by the scope of the appended claims. | A method for screening cancer comprises the following steps: (1) providing a test specimen; (2) detecting the methylation state of the CpG sequence in at least one target gene within the genomic DNA of the test specimen, wherein the target genes is consisted of SOX1, PAX1, LMX1A, NKX6-1, WT1 and ONECUT1; and (3) determining whether there is cancer or cancerous pathological change in the specimen based on the presence or absence of the methylation state in the target gene; wherein method for detecting methylation state is methylation-specific PCR (MSP), quantitative methylation-specific PCR (QMSP), bisulfite sequencing (BS), microarrays, mass spectrometer, denaturing high-performance liquid chromatography (DHPLC), and pyrosequencing. | 2 |
TECHNICAL FIELD
[0001] The present invention relates to an electroplating solution, and in particular, to a cyanide-free copper preplating electroplating solution and a preparing method thereof, belonging to the technical field of copper plating of electrochemistry.
BACKGROUND
[0002] A copper-nickel-chrome or copper-nickel-imitation gold or copper-multilayer nickel-chrome plating process is an electroplating combined process that is very widely used. At present, a bottom plating copper layer in these electroplating combined processes is obtained by a cyaniding electroplating process, the copper layer can prevent a replacement reaction, influencing a binding force between the plating and a base material, between a plated workpiece and copper, the plating obtained by a copper preplating electroplating solution containing cyanide is fine and good in binding force, and the electroplating solution is very good in plating uniformity, flatness and stability. However, the cyanide is a highly toxic chemical, its lethal amount for people is only 0.005 g, the cyanide harms the body health of an operator and pollutes the environment, in addition, sewage is hard to dispose, a sewage disposal cost is very high, therefore, in order to protect the environment and reduce public hazards, there is an urgent need to develop a cyanide-free copper preplating electroplating solution.
[0003] Currently, the cyanide-free copper preplating electroplating solution adopts the following several electroplating processes: 1. pyrophosphate copper plating: potassium pyrophosphate is taken as a complexing agent and has better complexing capacity, the stability constant of a complex formed by copper ions and pyrophosphate radicals is K 1 =6.7, K 2 =9.0, the electroplating solution taking the potassium pyrophosphate as the complexing agent is stable in quality, can adopt a wider process range, but has a defect that the electroplating cannot be performed on a steel substrate directly, otherwise replacement occurs on the substrate surface and causes a poor complexing capacity, therefore, the electroplating solution taking the potassium pyrophosphate as the complexing agent has a limited application range; 2. citrate copper plating: citric acid has higher complexing capacity and can generate a very stable substance together with the copper ions in the electroplating solution, the stability constant of a complex formed by the copper ions and the citrate radicals is K 2 =19.30, no replacement phenomenon is generated on the surface of the steel substrate if such process is adopted to plate copper, but the process has the defect that the electroplating solution taking the citric acid as the complexing agent is not stable enough in quality, dispersity of the electroplating solution needs to be improved, and the electroplating solution is deteriorated at high temperature; 3. HEDP copper plating: HEDP is an organic phosphonate, has well complexing capacity, and can form relatively stable substances when reacting with many metals, the electroplating solution taking the HEDP as the complexing agent has stable quality and good dispersity, but the HEDP has the defect that it is found in actual production that the electroplating solution has a process current density range, a plating easily generates copper powder, iron impurities in the electroplating solution reduces a deposition rate and results in a poor binding force between the plating and the substrate, therefore, the electroplating solution taking the HEDP as the complexing agent is not widely used.
SUMMARY
[0004] An objective of the present invention is to solve the defects of prior art and provide a cyanide-free copper preplating electroplating solution.
[0005] Another objective of the present invention is to provide a preparing method of a cyanide-free copper preplating electroplating solution.
[0006] A technical solution adopted by the present invention to solve the technical problems is as follows:
[0007] A cyanide-free copper preplating electroplating solution is prepared from following components in mass percent: 1-60% of complexing agent, 0.5-30% of copper salt and the balance of water, wherein the complexing agent has a general formula M x H y P n O 3n+1 R z , wherein M is any one or more of alkali metal ions and NH4+, R is acyl, the copper salt has a general formula Cu x/2 H y P n O 3n+1 R z , x, n and z are positive integers, y is 0 or a positive integer and x+y+z=n+2.
[0008] The structure of the complexing agent in aforesaid components is explained by plural examples as follows:
[0009] a: when x=1, y=1 and z=n, the complexing agent has a general formula MHP n O 3n+1 R n and a structural formula is as shown in formula (1):
[0000]
[0010] b: when x=n, y=0 and z=2, the complexing agent has a general formula M n P n O 3n+1 R 2 and a structural formula is as shown in formula (2):
[0000]
[0011] c: when x=1, y=n−1 and R=2, the complexing agent has a general formula MH n−1 P n O 3n+1 R 2 and a structural formula is as shown in formula (3):
[0000]
[0012] The cyanide-free copper preplating electroplating solution of the present invention is formed by mixing the complexing agent, copper salt and water, wherein the complexing agent is strong in complexing capacity, a complexing constant for copper ions is up to 10 26-27 and is far superior than that of the common complexing agents in the prior art, the electroplating solution prepared by the complexing agent is greatly improved in stability, the quality of the electroplating solution is high, when the cyanide-free electroplating solution is used for preplating, no replacement reaction occurs between main salt metal ions in the electroplating solution and a metal base material, and no loose replacement structures are generated, therefore, a binding force between an electroplating layer and the metal base material is strong, a plating surface is smooth, and the quality of the electroplating layer is greatly improved.
[0013] Preferably, the electroplating solution is prepared from following components in mass percent: 5-45% of complexing agent, 1-20% of copper salt and the balance of water, wherein the complexing agent has a general formula M x H y P n O 3n+1 R, wherein M is any one or more of Na + , K + and NH4+, R is acyl, the copper salt has a general formula Cu x/2 H y P n O 3n+1 R, x, n are positive integers, y is 0 or a positive integer and x+y=n+1. The proportion of the complexing agent, copper salt and water is reasonable, and the cyanide-free electroplating solution under such proportion condition has the best stability and the best quality.
[0014] The composition of the complexing agent in the preferable technical solution is explained by plural examples as follows:
[0015] d: when y=0 and x=n+1, the complexing agent has a general formula M n+1 P n O 3n+1 R and a structural formula is as shown in formula (4):
[0000]
[0016] e: when y=1 and x=n, the complexing agent has a general formula M n HP n O 3n+1 R and a structural formula is as shown in formula (5):
[0000]
[0017] f: when y=n−1 and x=2, the complexing agent has a general formula M 2 H n−1 P n O 3n+1 R and a structural formula is as shown in formula (6):
[0000]
[0018] A preparing method of a cyanide-free copper preplating electroplating solution comprises:
[0019] (1) preparing a complexing agent: mixing alkali, carbonate or bicarbonate containing M, phosphoric acid and an acidic salt of monoprotic organic acids or polybasic organic acids containing an R group for reacting according to a molar ratio, then carrying one step polymerization on a reaction solution at 100-800° C. for 0.5-10 h to obtain a finished product of the complexing agent; or drying the reaction solution firstly, and then performing polymerization at 100-800° C. for 0.5-10 h to obtain a finished product of the complexing agent;
[0020] (2) preparing a copper salt: uniformly mixing the complexing agent prepared in step (1) with a bivalent copper compound in a water phase system according to a molar ratio, reacting for 0.5-1.0 h at 25-100° C., and centrifuging for separation and drying to obtain the copper salt after the reaction;
[0021] (3) preparing an electroplating solution: dissolving the complexing agent in step (1) in proper amount of water, then dissolving the copper salt in step (2) in the complexing agent water solution in proportion, supplementing the balance of water and uniformly mixing, and then adjusting a pH value to 8.5-9.5 to obtain the cyanide-free copper preplating electroplating solution.
[0022] In the preparing method of a cyanide-free copper preplating electroplating solution of the present invention, the production cost is low, the cost performance of a product is high, the drying manner in step (1) is spray drying or flashing drying, a whole preparing process is environment-friendly, the charging quantity in step (1) and step (2) is accurate, the conversion rate of raw materials is up to 100%, impurities in reacted wastewater are low in content and a sewage disposal cost is low.
[0023] Preferably, when M is Na + , the complexing agent in step (1) is prepared by: mixing sodium hydroxide, sodium carbonate or sodium bicarbonate, phosphoric acid and an acidic salt of monoprotic organic acids or polybasic organic acids containing an R group for reacting according to a molar ratio, then performing one step polymerization on a reaction solution at 200-400° C. for 0.5-10 h to obtain a finished product of the complexing agent; or drying the reaction solution firstly, and then performing polymerization at 200-400° C. for 0.5-10 h to obtain a finished product of the complexing agent.
[0024] Preferably, when M is K + , the complexing agent in step (1) is prepared by: mixing potassium hydroxide, potassium carbonate or potassium bicarbonate, phosphoric acid and an acidic salt of monoprotic organic acids or polybasic organic acids containing an R group for reacting according to a molar ratio, then performing one step polymerization on a reaction solution at 250-800° C. for 0.5-10 h to obtain a finished product of the complexing agent; or drying the reaction solution firstly, and then performing polymerization at 250-800° C. for 0.5-10 h to obtain a finished product of the complexing agent.
[0025] Preferably, when M is NH4+, the complexing agent in step (1) is prepared by: mixing ammonium hydroxide, ammonium carbonate or ammonium bicarbonate, phosphoric acid and an acidic salt of monoprotic organic acids or polybasic organic acids containing an R group for reacting according to a molar ratio, then performing one step polymerization on a reaction solution under 100-300° C. for 0.5-10 h to obtain a finished product of the complexing agent; or drying the reaction solution firstly, and then performing polymerization under 100-300° C. for 0.5-10 h to obtain a finished product of the complexing agent.
[0026] Besides the copper salts listed above, the copper salt in the cyanide-free copper preplating electroplating solution can be directly selected from any one or plural from copper sulfate, copper chloride or basic cupric carbonate, and when such technical solution is adopted, the preparing method of a cyanide-free copper preplating electroplating solution comprises:
[0027] (1) preparing a complexing agent: mixing alkali, carbonate or bicarbonate containing M, phosphoric acid and an acidic salt of monoprotic organic acids or polybasic organic acids containing an R group for reacting according to a molar ratio, then carrying one step polymerization on a reaction solution at 100-800° C. for 0.5-10 h to obtain a finished product of the complexing agent; or drying the reaction solution firstly, and then performing polymerization at 100-800° C. for 0.5-10 h to obtain a finished product of the complexing agent;
[0028] (2) preparing an electroplating solution: dissolving the complexing agent in step (1) in proper amount of water, then dissolving the copper salt in the complexing agent water solution in proportion, supplementing the balance of water, and then adjusting a pH value to 8.5-9.5 to obtain the cyanide-free copper preplating electroplating solution.
[0029] The present invention has the beneficial effects:
[0030] (1) The cyanide-free copper preplating electroplating solution of the present invention is formed by mixing the complexing agent, copper salt and water, wherein the complexing agent is strong in complexing capacity, a complexing constant for copper ions is up to 10 26-27 and is far superior than that of the common complexing agents in the prior art, the electroplating solution prepared by the complexing agent is greatly improved in stability, the quality of the electroplating solution is high, when the cyanide-free electroplating solution is used for preplating, no replacement reaction occurs between main salt metal ions in the electroplating solution and a metal base material, and no loose replacement structures are generated, therefore, a binding force between an electroplating layer and the metal base material is strong, a plating surface is smooth, and the quality of the electroplating layer is greatly improved.
[0031] (2) The cyanide-free copper preplating electroplating solution can be used for electroplating at process temperature from normal temperature to 65° C., the deposition rate of a plating is faster, actual production requirements are met and the electroplating production efficiency is improved.
[0032] (3) The dispersity of the cyanide-free copper preplating electroplating solution of the present invention at higher process temperature and the binding force with the plating are obviously improved, since the components of the electroplating solution are not easily volatilized, the composition of the electroplating solution is stable, a prepared plating is compact and has smooth surface, and the defect of instable quality of the electroplating solution caused by the fact that components of the electroplating solution in the prior art are easily volatilized at higher temperature is avoided.
[0033] (4) The cyanide-free copper preplating electroplating solution of the present invention can be well combined with metal base materials, has no corrosion to the metal base materials, is wide in application range, and especially prevents the corrosion to the metal base materials caused by the electroplating solution in the prior art when applied to multiple metal base materials such as zinc, aluminum, magnesium or alloy thereof.
DESCRIPTION OF EMBODIMENTS
[0034] The technical solution of the present invention is further and specifically explained by specific embodiments.
[0035] Reagents or raw materials in each embodiment are conventional materials purchased from the market, the purity is analytically pure and the percent in each embodiment is mass percent.
Embodiment 1
[0036] A preparing method of a cyanide-free copper preplating electroplating solution comprises the following steps:
[0037] (1) preparing a complexing agent, wherein the complexing agent has a general formula M x H y P n O 3n+1 Rz, wherein x=3, y=0, n=2 and z=1, M is K + , R is acetyl and a specific structural formula is as follows in formula (9):
[0000]
[0038] mixing potassium hydroxide with phosphoric acid and acetic acid for reacting according to a molar ratio of 3:2:1, performing spray drying on the reaction solution to obtain partially polymerized intermediate powder, and placing the intermediate powder in a rake type dryer for polymerization reaction at 250° C. for 10 h to obtain a finished product of the complexing agent after the polymerization reaction is finished;
[0039] (2) preparing a copper salt: uniformly mixing the complexing agent prepared in step (1) with copper sulfate in a water phase system according to a molar ratio of 2:3, reacting for 1 h at 25° C. and centrifuging for separation and drying to obtain the copper salt after the reaction, wherein a structural formula of the copper salt is as follows:
[0000]
[0040] (3) preparing an electroplating solution: dissolving 1.0% of the complexing agent in step (1) in 50% of water, then adding 0.5% of the copper salt in step (2) in the complexing agent water solution, adding 48.5% of water and uniformly mixing, and then adjusting a pH value to 8.5 to obtain the cyanide-free copper preplating electroplating solution.
Embodiment 2
[0041] A preparing method of a cyanide-free copper preplating electroplating solution comprises the following steps:
[0042] (1) preparing a complexing agent, wherein the complexing agent has a general formula M x H y P n O 3n+1 R z , wherein x=3, y=0, n=3 and z=2, M is K + and Na + , R is acetyl and a specific structural formula is as follows:
[0000]
[0043] mixing sodium hydroxide with phosphoric acid and acetic acid for reacting according to a molar ratio of 3:3:2, performing flashing drying on the reaction solution to obtain partially polymerized intermediate powder, and placing the intermediate powder in a rake type dryer for polymerization reaction at 200° C. for 10 h to obtain a finished product of the complexing agent after the polymerization reaction is finished;
[0044] (2) preparing a copper salt: uniformly mixing the complexing agent prepared in step (1) with copper sulfate in a water phase system according to a molar ratio of 2:3, reacting for 0.5 h at 100° C., and centrifuging for separation and drying to obtain the copper salt after the reaction, wherein a structural formula of the copper salt is as follows:
[0000]
[0045] (3) preparing an electroplating solution: dissolving 30.0% of the complexing agent in step (1) in 40% of water, then adding 10% of the copper salt in step (2) in the complexing agent water solution, adding 20.0% of water and uniformly mixing, and then adjusting a pH value to 8.8 to obtain the cyanide-free copper preplating electroplating solution.
Embodiment 3
[0046] A preparing method of a cyanide-free copper preplating electroplating solution comprises the following steps:
[0047] (1) preparing a complexing agent, wherein the complexing agent has a general formula M x H y P n O 3n+ 1R z , wherein x=1, y=100, n=100 and z=1, M is Na + , R is acetyl and a specific structural formula is as follows:
[0000]
[0048] mixing sodium bicarbonate with phosphoric acid and acetic acid for reacting according to a molar ratio of 1:100:1, performing flashing drying on the reaction solution to obtain partially polymerized intermediate powder, and placing the intermediate powder in a rake type dryer for polymerization reaction at 300° C. for 2.5 h to obtain a finished product of the complexing agent after the polymerization reaction is finished;
[0049] (2) preparing a copper salt: uniformly mixing the complexing agent prepared in step (1) with copper sulfate according to a molar ratio of 2:1, reacting for 1.0 h at 25° C., and centrifuging for separation and drying to obtain the copper salt after the reaction, wherein a structural formula of the copper salt is as follows:
[0000]
[0050] (3) preparing an electroplating solution: dissolving 40.0% of the complexing agent in step (1) in 30% of water, then adding 15% of the copper salt in step (2) in the complexing agent water solution, adding 15.0% of water and uniformly mixing, and then adjusting a pH value to 8.7 to obtain the cyanide-free copper preplating electroplating solution.
Embodiment 4
[0051] A preparing method of a cyanide-free copper preplating electroplating solution comprises the following steps:
[0052] (1) preparing a complexing agent, wherein the complexing agent has a general formula M x H y P n O 3n+1 R z , wherein x=1, y=100, n=100 and z=1, M is Na + , R is acylamino formed by dehydrating alanine and a specific structural formula is as follows:
[0000]
[0053] mixing sodium bicarbonate with phosphoric acid and alanine for reacting according to a molar ratio of 1:100:1, performing flashing drying on the reaction solution to obtain partially polymerized intermediate powder, and placing the intermediate powder in a rake type dryer for polymerization reaction at 300° C. for 2.5 h to obtain a finished product of the complexing agent after the polymerization reaction is finished;
[0054] (2) preparing a copper salt: uniformly mixing the complexing agent prepared in step (1) with copper sulfate according to a molar ratio of 2:1, reacting for 1.0 h at 25° C., and centrifuging for separation and drying to obtain the copper salt after the reaction, wherein a structural formula of the copper salt is as follows:
[0000]
[0055] (3) preparing an electroplating solution: dissolving 60.0% of the complexing agent in step (1) in 20% of water, then adding 10% of the copper salt in step (2) in the complexing agent water solution, adding 10.0% of water and uniformly mixing, and then adjusting a pH value to 8.5 to obtain the cyanide-free copper preplating electroplating solution.
Embodiment 5
[0056] A preparing method of a cyanide-free copper preplating electroplating solution comprises the following steps:
[0057] (1) preparing a complexing agent, wherein the complexing agent has a general formula M x H y P n O 3n+1 R z , wherein x=3, y=0, n=2 and z=1, M is Na + , R is methyl formed by dehydrating methyl orthophosphoric acid and a specific structural formula is as follows:
[0000]
[0058] mixing sodium hydroxide with phosphoric acid and methyl orthophosphoric acid for reacting according to a molar ratio of 3:2:1, performing flashing drying on the reaction solution to obtain partially polymerized intermediate powder, and placing the intermediate powder in a rake type dryer for polymerization reaction at 300° C. for 5 h to obtain a finished product of the complexing agent after the polymerization reaction is finished;
[0059] (2) preparing a copper salt: uniformly mixing the complexing agent prepared in step (1) with copper sulfate according to a molar ratio of 2:3, reacting for 1.0 h at normal temperature, and centrifuging for separation and drying to obtain the copper salt after the reaction, wherein a structural formula of the copper salt is as follows:
[0000]
[0060] (3) preparing an electroplating solution: dissolving 40.0% of the complexing agent in step (1) in 20% of water, then adding 20% of the copper salt in step (2) in the complexing agent water solution, adding 20.0% of water and uniformly mixing, and then adjusting a pH value to 9.5 to obtain the cyanide-free copper preplating electroplating solution.
[0061] In the preparing method of a cyanide-free copper preplating electroplating solution, besides the complexing agents in embodiments 1-5, complexing agents in embodiments 6 and 7 can also be used, the complexing agents prepared in embodiments 6 and 7 react with copper sulfate or copper chloride respectively according to a certain molar ratio to generate a copper salt, which is then uniformly mixed with the complexing agent and water in proportion, and a pH value is adjusted to 8.5-9.5 to obtain the electroplating solution of the present invention.
Embodiment 6
[0062] A complexing agent has a general formula M x H y P n O 3n+1 R z , wherein x=5, y=0, n=5 and z=2, M is Na + , R is acyl formed by dehydrating acetyl and sodium bitartrate and a specific structural formula is as follows:
[0000]
[0063] A preparing method of the complexing agent comprises: mixing sodium bicarbonate, phosphoric acid, acetic acid and sodium bitartrate for reacting according to a molar ratio of 5:5:1:1, then performing flashing drying on the reaction solution to obtain partially polymerized intermediate powder, and placing the intermediate powder in a rake type dryer for polymerization reaction at 400° C. for 0.5 h to obtain a finished product of the complexing agent after the polymerization reaction is finished.
Embodiment 7
[0064] A complexing agent has a general formula M x H y P n O 3n+1 R z , wherein x=10, y=1, n=10 and z=1, M is K + and Na + , R is acyl formed by dehydrating sodium bitartrate and a specific structural formula is as follows:
[0000]
[0065] A preparing method of the complexing agent comprises: mixing sodium hydroxide, potassium hydroxide, phosphoric acid and sodium bitartrate for reacting according to a molar ratio of 1:9:10:1, then performing spray drying on the reaction solution to obtain partially polymerized intermediate powder, and placing the intermediate powder in a rake type dryer for polymerization reaction at 800° C. for 0.5 h to obtain a finished product of the complexing agent after the polymerization reaction is finished.
Embodiment 8
[0066] A complexing agent has a general formula M x H y P n O 3n+1 R z , wherein x=10, y=1, n=10 and z=1, M is Na + , R is acyl formed by dehydrating disodium hydrogen citrate and a specific structural formula is as follows:
[0000]
[0067] A preparing method of the complexing agent comprises: mixing sodium carbonate, phosphoric acid and disodium hydrogen citrate for reacting according to a molar ratio of 5:10:1, then performing flashing drying on the reaction solution to obtain partially polymerized intermediate powder, and placing the intermediate powder in a rake type dryer for polymerization reaction at 400° C. for 0.5 h to obtain a finished product of the complexing agent after the polymerization reaction is finished.
[0068] The electroplating solutions prepared in embodiments 1-5 are researched as follows.
[0069] 1. Hull cell test (267 ml)
[0070] 1.1 Preliminary test: the electronic solutions prepared in embodiments 1-5 are used for sheet plating under the conditions of 25° C., current 1 A (stable) and air stirring for 5 min, and characteristics of relatively stable cell voltage and semi light spots and fine crystal on a large area of the plated sheet are observed under the conditions of stable current in the sheet plating process.
[0071] 1.2 Current density ranged determined by the Hull cell test
[0072] The electronic solutions prepared in embodiments 1-5 are used for sheet plating through Hull under the conditions of 55° C. and current 1 A for 10 min to determine an optimal current density range, and the sheet for sheet plating is a 0.5*70*100 A3 steel sheet, which is sanded and polished with 600# waterproof abrasive paper. A current density of each spot is calculated by referring to an empirical formula J k =45.1-5.24 LgL). It can be obtained by sheet plating and calculating the current density that a current density range of the electroplating solutions prepared in embodiments 1-5 is between 0.5 A/dm 2 and 2.5 A/dm 2 .
[0073] 2. Electroplating solution and electroplating performance test
[0074] 2.1 Determining of current efficiency: a copper coulombmeter is adopted to measure, the current efficiency of the electroplating solution prepared in embodiment 1 is 93.0%, the current efficiency of the electroplating solution prepared in embodiment 2 is 92.8%, the current efficiency of the electroplating solution prepared in embodiment 3 is 93.1%, the current efficiency of the electroplating solution prepared in embodiment 4 is 93.8%, and the current efficiency of the electroplating solution prepared in embodiment 5 is 93.4%.
[0075] 2.2 Electroplating solution dispersity determining:
[0076] A curved cathode method is used to determine the dispersity of the electroplating solution under the conditions of current 1 A, oil-free air stirring and 55° C. for 30 min, a test material adopts a 0.5*70*100 A3 copper sheet, which is sanded and polished with 600# waterproof abrasive paper.
[0077] Through determining, the dispersity of the electroplating solution in embodiment 1 is 93.5%, the dispersity of the electroplating solution in embodiment 2 is 92.5%, the dispersity of the electroplating solution in embodiment 3 is 93.3%, the dispersity of the electroplating solution in embodiment 4 is 93.1%, and the dispersity of the electroplating solution in embodiment 5 is 93.3%.
[0078] 2.3 Determining of covering capacity
[0079] An inner hole method is adopted to measure the covering capacity of the electroplating solution, a copper pipe has a size of 10 mm*100 mm, a through hole and blind hole method is adopted, the electroplating solution is at 55° C., a cathode current density is 0.5 A/dm 2 , and time is 5 min. The iron pipe is sectioned to observe a plating condition in the pipe.
[0080] The electroplating solutions in embodiments 1-5 are used as test electroplating solutions, after the test, it is found that through holes and blind holes are plated with a copper layer, which indicates that the covering capacity of the electroplating solutions prepared in embodiments 1-5 is good.
[0081] 2.4 Binding force test
[0082] 2.4.1 Bending test: a polished iron sheet (A3) which is 0.5 mm thick is adopted, the electroplating solution is at 55° C., a cathode current density is 2 A/dm 2 , and time is 15 min.
[0083] The electroplating solutions in embodiments 1-5 are used as test electroplating solutions, after the test, the plated test sheet is repeatedly bent till breakage, no peeling phenomenon exists at the cracks, proving that the plating and a substrate are basically not separated. 2.4.2 Thermal shock test: a polished iron sheet (A3) which is 0.5 mm thick is adopted, the electroplating solution is at 55° C., a cathode current density is 2 A/dm 2 , and time is 15 min.
[0084] The electroplating solutions in embodiments 1-5 are used as test electroplating solutions, after the test, the plated test sheet is placed in an oven till 200° C., is continuously baked for 1 h, and is immediately immersed in 0° C. water for shock chilling, and a result is that the plating has no blistering and peeling phenomena.
[0085] 2.5 Plating tenacity test: an A3 steel sheet which is 0.1 mm thick is passivated with lead acid, and is directly hung in the electroplating solutions prepared in embodiments 1-5 after cleaning, the plating is peeled after the thickness of the plating is 20 μm and is bent for 180 degrees, the bent part is extruded, and the plating is not broken which indicates that the plating is good in tenacity.
[0086] 2.6 Plating porosity test: a polished iron sheet (A3) which is 0.5 mm thick is adopted, the electroplating solution is 55° C., a cathode current density is 1 A/dm 2 , time is 20 min, and the porosity test is performed by adopting an experiment method of attaching a potassium ferricyanide solution to filter paper.
[0087] Potassium ferricyanide is 10 g/1; sodium chloride is 20 g/1.
[0088] A test result shows that the porosity of the plating formed by taking the electroplating solutions in embodiments 1-5 as test objects is smaller than or equal to 1/dm 2 .
[0089] 2.7 Deposition rate determining: current is set to be 1 A, temperature is 55° C., and time is 30 min; a determining result shows that the deposition rate of the electroplating solution prepared in embodiment 1 is 0.6 μm/min, the deposition rate of the electroplating solution prepared in embodiment 2 is 0.62 μm/min, the deposition rate of the electroplating solution prepared in embodiment 3 is 0.56 μm/min, the deposition rate of the electroplating solution prepared in embodiment 4 is 0.52 μm/min, and the deposition rate of the electroplating solution prepared in embodiment 5 is 0.55 μm/min.
[0090] The electroplating solutions prepared in embodiments 1-5 are subjected to a pilot test further, wherein pilot test parameters are as follows:
[0091] Process flow: steel workpiece, ultrasonic deoiling, water washing 1, water washing 2, anode electrolysis deoiling, water washing 1, water washing 2, pickling deoiling, water washing 1, water washing 2, hydrochloric acid washing, water washing 1, water washing 2, terminal electrolysis deoiling, water washing 1, water washing 2, acid activating, water washing 1, water washing 2, electroplating solution in embodiments 1-5, recycling, water washing 1, water washing 2, acid activating and copper acidizing.
[0092] Ultrasonic deoiling: concentration of deoiling powder is 50±5 g/L, temperature is 70±5° C., current density is 1-5 A/dm 2 and time is 5 min.
[0093] Cathode electrolysis deoiling: concentration of electrolysis deoiling powder is 50±5 g/L, temperature is 70±5° C., current density is 1-5 A/dm 2 and time is 5-7 min.
[0094] Anode electrolysis deoiling: concentration of electrolysis deoiling powder is 50±5 g/L, temperature is 70±5° C., current density is 1-5 A/dm 2 and time is 3-5 min.
[0095] Pickling: concentration of technical hydrochloric acid is 15-20%, time is 8-10 min and temperature is room temperature.
[0096] Activating: concentration of technical hydrochloric acid is 5-10%, time is 3-5 min and temperature is room temperature.
[0097] The electroplating solution in embodiments 1-5: a baume degree is 32-36, a pH value is 8.5-9.5, temperature is 50-55° C., a current density is 0.5-2.5 A/dm 2 , time is 5 min to several hours, and practice proves that the flatness and brightness are still very good till plating to 100 μm.
[0098] Through continuous operation of a 50 L pilot test electroplating production line for 20 months and continuous operation of a 350 L pilot test electroplating production line for 11 months, it is proved that the electroplating solution prepared in embodiments 1-5 has reliability, is stable in performance, and has consumption of 10-50 ml/KAH.
[0099] Based on the pilot test, process conditions of the electroplating solution prepared in embodiments 1-5 for industrial production are obtained.
[0100] 1. Steel workpiece:
[0101] Process flow: steel workpiece, ultrasonic deoiling, water washing 1, water washing 2, anode electrolysis deoiling, water washing 1, water washing 2, pickling deoiling, water washing 1, water washing 2, hydrochloric acid washing, water washing 1, water washing 2, terminal electrolysis deoiling, water washing 1, water washing 2, acid activating, water washing 1, water washing 2, presoaking, electroplating solution in embodiments 1-5, recycling, water washing 1, water washing 2, acid activating and copper acidizing.
[0102] Process conditions:
[0103] Electroplating solution density: 32-36 baume degrees
[0104] Temperature: 45-65° C.
[0105] pH value: 8.60-9.50
[0106] Stirring: air stirring plus cathode moving
[0107] Anode: electrolysis copper or anaerobic electrolysis copper
[0108] Ratio of a cathode area to an anode area: 1:1.5-2
[0109] Current: 0.5-2.5 A/dm 2
[0110] 2. Zinc alloy workpiece:
[0111] Process flow: zinc alloy workpiece, hot dipping dewaxing, ultrasonic dewaxing, water washing 1, water washing 2, ultrasonic deoiling, water washing 1, water washing 2, anode electrolysis deoiling, water washing 1, water washing 2, hydrochloric acid activating, water washing 1, water washing 2, presoaking in ultrasonic presoaking solution for 30 s, electroplating solution in embodiments 1-5 (placing in a cell in an electrified state at 25-35° C.), recycling, water washing 1, water washing 2, acid activating and copper acidizing.
[0112] Process conditions:
[0113] Electroplating solution density: 32-38 baume degrees
[0114] Temperature: 25-35° C.
[0115] pH value: 8.60-9.50
[0116] Stirring: air stirring plus cathode moving
[0117] Anode: electrolysis copper or anaerobic electrolysis copper
[0118] Ratio of a cathode area to an anode area: 1:1.5-2
[0119] Current: 0.5-1.5 A/dm 2
[0120] Aforesaid embodiments are merely preferably solutions of the present invention instead of limiting the present invention in any form, and other variants and modifications can be realized under the premise of not changing the technical solution recorded in claims. | The present invention relates to a cyanide-free copper-preplating electroplating solution, wherein the electroplating solution is prepared from following components in mass percent: 1-60% of complexing agent, 0.5-30% of copper salt and the balance of water, wherein the complexing agent has a general formula M x H y P n O 3n+1 R z , wherein M is any one or more of alkali metal ions and NH4+, R is acyl, the copper salt has a general formula Cu x/2 H y P n O 3n+1 R z , x, n and z are positive integers, y is 0 or a positive integer and x+y+z=n+2. A preparing method comprises: (1) preparing a complexing agent: mixing alkali, carbonate or bicarbonate containing M, phosphoric acid and an acidic salt of monoprotic organic acids or polybasic organic acids containing an R group for reacting according to a molar ratio, then carrying one step polymerization on a reaction solution at 100-800° C. for 0.5-10h to obtain a finished product of the complexing agent; (2) preparing a copper salt: uniformly mixing the complexing agent prepared in step (1) with a bivalent copper compound in a water phase system according to a molar ratio, reacting for 0.5-1.0h at 25-100° C., and centrifuging for separation and drying to obtain the copper salt after the reaction; (3) preparing an electroplating solution: uniformly and proportionally mixing respective components to obtain the electroplating solution. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for preparing large oxide single crystalline materials useful as a “RE123 oxide superconductor” or “LiNdO 3 oxide laser transmitting element”, respectively.
2. Description of the Related Art
Recently, there has been remarkably developed a new technology utilizing specific properties of oxide crystalline materials and, for example, crystalline materials of RE123 oxides (wherein RE represents one or more rare earth elements) and LiNdO 3 crystalline materials play an important part as a high temperature superconductive material and a laser transmitting element, respectively.
The “Solidification process” has been conventionally known as a general procedure to yield oxide crystalline materials used for the above mentioned purpose, in which a molten material, i.e., crystalline precursor material, is cooled at a slow speed from a temperature around the melting point to promote solidification and crystal growth.
In such a conventional process as described above, however, it takes a long period of time to yield the desired crystals, which is practically disadvantageous.
In order to improve the conventional disadvantage by reducing the time period of crystal growth, the “supercooling (undercooling) solidification process” has been proposed as a novel crystal growing method.
The supercooling solidification process is a single crystal growing method utilizing such characteristics that “when a molten or semi-molten liquid of an oxide crystal precursor is supercooled, i.e., kept in a supercooled condition at a temperature below the melting point, the crystal growth rate is remarkably accelerated”. Several methods for preparing Y-oxide superconductive crystals based on the above mentioned supercooling method have been described in, for example, JP-A No. 6-211,588; Journal of Materials Research, Vol. 11, No. 4, pp. 795-803, April 1996; and ibid., Vol. 11, No. 5, pp. 1114-1119, May 1996.
According to the above mentioned references including JP-A No. 6-211,588, the most characteristic feature is that “A Y-oxide superconductor precursor material, which has been added with a seed crystal as nuclei for crystal growth followed by raising the temperature above the peritectic temperature or raising the temperature above the peritectic temperature followed by addition of the seed crystal, is subjected to supercooling (undercooling) by cooling it under the peritectic temperature and further cooling it continuously but slowly, for example at a cooling rate of 1° C./ hr. or isothermally keeping it at the supercooled temperature to grow Y-oxide superconductor crystals, the oxides never solidify at once completely when they are supercooled, which is distinct from pure metals”. On the other hand, the “supercooling solidification process” is a method for growing crystals in which a molten precursor material is supercooled to a temperature region below the melting point in a molten or semi-molten state and then slowly cooled, usually at a cooling rate of 1 to 10° C./hr., or kept at the supercooled temperature, and the existence of the above mentioned “seed crystal” is not necessarily essential to the process. That is, such a process is employed for a purpose to increase the crystal growth rate.
FIG. 1 shows a relationship between the crystal growth rate of Sm123 and the degree of supercooling. It is apparent from FIG. 1 that the crystal grow rate increases as an increase in the degree of supercooling.
The inventors have investigated the preparation of larger oxide single crystals from various viewpoints and come to a conclusion that the supercooling solidification process has a limit in the preparation of large single crystals and is not sufficient to yield homogeneous large single crystals with less defects.
As evident from FIG. 1, the crystal growth rate increases as an increase in the degree of supercooling, resulting in it being possible to prepare large crystals in a short time.
However, as evident from the relationship between supercooling degree and frequency of nucleation in FIG. 2, the nucleation increases rapidly relative to an increase in the degree of supercooling.
The increase in the frequency of nucleation inhibits the preparation of large single crystals (for example, crystals grown from seed crystals), resulting in a limitation of the size of single crystals.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a method for easily preparing large and perfect oxide single crystals without consuming a longer time.
To accomplish this and further objects of the present invention, the inventors have keenly investigated and finally obtained novel information in which, when a highly heated oxide crystal precursor material is supercooled below the melting point and then subjected to continuous slow heating within the supercooling region to grow crystals, nucleation which hinders single crystal particles from growing is controlled, while keeping a high crystal growth rate, so that large single crystals can be grown without consuming a longer period of time.
The present invention has been achieved on the basis of the above mentioned information and provides a method for preparing a large oxide single crystalline material as in the following.
1. A method for preparing a large oxide single crystalline material, characterized in that a crystal precursor material is supercooled prior to the solidification thereof in the course of the crystal growth of an oxide by a supercooling solidification process, followed by subjecting said precursor material to continuous slow heating while keeping the supercooled condition to promote crystal growth.
2. A method for preparing a large RE123 oxide superconductive single crystalline material, wherein RE is one or more rare earth elements in which Y is not excluded, characterized in that a RE123 oxide superconductive crystalline precursor material added with seed crystals is supercooled below its peritectic temperature prior to the solidification thereof in the course of crystal growth of the RE123 oxide superconductive crystal, followed by subjecting said precursor material to continuous slow heating while keeping the supercooled condition to promote crystal growth.
Oxide crystals prepared by the present invention are not limited to a specific oxide but may cover any material including the above mentioned LiNdO 3 oxide crystal used as a laser transmitting element. Especially, an excellent practical effect is exhibited when the present invention is applied to prepare RE123 oxide superconductive single crystalline materials in which the growth of large crystals has been difficult.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing a relationship between crystal growth rate of Sm123 oxide and supercooling degree;
FIG. 2 is a graph showing a relationship between supercooling degree and frequency of nucleation;
FIG. 3 illustrates an example of a means of introducing a nucleating source into an oxide crystalline material;
FIG. 4 illustrates another example of a means for introducing a nucleating source into an oxide crystalline material;
FIG. 5 illustrates still another example of a means for introducing a nucleating source into an oxide crystalline material;
FIG. 6 illustrates a further example of a means for introducing a nucleating source into an oxide crystalline material;
FIG. 7 is a heat treatment hysteresis curve of a material used in an example;
FIGS. 8A and 8B are an Sm123 single crystal prepared by the above mentioned example;
FIG. 9 is a heat treatment hysteresis curve of a material used in a comparative example; and
FIGS. 10A and 10B are an Sm123 single crystal prepared by the above mentioned comparative example.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will be described with respect to the functions thereof.
As shown in FIG. 1, the crystal growth rate increases with an increase in the supercooling degree when an oxide crystal is grown by a supercooling solidification process. As a result, it is possible to remarkably reduce the time period required to grow an oxide crystal according to the supercooling solidification process.
When the supercooled degree increases, however, the frequency of nucleation in a molten or semi-molten material is enhanced extraordinarily, thereby the growth of a single crystal being inhibited by crystals grown from nuclei.
FIG. 2 shows a relationship between the supercooled degree and the frequency of nucleation. It is apparent from FIG. 2 that the frequency of nucleation increases exponentially with an increase in the supercooled degree. That is, conversely speaking, the frequency of nucleation decreases drastically with a decrease in the supercooled degree, which is achieved by slowly heating a condition of higher supercooled degree.
It is clear from FIGS. 1 and 2 that nucleation from a crystal precursor material prior to solidification can be drastically reduced, while a decrease in crystal growth rate is controlled to a low level when a crystal precursor material is supercooled prior to the solidification thereof in the course of crystal growth by a supercooling solidification process, followed by subjecting the precursor material to slow heating to gradually reduce the supercooled degree without further slowly cooling from a supercooled temperature thus obtained or isothermally keeping this temperature as in a conventional manner.
The crystal growth rate increases with an increase in the supercooling degree while the frequency of nucleation increases exponentially with an increase in the supercooled degree. On the contrary, in the case where the supercooled degree is reduced by slow heating, the reduction of the crystal growth rate is small relative to the reduction of the frequency of nucleation.
That is, an application of slow heating while keeping a supercooled condition makes it possible to decrease the supercooled degree so as to remarkably reduce the nucleation caused by an intentional nucleating source such as seed crystals and, at the same time, to control such intentional crystal growth rate so as to keep the growth rate at a high level and to prepare perfect and large oxide single crystals within a relatively short period of time.
Accordingly, nucleation other than at an intentional site such as seed crystals can be inhibited so that crystals grown from seed crystals can be large-sized.
As shown in FIGS. 1 and 2, the effect of changes in supercooled degree is gentle on the crystal grow rate and expressed as a unit of length (mm/sec). On the other hand, such an effect is extreme on the frequency of nucleation and expressed as “numbers of produced nuclei/mm 3 ·sec”, i.e., the size of the sample being exclusively defined by a time period regardless of either rapid or slow growth rate, and, in addition, nucleation occurs almost in a moment as shown in FIG. 2 . It is the most characteristic feature of the present invention to make use of this difference so as to promote effective crystal growth while keeping “a supercooled region of lower degree” where nucleation does not occur.
As the crystal growth rate of oxides is slower than that of metals and other materials, control of supercooling in the supercooled region is comparatively easy. Accordingly, it is possible to produce a temperature gradient through slow heating without missing the supercooled region while controlling external heat.
Such slow heating while keeping a supercooled condition, for example, at a heating rate of about several ° C. per 100 hours, does not cause an industrial problem.
A source of nuclei which is intentionally introduced into a crystal precursor material to grow single crystals in the present invention includes well known “seed crystals” and may also be prepared as in the following:
(1) One end of a satisfactorily heat-resistant and heat-conductive metal wire 2 such as Pt, Rh, etc., in a cooled condition, is brought into contact with a nucleating position of an oxide crystal precursor material 1 which has been molten or semi-molten by high temperature heating as shown in FIG. 3, the material in a molten condition being kept in a crucible;
(2) A fine oxide tube 3 is put close to a nucleating position of an oxides crystal precursor material 1 which has been molten or semi-molten by high temperature heating, while blowing cooled air through the tube 3 to partially cool the material 1 as shown in FIG. 4; and
(3) An acute cavity or cut is formed at a nucleating position on a molten or semi-molten crystal precursor material 1 which shape can be kept from deformation by means of an acute drill-like tool 4 as shown in FIG. 5 or a sharp knife-like blade 5 as shown in FIG. 6, respectively.
For preparation of a RE123 superconductive single crystalline material according to the present invention, it is possible to yield a single crystalline material of about 40 mm in diameter, which is nearly two times the size of a conventional one. The conventional “supercooling solidification process” yields a single crystalline product of at most 20 mm or so in diameter.
Further, when oxide superconductors of a higher Tc (critical temperature), such as those of Nd (16) or Sm (14) types are prepared by the conventional “supercooling molten solidification process” in which crystal growth proceeds under a slow cooling condition in a supercooled region, Nd or Sm and Ba replaced each other in the course of crystal growth, thereby causing an inconvenient change in composition between starting and terminal portions of the crystals. According to the method of the present invention, however, large RE123 oxide superconductive crystals can be stably grown without causing such an inconvenience.
Although the present invention will be further described by a specific example together with a comparative example, it should be understand that the spirit and scope thereof is not limited by such examples.
EXAMPLE
Starting powders of Sm 2 O 3 , BaCO 3 and CuO were prepared, weighed and mixed to form a composition “SmBa 2 Cu 3 O 7-d +40 mol % Sm 2 BaCuO 5 ”. The thus obtained mixture was then calcined to form a calcined disk material of 40 mm in diameter and 20 mm in height.
The calcined disk material was then put on a magnesia single crystal plate and placed in a soaking zone a of heating oven to form a semi-molten material by raising the temperature up to 1150° C. in the atmosphere, followed by maintaining such a condition for 30 minutes.
The semi-molten material was then cooled to 1,080° C., i.e., around the “peritectic temperature (about 1,065 to 1,070° C.) of Sm123 crystal (SmBa 2 CU 3 O 7-d single crystal)” within 10 minutes, kept at this temperature for one hour to render the material as a whole isothermal, followed by seeding a Nd123 single crystal (Nd Ba 2 Cu 3 O 7-d single crystal), which was immediately quenched to 1,055° C. to subject it to supercooling.
Further, the semi-molten material was slowly heated for 100 hours up to 1,065° C. at a heating rate of 0.1° C./hr. to yield a large single crystal of Sm123 grown from the seed crystal (Nd 123 single crystal). The oven was cooled to room temperature after the material was slow-heated for 100 hours.
FIG. 7 shows a heat treatment hysteresis of the material starting from calcination to completion of oven cooling after crystal growth. FIG. 8 shows the appearance of a Sm123 single crystal thus obtained, in which FIG. 8 ( a ) is a visual photograph of the crystal and FIG. 8 ( b ) is an illustration thereof.
It is confirmed from FIG. 8 that a large Sm123 single crystal of about 35 mm in diameter can be prepared by the above mentioned example according to the present invention.
The thus obtained Sm123 single crystal shows a critical temperature of 90 K or more as superconductive properties.
COMPARATIVE EXAMPLE
A calcined disk material having a composition “SmBa 2 Cu 3 O 7-d +40 mol % Sm 2 BaCuO 5 “ prepared under a similar condition as that of the Example was subjected to heating, cooling and seeding, and immediately followed by supercooling while quenching to 1.060° C.
The thus obtained semi-molten material was kept at an isothermal temperature of 1.060° C. for 72 hours to allow a crystal to grow and then cooled to room temperature by cooling the oven.
FIG. 9 shows a heat treatment hysteresis of the material starting from calcination to completion of oven cooling after crystal growth.
FIG. 10 shows the appearance of a Sm123 single crystal thus obtained, in which FIG. 10 ( a ) is a visual photograph of the crystal and FIG. 10 ( b ) is an illustration thereof.
It is confirmed from FIG. 10 that, according to the conventional “supercooling molten solidification process”, crystal growth from a seed crystal is remarkably inhibited by crystals which have grown by nucleation other than at the seed crystal, and the size of Sm123 single crystal grown from the seed crystal is as large as at most about 20 mm in diameter.
As has been described above, according to the present invention, it is possible to prepare large and perfect oxide single crystals at an improved productivity without using complicated and expensive equipment, which greatly heightens industrial effects including, for example, contribution to cheep production of oxide superconductors of high quality. | There is provided a method for preparing a large and perfect oxide crystal useful for oxide superconductors and laser transmitting elements. In the present method for preparing a large oxide single crystalline material such as superconductive crystals of RE123, a crystal precursor material is supercooled prior to the solidification thereof in the course of crystal growth of the oxide by a supercooling solidification process, followed by subjecting said precursor material to continuous slow heating while keeping the supercooled condition to promote crystal growth, as shown in FIG. 7. Seed crystals may be added to the crystal precursor material prior to solidification, if necessary, as also shown in FIG. 7. | 2 |
FIELD OF THE INVENTION AND BACKGROUND
[0001] This invention relates in general to respiratory care and therapy, and, in particular, to the controlled delivery of heated and/or humidified respiratory gases to a user being so cared for or treated. More particularly, this invention relates to controlling the temperature of the gas or gases used for such care or treatment at the point of the delivery of such gas or gases to the user.
[0002] In the administration of heated and/or humidified gas or gases to a user or patient, especially those considered as requiring neonatal care, such as premature infants and some pediatric patients, it is desirable to closely control and monitor the temperature at which the gas or gases are delivered. Such gases may be oxygen, heliox, nitrogen, or combinations thereof, as well as other gases known to those healthcare providers or clinicians providing such services. For convenience of illustration the term “gas” will be used hereinafter, but it is to be understood that such term includes a single gas as well as a combination of gases used in respiratory care and therapy by a user or patient. Also, for purposes of convenience, the term user or patient will be referred to hereinafter as “patient”.
[0003] Respiratory gas delivered to, for example, neonate patients is preferably delivered at a low flow rate, between about 1 and about 15 liters per minute. When heated gas flows through a delivery conduit at such low flow rates, the temperature of the gas will decrease in transit to the patient delivery point, resulting in a lower temperature gas being applied to the patient and condensate being formed in the gas delivery conduit. The lower temperature gas can cause irritation of the nares and other discomforts to the patient, as well as reducing the core temperature of the patient. In addition, the accumulation of condensate can result in the gas propelling a bolus of condensate into the patient's respiratory system causing coughing or choking. Accordingly, it is highly desirable that the temperature of the respiratory gas being delivered to the patient be controlled at the very point where the gas is being delivered to the patient, to insure that the desired gas temperature is being applied to the patient with the desired humidification level. Such controlled delivery will increase the patient's comfort level, and reduce the amount of condensate heretofore occurring in available heated-gas delivery systems.
SUMMARY
[0004] The above and other needs are met by a low flow heated/humidified respiratory gas delivery system, especially useful for low flow rates as preferred in the treatment of neonate and other such patients, wherein the respiratory gas is heated and humidified as desired for delivery to the patient and the temperature is monitored at the point of delivery to the patient. In this manner, the gas temperature can be controlled so that the temperature of the gas being applied to the patient is accurately maintained, and the formation of condensate in the delivery conduit is minimized to reduce accumulation. Patients are believed to be much more tolerable of such a treatment, and less likely to be disengaged therefrom. Fewer adverse reactions, such as abrasions, are believed to be incurred, and the patient can still be fed or can eat without necessitating the removal or disconnecting of the gas delivery system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Further advantages of the invention are apparent by reference to the detailed description when considered in conjunction with the drawing figures, which are not to scale so as to more clearly show the details, wherein like reference numbers indicate like elements throughout the several views, and wherein:
[0006] FIG. 1 is an illustration of the delivery system wherein a delivery tube or conduit is coupled with a suitable heater to deliver heated/humidified gas to a patient through a nose cannula;
[0007] FIG. 2 is an enlarged partial sectional view of a portion of the delivery tube or conduit through which heated/humidified gas is delivered to the nose cannula to illustrate the manner in which the respiratory gas is heated;
[0008] FIG. 3 is an exploded illustration of a portion of the delivery tube or conduit through which heated/humidified gas is delivered to the nose cannula for application to the patient;
[0009] FIG. 4 is an exploded illustration of another portion of the delivery tube or conduit through which the temperature of the heated/humidified gas is monitored at the point of delivery to the patient;
[0010] FIG. 5 is an enlarged illustration of a portion of the delivery tube or conduit illustrated in FIGS. 3 and 4 in an embodiment in which the nose cannula is formed with a partition which separates the input of respiratory gas to the patient from the sensing of the gas temperature for controlling the operation of the heater to better illustrate the monitoring of the temperature of the gas as it is being applied to the patient, and the path of the air flow; and
[0011] FIG. 6 is an enlarged illustration of a portion of the delivery tube or conduit illustrated in FIGS. 3 and 4 in an embodiment in which the nose cannula is formed without a partition which separates the input of respiratory gas to the patient from the sensing of the gas temperature for controlling the operation of the heater to better illustrate the monitoring of the temperature of the gas as it is being applied to the patient, and the path of the air flow.
DETAILED DESCRIPTION
[0012] Referring now to FIG. 1 , there is illustrated a respiratory gas delivery system 100 wherein a source of suitable respiratory gas (not shown) is coupled to a connector 8 and passes through a conduit 9 for connection to a humidification chamber which may be, for example, a reusable or a single-patient-use humidification or nebulizing chamber 10 through an inlet coupling 11 . As is known to those skilled in the art, the respiratory gas may nebulize a liquid, or a liquid with medicant, contained in the chamber 10 , or the respiratory gas may be bubbled through the liquid if desired, and the heated gas passed from the chamber 10 with, or without, a vapor mist as prescribed by a healthcare provider or clinician. The temperature of the respiratory gas passing from the chamber 10 is heated by means of a heater 15 , such as the heater disclosed in U.S. Pat. No. 6,988,497 assigned to Smiths Medical ASD, Inc. of Rockland, Mass.
[0013] The heated gas is passed out from the chamber 10 through an outlet connector 12 and passes through a standard flexible delivery tube or conduit 20 , for delivery to a patient through a nose cannula 50 . As illustrated in FIG. 2 , the delivery tube or conduit 20 may be of the type disclosed in Anthony V. Beran, et al, U.S. Pat. No. 6,167,883, “MEDICAL AIR-HOSE INTERNAL FLOW HEATER” assigned to the assignee of the present invention and the disclosure of which is incorporated herein by reference. As illustrated therein, a flexible ribbon 34 spans the width of a first portion 20 a of the flexible tube 20 , and carries therein a heating element 42 , preferably an electrically conductive wire or plurality of wires connected to a power supply in order to heat the flow of gas traveling within this portion of the delivery tube 20 a . While there is illustrated a heater wire 42 carried within the tube 20 by a flexible ribbon 34 , the wire 42 may be positioned within the tube 20 without being supported by a flexible ribbon such as, for example, by being coiled along the interior of the tube 20 .
[0014] As better illustrated in FIG. 4 , the distal portion 42 a of the heating element 42 terminates at the entrance into the nose cannula 50 , at the point at which the heated gas is applied or administered essentially directly to the patient. In this manner, the respiratory gas is heated all the way through the first portion 20 a of the flexible tube 20 so that the slow rate of flow of the respiratory gas will not cool the gas below the desired temperature, but is applied directly to the patient at the clinician prescribed temperature level. Maintaining the respiratory gas heated to the prescribed temperature level at the point of delivery to the patient, will thereby minimize the occurrence of condensate formation.
[0015] The temperature of the respiratory gas being delivered to the nose cannula 50 through the flexible tube 20 , is controlled by a sensor 60 , preferably a thermister, which is carried within a second portion 20 b of the flexible tube 20 extending from an input 13 from the heater 15 to a position within the nose cannula 50 directly adjacent to the point at which the respiratory gas is applied or administered, 56 , essentially directly to the patient, as best illustrated in FIGS. 5 and 6 . The positioning of the sensor in this position, in the nose cannula, will give direct feedback to the clinician of the temperature of the respiratory gas entering the patient's nose. The output from the sensor 60 may, if desired, be coupled to a digital display 65 to provide the clinician with an accurate visual display of the temperature of the respiratory gas as actually being administered to the patient.
[0016] Because the air flow is constantly flowing from the outlet 12 of the chamber 10 to the patient's nose cannula 50 , only inspiratory air is delivered to the patient through the first portion 20 a of the flexible tube 20 . Accordingly, re-breathing of exhaled air by the patient is substantially minimized or eliminated entirely.
[0017] As best illustrated in the embodiment of FIG. 5 , the nose cannula 50 may be formed with a partition 55 which separates the input of the respiratory gas to the patient from the sensing of the gas temperature for controlling the operation of the heater 15 . The positioning of the sensor 60 in this manner, in the nose cannula 50 in thermal contact with the respiratory gas at the point of administration of the gas to the patient, 56 , results in substantially reducing or eliminating the effect that ambient room temperature and humidity might have on control of the gas temperature and moisture content. It is to be understood, however, that the nose cannula 50 may be constructed without the partition 55 separating the input of the respiratory gas to the patient from the sensing of the gas temperature. In such an embodiment the sensor 60 , however, is still to be positioned in substantially direct thermal contact with the respiratory gas at the point of administration, 56 , of the gas to the patient.
[0018] As best shown in the embodiment of FIG. 6 , the nose cannula 50 is constructed without the partition 55 , and the sensor 60 is still positioned directly adjacent to the point of administration, 56 , of the gas to the patient.
[0019] The foregoing description of a preferred embodiment for this invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment described has been chosen and described in an effort to provide the best illustrations of the principles of the invention and its practical application, and to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited for the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
[0020] Also, this application was prepared without reference to any particular dictionary. Accordingly, the definition of the terms used herein conforms to the meaning intended by the inventors acting as their own lexicographer in accordance with the teaching of the application, rather than any dictionary meaning which is contrary to or different from the inventors' meaning regardless of the authoritativeness of such dictionary. | A low flow heated/humidified respiratory gas delivery system, especially useful for low flow rates as preferred in the treatment of neonate and other such patients, wherein the respiratory gas is heated and humidified as desired for delivery to the patient and the temperature is monitored at the point of delivery to the patient. | 0 |
This application is a continuation of prior applications, Ser. No. 595,838 filed Apr. 2, 1984 and Ser. No. 820,708 filed Jan. 17, 1986, the benefit of which is claimed herein, now abandoned.
BACKGROUND OF INVENTION
This invention relates to a drill bit and sub-assembly for use with a reverse circulation hammer type drill pipe.
Conventional reverse circulation hammer drill bits have generally been unable to provide a high consistency of recovery of core samples throughout the depth of the drilling operation. Lack of consistent air flow and pressure through the central return has caused inconsistent recovery of samples which has resulted, in many cases, in incorrect and misleading mineral content assays of the sample. Additionally, the design of conventional hammer drill bits has resulted, not only in lack of consistency of recovery of core samples, but also in inefficiency in drilling.
The primary object of the present invention is to improve consistency of recovery of core samples and efficiency of drilling. The primary object is achieved by improvements in the construction and design of the drill bit and sub-assembly which improve cutting and removal of chips and maintenance of air pressure in the inner pipe.
BRIEF DESCRIPTION OF DRAWING
FIG. 1 is an exploded isometric sectional view of the drill bit and sub-assembly of the present invention;
FIG. 2 is a sectional view of the drill bit of the present invention;
FIG. 3 is an enlarged cross-sectional view of the drill bit.
FIG. 4 is an end view of the drill bit of FIG. 3;
FIG. 5 is a cross-section of a drill bit and sub-assembly of the present invention; and
FIG. 6 is an alternative embodiment illustrating carbide inserts used in conjunction with the hammer drill bit of the present invention
DETAILED DESCRIPTION
As shown in FIG. 1, the drill bit assembly comprises a drill bit 20, known as a Selcon bit, which is connected to the downhole end of a bit sub-connector means 22 which is, in turn, connected to the downhole end of the outer pipe 28 of a section of dual wall drill string 26. The inner pipe 30 of drill string 26 is coupled to bit sleeve 24 by a connector sleeve means 32 which fits over O-rings 34, 36 which are mounted in grooves 38, 40, respectively on bit sleeve 24.
In operation, one or more sections of drill string 26 are raised and lowered by a conventional hammer drill type rig to reciprocably drive the drill bit 20 into the earth to cut a drill hole. Compressed air or other fluid under pressure to forced down the outer passage 42 of the dual wall drill string sections, as indicated by arrows 44, 46, and into a central cavity 48 in the drill bit 20, which is connected to center passage 50 of bit sleeve 24 through a center passage in inner pipe 30. Thus, loose bits and pieces of earthen materials are carried upwardly to the surface by air pressure where they can be analyzed and evaluated.
The drill bit 20 comprises a one-piece member made from a casting of metallic material such as 4100 to 4300 series steel. Bit sleeve 24 and bit sub 22 are machined from 4140 or 4300 series steel tubing. Drill bit 20 and bit sub 22 are case hardened by electrical induction or sand base hardening to a hardness of between 35 and 50 on the Rockwell scale. The upper end of drill bit 20 is provided with a large diameter bore having threads 52 for connection to the lower threaded end portion 54 of the bit sub 22. The lower end portion of drill bit 20 is provided with a reduced diameter bore which provides an annular seat 76 abutting against lower surface 74 of bit sleeve 24. Annular seal and shock ring 62 is disposed on annular flange 64 to provide an air tight seal between the bottom surface 65 of annular ring 68 and the inner wall of bit sub 22 to ensure passage of air as indicated by arrows 44, 46 and to absorb shock from bit sleeve 24.
Bottom surface portion 74 of bit sleeve 24 abuts against surface 76 such that air passing between the outer wall surface 78 at bit sleeve 24 and annular ring 68 flow through notched air passage means 80, 82 which extend through shortened and elongated cutting teeth 84, 86, respectively. Threaded portion 70 of bit sub 22 engages threaded portion 72 of drill string 26 for assembly of the drill bit assembly illustrated in FIG. 1.
FIG. 2 illustrates a plurality of circumferentially and alternately spaced shortened intermediate cutting means 90 located on an intermediate side wall portion of the drill bit and elongated lowermost cutting means 92 on the lower end portion of the drill bit. Each shortened intermediate and elongated lowermost cutting means have shortened and elongated cutting teeth 84, 86, respectively, with notched air passage means formed therein for enabling compressed air to flow into central cavity 48, as set forth above.
FIGS. 3 and 4 illustrate axially extended cutting means 92 which comprises an arcuate segmental peripheral cutting edge means 94 formed by the intersection of annular drill bit outer surface 96 and beveled surfaces 98, 100 located on opposite sides of a radially inwardly extending rib portion forming elongated cutting tooth 86 having an upwardly and inwardly sloping cutting edge 102. Each cutting tooth 86 has flat circumferentially spaced axially extending side surfaces 104, 106 connected by curved end surfaces 108, 110 which intersect to form cutting edge 102. Each cutting tooth 86 also has arcuate segmental inner surfaces 112. Air passage means 82 are centrally located in cutting tooth 86 and open through surfaces 112. Each axially extended cutting means is further defined by axially extending side wall portions 116, 118 which define lateral circumferentially spaced gaps 120 therebetween. Surfaces 116, 118 comprise a flat parallel outermost portion 122 and a concave innermost portion 124.
Each axially shortened cutting means 90 comprises an arcuate segmental peripheral cutting edge portion 126 formed by the intersection of annular outer drill bit surface 96 and slightly beveled surfaces 128, 130 located on opposite sides of a radially inwardly extending cutting tooth 132 having a laterally inwardly sloping cutting edge 134 on the lower end thereof. Each cutting tooth 132 has flat circumferentially spaced axially extending side surfaces 136, 138 connected by curved end surfaces 140, 142 which intersect to form cutting edge 134. Each rib portion also has arcuate segment and inner surfaces 144 defining circumferentially spaced portions of bore 48. Air passage means 80 are centrally located in cutting tooth 132 and open through surfaces 144.
Each of the cutting teeth 86, 132 extend downwardly in the drilling position from a common plane 146 spaced downwardly from surface 148 a relatively short axial distance. Each of the air passages 80, 82 begin at annular lateral surface 150 which defines the end of threaded portion 52. Air passages 82 extend axially downwardly beyond cutting surfaces 126 with a lowermost portion 152 located radially opposite gaps 120 below lateral surfaces 128, 130. Thus, gaps 120 provide the additional function of air flow between adjacent ones of the axially extended cutting means. The oppositely curved side walls 124 form pockets to facilitate collection of cuttings and facilitate flow of cuttings into central cavity 48 and upwardly into connector tube passage 50.
In the presently preferred embodiment, the angles of the beveled surfaces 98, 100, 128, 130 are approximately 65 degrees from the vertical axis of the drill bit. The angle of cutting edges 102, 134 is approximately 83 degrees from the vertical axis of the drill bit. Thus, the drill bit provides a plurality of axially extended lowermost cutting means circumferentially disposed on circumferentially spaced lowermost arcuate segmental side wall portions which are of uniform size and shape and which have opposite parallel circumferentially spaced side surfaces forming a plurality of uniform size and shape circumferentially spaced radially inwardly and axially upwardly extending end slots spaced around the periphery of the drill bit and extending radially between the generally cylindrical outer peripheral surface portion of the drill bit and the generally cylindrical central opening extending axially through the drill bit; and a plurality of axially shortened intermediate cutting means axially upwardly spaced from the axially extended lowermost cutting means and disposed on circumferentially spaced arcuate intermediate segmental sections of the drill bit of uniform size and shape which are located axially adjacent and in part define the end slots and are disposed between the opposite parallel circumferentially spaced side surfaces of the lowermost segmental portions.
FIG. 5 is a cutaway assembly drawing of the drill bit assembly of the present invention in an assembled configuration. Drill string 26 is attached to bit sub 22 by way of threaded portions 72 of drill string 26 and threaded portions 70 of bit sub 22. In a similar manner, bit sub 22 is coupled to drill bit 20 by way of male threaded portions 54 of bit sub 22 and female threaded portions 52 of drill bit 20. Bit sleeve 24 is disposed in the central opening formed by the assembly of drill bit 20, but sub 22 and drill string 26. Bit sleeve 24 is disposed between flange portion 32 of inner pipe 30 and annular seal 62 disposed in bit sub 22. Bit sleeve 24 forms an annular cylindrical cavity having a center passage 50 for movement of air and collected bit samples in an upward direction. Bit sleeve 24 separates center passage 50 from external air passage 42. O-rings 34, 36 provide an airtight seal between outer passage 42 and center passage 50. Air is pumped down the outer passageway 42 of the drill string from the surface and proceeds along the outer passage as indicated by arrows 44, 46. Air passes between the inner surface of annular ring 68 and outer surface 78 of bit sleeve 24 into notched portions 80, 82 of cutting teeth 84, 86. Annular ring 62 provides an airtight seal between annular ring 68 and the inner wall of bit sub 22 and absorbs shock transmitted by bit sleeve 24.
The configuration of air passage means 80, 82 directs the airflow in an inward and upward direction to provide a more consistent air return. Both pressure and velocity of the air return remain more constant during the drilling process because of the inward and upward angle at which the air is directed through air passages 80, 82. The air medium functions to blow the sample away from the cutting edges of the bit and direct the sample through opening 48 into the void area of central passage 50 such that the sample is directed along the path of least resistance through central passage 50. In this manner, the consistency of the sample by volume is constant during the entire drilling process so as to provide a sample of mineral content which remains constant with vertical drilling depth. This is of high importance in exploratory drilling, especially of desert aluvials and placer exploration, to accurately determine mineral content of samples to accumulate data for the purpose of evaluating the feasibility of a mining operation. Failure to efficiently and consistently return the sample to the surface may affect the accuracy of the percentage per ton of rare metals of the sample retrieved during the drilling process.
The present invention also provides extra cutting edge. The axially shortened cutting means 90 provides room for expansion of samples which have been cut by axially extended cutting means 92 until the sample is removed through central opening 50. The cutting edges are beveled to increase the feed angle and to streamline the removal of sample from the cutting surfaces during the drilling process. The angle of the cutting edges provides for more cutting edge as the cutting process proceeds into the cut material. Moreover, the design of the present invention provides for additional cutting teeth to further increase the efficiency of the hammer drill bit of the present invention.
FIG. 6 illustrates an alternative embodiment which utilizes carbide inserts 160, 162, 164, 168 adjacent cutting edges in drill bit 20. Each of the carbide inserts is inserted into a groove such as groove 170 adjacent the cutting edge and secured in place by gluing or other suitable means of attaching the carbide inserts in the grooves. The carbide inserts function to increase the hardness of the cutting edges and consequently extend the effective use of the drill bit and premature wear of the cutting edges. The grooves in the cutting edges are machined in drill bit 20 prior to the hardening process. Once the grooves are machined in the drill bit 20, the surfaces are case hardened by electrical induction, as described above.
The foregoing description of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and other modifications and variations may be possible in light of the above teachings. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and various modifications as are suited to the particular use contemplated. It is intended that the appended claims be construed to include other alternative embodiments of the invention except insofar as limited by the prior art. | A cylindrical hammer drill bit with a central fluid passage and having a first group of circumferentially spaced lowermost cutting surfaces located on lowermost arcuate segments spaced by elongated upwardly extending circumferentially spaced slots and a second group of circumferentially spaced uppermost cutting surfaces located in intermediate arcuate segments at the upper end of the slots. Each of the cutting surfaces has an arcuate segment portion on the outer periphery of the drill bit formed at the intersection of upwardly inwardly sloping surfaces with the periphery of the drill bit; and radially inwardly upwardly inclined radial segment portions located on radially rib portions on the upwardly inwardly sloping surfaces. Each radial rib portion is connected to an elongated inwardly facing fluid slot. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional application of U. S. application Ser. No. 10/327,532, filed Dec. 20, 2002, now U.S. Pat. No. 7,177,068 the entire disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to an improved micro-mechanical beam or spring configuration for using micro-mechanical applications, micro-mechanical mirrors.
BACKGROUND OF THE INVENTION
German Published Patent Application No. 198 51 667 refers to a basic configuration of a micro-mechanical mirror arrangement, in which a micro-mechanical mirror plate is suspended by one or more torsional beams or beam springs. To allow large deflection angles of the mirror plate, the torsional beams may be required to be thin and long which may be prone to break.
German Published Patent Application No. 199 63 382 and German Published Patent Application No. 199 41 045 refer to a modification which may provide a more robust configuration of the micro-mechanical mirror arrangement. The modification may relieve stress upon the micro-mechanical torsional beams if the micro-mechanical mirror plate is moved in a direction that is vertical to the plane of the micro-mechanical mirror plate, but not if the micro-mechanical mirror plate is moved in a direction that is parallel or “in-plane” with the micro-mechanical mirror plate. To increase the robustness further, the thickness of the micro-mechanical beams may be increased and/or their length may be reduced. However, such changes to the length and thickness may decrease the “freedom of movement” of the micro-mechanical beam.
German Published Patent Application No. 199 63 382 and German Published Patent Application No. 199 41 045 refer to a two parallel beam configuration, as well as the transformation of bending in a vertical direction perpendicular to the surface of the substrate (i.e. the Z-direction) in tension by using a transversal beam. The resulting stiffness of the whole structure may therefore be significantly higher than that for a single spring of the basic configuration.
SUMMARY OF THE INVENTION
It is believed that an exemplary embodiment of the present invention may provide enhanced protection for micro-mechanical torsional beam springs via the addition of one or more support structures that may attach directly to the micro-mechanical beam. The attachable structures may assist in limiting the “freedom of movement” of the micro-mechanical beam in a more precise manner by preventing undesirable bending actions of the micro-mechanical beam at specific points along the beam. Such targeting or “pin-pointing” may increase the bending stiffness of the beam at the specific points with only a marginal influence to its torsional stiffness. Thus, the protective support structures may increase the robustness of the micro-mechanical beam and may permit their use under harsh and/or tough environmental conditions. The structures may also facilitate the production of moveable structures (such as, for example, mirrors with much higher robustness) as well as making mass application and/or higher yields feasible.
The attachable structures may be applied in devices such as bar-code readers, leveling devices, scanners, display technology devices, and in particular, micro-mechanical mirrors. For example, the attachable support structures may provide an effective way to reduce the freedom of the in-plane movement of a micro-mechanical mirror that is suspended by one or more micro-mechanical beams. The attachable support structures may also provide enhanced protection for devices in a mobile configuration, such as, for example, an automotive application, where movement-induced vibration may be a major concern.
An exemplary embodiment of the present invention is directed to providing an arrangement for use with a micro-mechanical beam, having a support structure configured to directly attach to the micro-mechanical beam to increase bending stiffness of the micro-mechanical beam without significantly influencing torsional stiffness.
Another exemplary embodiment is directed to an arrangement in which the support structure is positioned at a point of a maximum bending of the micro-mechanical beam.
Yet another exemplary embodiment is directed to an arrangement in which the support structure is constructed to reduce stiction.
Still another exemplary embodiment is directed to an arrangement in which the support structure includes a rounded contact area.
Yet another exemplary embodiment is directed to an arrangement in which the support structure includes a tapered end near a point of attachment with the micro-mechanical beam.
Still another exemplary embodiment is directed to an arrangement in which the support structure is arranged at a point of maximum bending of the micro-mechanical beam and includes a rounded contact area and a tapered end near a point of attachment.
Yet another exemplary embodiment is directed to an arrangement in which a shape of the support structure includes at least one of round, cubic, cylindrical, tubular, coil-shaped, quonset-shaped, prism-shaped, pyramid, obelisk, wedge, spherical, prolate spheroid, cone-shaped, catenoid, ellipsoid, paraboloid, conoid, disc-shaped, toroid, serpentine, helix, concave, and convex.
Still another exemplary embodiment is directed to an arrangement having at one additional support structure.
Yet another exemplary embodiment is directed to an arrangement in which the support structure and the at least one additional support structure are equal in at least one of length, size, and shape.
Still another exemplary embodiment is directed to an arrangement in which the support structure and the at least one additional support structure are unequal in at least one of length, size, and shape.
Yet another exemplary embodiment is directed to a device for use with a micro-mechanical beam having a protective structure to restrict a bending action of the micro-mechanical beam, and configured to directly attach to the micro-mechanical beam at specific points along the beam.
Still another exemplary embodiment is directed to a device in which the protective structure includes at least two adjacent support structures arranged to touch each upon reaching a predetermined bending action of the micro-mechanical beam and prevent a further bending action of the micro-mechanical beam.
Yet another exemplary embodiment is directed to a device in which the at least two adjacent support structures are positioned at points of most severe deflection of the micro-mechanical beam.
Still another exemplary embodiment is directed to a device in which the protective structures are distributed uniformly with an even length along an axis of the micro-mechanical beam.
Yet another exemplary embodiment is directed to an device in which the protective structures are distributed non-uniformly along an axis of the micro-mechanical beam.
Still another exemplary embodiment is directed to a device in which the protective structures are distributed with a decreasing length along the axis of the micro-mechanical beam.
Yet another exemplary embodiment is directed to a device in which the protective structures are distributed with an increasing length along the axis of the micro-mechanical beam.
Still another exemplary embodiment is directed to a device in which the protective structure restricts the bending action in at least one of a variety of directions and all directions.
Yet another exemplary embodiment is directed to an arrangement for use with a micro-mechanical mirror having a micro-mechanical beam attached to the micro-mechanical mirror and a support structure attached to the micro-mechanical beam to restrict a bending action of the micro-mechanical beam.
Still another exemplary embodiment is directed to an arrangement having a micro-mechanical mirror plate, a micro-mechanical beam attached to the micro-mechanical mirror plate, and a support structure to restrict a bending action of the micro-mechanical mirror beam.
Yet another exemplary embodiment is directed to an arrangement to protect a micro-mechanical mirror plate having a support structure configured to restrict an in-plane movement of the micro-mechanical mirror plate, and being directly attachable to a micro-mechanical beam that suspends the micro-mechanical mirror plate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a shows a micro-mechanical mirror arrangement.
FIG. 1 b shows a partial view of the micro-mechanical mirror arrangement of FIG. 1 a with the addition of a micro-mechanical mirror stop to limit the in-plane movement of the micro-mechanical mirror plate.
FIG. 1 c shows a partial view of micro-mechanical mirror arrangement and the additional micro-mechanical mirror stop of FIG. 1 b immediately after an applied shock.
FIG. 2 a shows a micro-mechanical beam arrangement to restrict an in-plane movement of a micro-mechanical mirror plate suspended by at least one micro-mechanical beam.
FIG. 2 b shows the micro-mechanical beam arrangement of FIG. 2 a in a deflective state under stress of an applied shock force, demonstrating how the micro-mechanical support structures may touch each other in case of a significant bending action and thereby limit the maximal bending action of the micro-mechanical beam.
FIG. 2 c shows the micro-mechanical beam arrangement of FIG. 2 a under the stress of an applied shock force demonstrating how the micro-mechanical support structures may touch in case of a twisting action, and thereby still limit the maximal bending action of the micro-mechanical beam.
FIG. 2 d shows a modified version of the micro-mechanical beam arrangement of FIG. 2 a having a non-uniform distribution of the micro-mechanical support structures along the axis of the micro-mechanical beam.
FIG. 3 a shows an exemplary variation of the micro-mechanical support structures.
FIG. 3 b shows an additional exemplary variation of the micro-mechanical support structures.
FIG. 3 c shows a further additional exemplary variation of the micro-mechanical support structures.
FIG. 4 shows an exemplary variation of the micro-mechanical support structures to reduce stiction.
DETAILED DESCRIPTION
FIG. 1 a shows a configuration of a micro-mechanical mirror arrangement 100 . The micro-mechanical arrangement 100 includes a micro-mechanical mirror plate 101 suspended by two torsional micro-mechanical beams 102 and 103 . The micro-mechanical beams 102 , 103 permit a certain “freedom of movement” of the micro-mechanical mirror plate 101 . In particular, the tension of the micro-mechanical beams 102 , 103 restricts a movement of the micro-mechanical mirror plate 101 in a direction X along the axis of the micro-mechanical beams 102 , 103 , and at the same time permits movement in a direction Y that is in-plane with the micro-mechanical mirror plate 101 (that is, perpendicular to the axis of the micro-mechanical beams 102 , 103 and a direction Z that is vertical to the plane of the micro-mechanical mirror plate 101 ).
To increase the freedom of movement of the micro-mechanical mirror plate 101 , the micro-mechanical beams 102 , 103 may be extended lengthwise in the direction X along the axis of the micro-mechanical beams 102 , 103 and/or their thickness may be reduced. However, the extended length or reduced thickness of the micro-mechanical beams 102 , 103 may make them prone to breakage or may not adequately restrict a particular undesired movement of the micro-mechanical mirror plate 101 .
To make the micro-mechanical beams 102 , 103 more robust and/or to restrict a particular undesired movement of the micro-mechanical mirror plate 101 , the micro-mechanical beams 102 , 103 may be shortened lengthwise and/or their thickness may be increased. However, such shortening and/or thickening of the micro-mechanical beams 102 , 103 may restrict the overall freedom of movement of the micro-mechanical mirror plate 101 . Furthermore, such shortening and/or thickening may also pose significant challenges to their production.
FIG. 1 b shows a partial view of the micro-mechanical mirror arrangement 100 of FIG. 1 a with the addition of a micro-mechanical mirror stop 104 to limit the in-plane movement of the micro-mechanical mirror plate 101 . The micro-mechanical mirror stop 104 may be made out of, for example, the same material or film as the micro-mechanical mirror plate 101 . However, in case of an applied shock to the micro-mechanical mirror arrangement 100 , the micro-mechanical mirror stop 104 may not prevent the micro-mechanical mirror plate 101 from tilting downwards and “diving” beneath the micro-mechanical mirror stop 104 .
FIG. 1 c shows a partial view of micro-mechanical mirror arrangement 100 and the additional micro-mechanical mirror stop 104 of FIG. 1 b immediately after an applied shock. As a result of the shock, an end 101 a of the micro-mechanical mirror plate 101 may be positioned beneath the micro-mechanical mirror stop 104 . Such a position of the end 101 a may be undesirable or may result in potential damage the micro-mechanical mirror plate 101 and/or the micro-mechanical beam 103 .
FIG. 2 a shows a micro-mechanical beam arrangement 200 to restrict an in-plane movement of a micro-mechanical mirror plate 201 suspended by at least one micro-mechanical beam 202 . The micro-mechanical beam arrangement 200 includes one or more micro-mechanical support structures 205 attached directly to the micro-mechanical beam 202 that limit the bending action of the micro-mechanical beam 202 . Such support structures 205 may greatly increase the stiffness of the micro-mechanical beam 202 in a direction Y perpendicular to the axis of the micro-mechanical beam 202 , with only marginal influence to the torsional stiffness.
Thus, for example, in case of a shock, the micro-mechanical mirror plate 201 , whose mass may be relatively high in comparison with the micro-mechanical beam 202 , may apply a force to the micro-mechanical beam 202 stressing it and causing it to bend resulting in an undesirable deflection of the micro-mechanical beam 202 . With the attachment of the micro-mechanical support structures 205 , the deflection of the micro-mechanical beam 202 may be limited as adjacent micro-mechanical support structures 205 touch each other and prevent further bending at points of the most severe deflection. Thus, the deflection caused by the applied shock may be spread more evenly. As a result, the micro-mechanical beam 202 may be able to absorb more energy and therefore withstand greater stresses. Thus, the addition of the micro-mechanical support structures 205 may enhance the maximal load and shock survival of the micro-mechanical beam 202 , as well as that of the micro-mechanical mirror plate 201 .
FIG. 2 b shows the micro-mechanical beam arrangement 200 of FIG. 2 a in a deflective state under stress of an applied shock force, demonstrating how the micro-mechanical support structures 205 may touch each other in case of a significant bending action and thereby limit the maximal bending action of the micro-mechanical beam 202 . In particular, if a deflection of the micro-mechanical beam 202 should occur, for example, in a direction Y that is in-plane with the micro-mechanical mirror plate 201 and perpendicular to the axis of the micro-mechanical beam 202 , the micro-mechanical support structures 205 prevent further bending beyond a certain limit at points P 1 and P 2 along the axis of the micro-mechanical beam 202 . Thus, the in-plane movement of the micro-mechanical mirror plate 201 may be limited and the required stress to break the micro-mechanical beam 202 may not be reached.
FIG. 2 c shows the micro-mechanical beam arrangement 200 of FIG. 2 a under the stress of an applied shock force demonstrating how the micro-mechanical support structures 205 may touch in case of a twisting action, and thereby still limit the maximal bending action of the micro-mechanical beam 202 . In particular, should a deflection of the micro-mechanical beam 202 induce, for example, a movement of the micro-mechanical mirror plate 201 in a rotational direction R about the axis of the micro-mechanical beam 202 , the micro-mechanical support structures 205 may still prevent bending beyond a certain limit at points P 1 and P 2 along the axis of the micro-mechanical beam 202 . Thus, the in-plane movement of the micro-mechanical mirror plate 201 may still be limited and the required stress to break the micro-mechanical beam 202 may not be reached.
To achieve more precise control, the maximum bending action of the micro-mechanical beam 202 may be adjusted by adjusting the length of the micro-mechanical structures 205 and/or the gap between them. For instance, the stress and bending action of the micro-mechanical beam 202 may vary along its length. In particular, the highest stress may be found at the points of the highest bending, which may be found, for example, near points where the micro-mechanical beam 202 is attached to the micro-mechanical mirror plate 101 . Since the bending action may vary depending on the position along the micro-mechanical beam, not every position along the micro-mechanical beam may require equal protection (for example, the bending action in the middle of a double clamped beam may be lower). Thus, by reducing and/or abandoning micro-mechanical support structures 205 .at points of low bending, thereby providing a non-uniform distribution of the micro-mechanical support structures 205 along the axis of the micro-mechanical beam 202 , the damping action may be targeted and localized along the length of the micro-mechanical beam 202 . An example of such a non-uniform distribution is shown in FIG. 2 d . Additionally, the length and thickness of the micro-mechanical support structures may be varied along the length to localize the damping action. Such localization of the damping action may permit a 37 tailoring” of the movement of the attached micro-mechanical mirror plate 201 .
FIGS. 3 a , 3 b , and 3 c show exemplary variations of the micro-mechanical support structures 205 . In FIG. 3 a , the micro-mechanical support structures 305 are distributed uniformly with an even length along the axis of the micro-mechanical beam 302 thereby providing uniform protection along the axis of the micro-mechanical beam with to a horizontal in-plane bending action in direction Y. In FIG. 3 b , the micro-mechanical support structures 305 are distributed with a decreasing length along the axis of the micro-mechanical beam 302 , starting from the micro-mechanical mirror plate 301 and extending lengthwise. In FIG. 3 c , the micro-mechanical support structures 305 are distributed with an increasing length along the axis of the micro-mechanical beam 302 starting from the micro-mechanical mirror plate 301 and extending lengthwise.
FIG. 4 shows an exemplary variation of the micro-mechanical support structures 405 to reduce “stiction” (the tendency of surfaces of the support structures to “stick together” due to, for example, electrostatic effects). The addition of the micro-mechanical support structures 405 may influence the natural spring constant of the beam spring 402 . To reduce such influences upon the natural spring constant, the micro-mechanical support structures 405 may be varied in shape and size. In particular, round contact areas 406 at points of contact between two micro-mechanical structures 405 and/or tapered ends 407 near their point of attachment with the beam spring may reduce effects such as stiction.
Although depicted in rectangular/parallelepiped form, the support structures 405 may be any suitably appropriate shape, including, for example, round, cubic, cylindrical, tubular, coil-shaped, quonset-shaped, prism-shaped, pyramid, obelisk, wedge, spherical, prolate spheroid, cone-shaped, catenoid, ellipsoid, paraboloid, conoid, disc-shaped, toroid, serpentine, helix, concave, and convex. Hence, with such a multitude of structure types, the support structures may provide protections in a variety of directions (e.g., X and Z directions) and/or all directions (i.e., “wrap around” protection—up to 360 degrees protection or part thereof). | An arrangement for use with a micro-mechanical beam, in which a plurality of support structures are configured to directly attach to the micro-mechanical beam to increase bending stiffness of the micro-mechanical beam without significantly influencing torsional stiffness. At least two of the support structures are arranged to touch each upon reaching a predetermined bending action of the micro-mechanical beam and prevent a further bending action of the micro-mechanical beam, and at least two of the support structures are non-identical. | 6 |
BACKGROUND OF THE INVENTION
This invention relates generally to modular construction systems and more particularly to a system of modular blocks which can be connected in various ways.
Various construction systems exist in which identical or similar modular elements are built up into larger structures. Known examples of modular building elements include bricks and concrete blocks. While these provide a modular configuration, they lack a self-connecting feature and must be assembled with separate fasteners, adhesives, or mortar.
Systems of interlocking construction blocks are also known. These are typically used for toys or small-scale models, and typically rely on friction or snap-type connectors. While these systems provide a self-connecting feature, the user is limited to preformed blocks which have fixed connector elements.
Accordingly, there is a need for a modular construction element having a connector that can be configured in different ways.
BRIEF SUMMARY OF THE INVENTION
Therefore, it is an object of the invention to provide a block that can be used to build up modular structures.
It is another object of the invention to provide a modular block with a connector that can be oriented in different directions.
These and other objects are achieved by the present invention, which in one embodiment provides a modular block apparatus, including: first and second blocks, each block having a generally upwardly protruding locking member and an internal recess sized to receive the locking member of the other block such that the blocks can be assembled with one block above the other. The blocks are secured together in a vertical direction by relative lateral movement of the locking member and the internal recess. Means are provided for preventing relative lateral movement of the locking member and the internal recess so as to retain the blocks in a connected condition.
According to another embodiment of the invention, a modular block apparatus includes: a block with top and bottom surfaces, a front sidewall, and an interior cavity formed therein, the interior cavity defining a locking recess communicating with the bottom surface, and a lug receptacle communication with the top surface; and a locking lug received in the lug receptacle, the locking lug having a laterally-extending hook protruding above the top surface.
According to another embodiment of the invention, the lug receptacle includes at least one protruding side boss disposed therein; and the locking lug includes at least one lug boss disposed thereon. The lug bosses and the side bosses are arranged such that the hook faces in a selected one of a plurality of directions relative to the front sidewall, and the lug is retained, by engagement of the bosses, against withdrawal from the lug receptacle in a vertical direction.
According to another embodiment of the invention, the interior cavity includes a generally vertical portion extending between the lug receptacle and the locking recess.
According to another embodiment of the invention, the modular block apparatus further includes a key disposed in the vertical portion which prevents lateral motion of the locking lug.
According to another embodiment of the invention, the key prevents lateral motion of a hook received in the locking recess.
According to another embodiment of the invention, the block has at least one generally vertical edge, and includes: at least one open corner slot formed in the vertical edge; and a generally vertically-extending corner hole disposed near the vertical edges and intersecting the corner slot.
According to another embodiment of the invention, the modular block further includes: a connector plate having a thickness sized to fit in the corner slot, and a connector pin hole formed therethrough; and a connector pin sized to fit into the corner hole and the connector pin hole to retain the connector plate in the corner slot.
According to another embodiment of the invention, the connector plate further includes additional connector pin holes formed therethrough and is sized for engaging corner slots of at least two adjacent blocks.
According to another embodiment of the invention, the modular block apparatus further includes a finish element having: a exterior surface having a desired shape; and a laterally-extending connector plate having a thickness sized to fit in the corner slot, and a connector pin hole formed therethrough.
According to another embodiment of the invention, the hook is substantially smaller than the locking recess.
According to another embodiment of the invention, the block includes a plurality of laterally-extending hooks protruding above the top surface, and each of the hooks is substantially smaller than the locking recess.
According to another embodiment of the invention, the hook is substantially larger than the locking recess.
According to another embodiment of the invention, the block includes a plurality of laterally-extending hooks protruding above the top surface, and each of the hooks is substantially smaller than the locking recess.
According to another embodiment of the invention, a modular block apparatus includes: a block with top and bottom surfaces, and at least one generally cylindrical core passage extending between the top and bottom surfaces; and a locking assembly received in the core passage, the locking assembly including: a core sized to be received in the core passage and having a through-bore extending therethrough, the through-bore defining alternating core grooves and lands; a locking rod having an array of alternating rod grooves and lands complementary to the core grooves and lands; and means for retaining the locking rod in engagement with the core with the locking rod protruding from the top surface.
According to another embodiment of the invention, the retaining means comprise a rod key received in the through-bore and urges the locking rod laterally against the core grooves and lands.
According to another embodiment of the invention, the core passage includes at least one key slot extending laterally therefrom, the key slot being in communication with the bottom surface; and the core carries at least one core key which is moveable between a retracted position and a laterally-extended position. Engagement of the locking means causes the core key to move to the laterally-extended position, where the core key engages the core key slot to prevent withdrawal of the core assembly from the core passage.
According to another embodiment of the invention, the modular block apparatus further includes: a connector plate having a thickness sized to fit in the connector slot, and a connector pin hole formed therethrough; and a connector pin sized to fit into the core passage and the connector pin hole to retain the connector plate in the connector slot.
According to another embodiment of the invention, the connector plate has a generally cylindrical stud protruding therefrom, the stud including a land sized and shaped to engage the core grooves and lands.
According to another embodiment of the invention, the block includes a plurality of core passages of different diameters formed therein.
According to another embodiment of the invention, the block is a generally rectangular solid.
According to another embodiment of the invention, the block is curved.
According to another embodiment of the invention, the block is trapezoidal.
According to another embodiment of the invention, the block includes a pair of lobes connected by a relatively narrow waist.
According to another embodiment of the invention, a modular block apparatus includes: a block with top and bottom surfaces, a front sidewall, and an interior space formed therein. The block includes; first and second spaced-apart side members each having an inner surface and an outer surface; and at least one locking lug disposed between the side members, the locking lug having upper and lower notches formed near each its upper and lower ends, respectively, so as to define upper and lower laterally-extending hooks, wherein the upper hook protrudes from the top surface, and is sized and shaped to engage a lower notch of a second block.
According to another embodiment of the invention, the hook extends towards the front sidewall.
According to another embodiment of the invention, the hook extends generally perpendicular to the front sidewall.
According to another embodiment of the invention, the side members and the locking lug are a single integral component.
According to another embodiment of the invention, the modular block apparatus further includes at least one generally vertical key groove formed in the side members.
According to another embodiment of the invention, the modular block apparatus further includes a key received in the interior space and having an alignment rail which engages the key groove, the key extending between upper and lower positioned blocks to prevent relative lateral movement thereof.
According to another embodiment of the invention, the key includes at least two spaced-apart alignment rails which are adapted to engage respectively key grooves of two laterally-adjacent blocks to prevent separation thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:
FIG. 1 is a perspective view of a modular block constructed in accordance with the present invention;
FIG. 2 is a another perspective view of the modular block of FIG. 1 ;
FIG. 3A is a perspective view of a pair of modular blocks constructed in accordance with the present invention in position to be connected;
FIG. 3B is a perspective view of the modular blocks of FIG. 3A in a partially contacting position;
FIG. 3C is a perspective view of the modular blocks of FIG. 3B in a fully contacting position;
FIG. 3D is a perspective view of the modular blocks of FIG. 3C in a fully engaged position;
FIG. 3E is a perspective view of the modular blocks of FIG. 3D , along with a locking key about to be inserted therein;
FIG. 3F is a perspective view of the modular blocks of FIG. 3E , with a locking key partially inserted therein;
FIG. 3G is a perspective view of the modular blocks of FIG. 3F , with a locking key fully inserted therein;
FIG. 4A is a perspective view of a modular block along with a connector plate and connector pin;
FIG. 4B is a perspective of a plurality of modular blocks connected with connector plates and pins;
FIG. 5A is a perspective view of a modular block along with a connector plate, connector pin, and a finish element;
FIG. 5B is a perspective view of a plurality of modular blocks connected with connector plates and pins, and having finish elements attached thereto;
FIG. 6 is a perspective view of a plurality of modular blocks having locking elements oriented in varied directions;
FIG. 7 is a perspective view of a structure built-up from a plurality of modular blocks having locking elements oriented in varied directions;
FIG. 8 is a perspective view of a structure built-up from a plurality of modular blocks having locking elements oriented in the same direction;
FIG. 9 is a perspective view of a truss structure built-up from a plurality of modular blocks;
FIG. 10 is a perspective view of a wall structure built-up from a plurality of modular blocks;
FIG. 11 is a perspective view of a group of modular blocks of different sizes;
FIG. 12 is a perspective view of a modular block adapted to be connected to a plurality of smaller modular blocks;
FIG. 13 is a perspective view of the modular block of FIG. 12 connected to a plurality of smaller modular blocks;
FIG. 14 is a perspective view of another modular block adapted to be connected to a plurality of smaller modular blocks;
FIG. 15 is a perspective view of the modular block of FIG. 14 connected to a plurality of smaller modular blocks;
FIG. 16 is a top perspective view of a modular block constructed according to an alternative embodiment of the present invention;
FIG. 17 is a bottom perspective view of the modular block of FIG. 16 ;
FIG. 18 is an enlarged view of a portion of the top of the modular block of FIG. 16 ;
FIG. 19 is an enlarged view of a portion of the bottom of the modular block of FIG. 16 ;
FIG. 20 is a perspective view of a locking assembly for use with the modular block of FIG. 16 ;
FIG. 21 is a top perspective view of a modular block having a locking assembly installed therein;
FIG. 22 is an enlarged view of a portion of the top of the modular block of FIG. 21 ;
FIG. 23 is an enlarged view of a portion of the bottom of the modular block of FIG. 21 ;
FIG. 24A is a perspective view of a core forming a portion of a locking assembly;
FIG. 24B is a perspective view of the core of FIG. 24A with a locking rod about to be inserted therein;
FIG. 24C is a perspective view of the core and locking rod of FIG. 24B connected together;
FIG. 24D is a perspective view of the core and locking rod of FIG. 24C with a rod key about to be inserted therein;
FIG. 24E is a perspective view of the core and locking rod of FIG. 24C with a rod key fully inserted therein;
FIG. 25 is a perspective view of a lower end of a rod key;
FIG. 26 is a perspective view of a core along with a rod key and a pair of core keys;
FIG. 27 is a perspective view of a plurality of modular blocks connected together;
FIG. 28 is a perspective view of a connector plate;
FIG. 29 is perspective view of a connector plate disposed in a groove of a modular block;
FIG. 30 is a perspective view of the modular block and connector plate of FIG. 29 with a connector pin inserted therein;
FIG. 31 is a perspective view of a pair of modular blocks connected end-to-end with a connector plate and connector pins;
FIG. 32 is a perspective view of another type of connector plate;
FIG. 33 is a perspective view of a plurality of modular blocks of varying sizes connected together;
FIG. 34 is a perspective view of another finish element;
FIG. 35 is a perspective view of a modular block with a plurality of finish elements connected thereto;
FIG. 36 is a perspective view of a rotational connector plate;
FIG. 37 is a perspective view of a modular block with the connector plate of FIG. 36 attached thereto;
FIG. 38 is a perspective view of a plurality of modular blocks connected together;
FIG. 39 is a perspective view of a plurality of modular blocks of varying sizes connected together;
FIG. 40 is a perspective view of the components of a locking assembly of a first size;
FIG. 41 is a perspective view of the components of a locking assembly of a second size;
FIG. 42 is a perspective view of the components of a locking assembly of a third size;
FIG. 43 is a schematic top view of a representative hole pattern in a modular block;
FIG. 44 is a perspective view of a wheeled vehicle constructed from modular blocks;
FIG. 45 is partially exploded view of the vehicle of FIG. 44 ;
FIG. 46 is a perspective view of a curved modular block;
FIG. 47 is a perspective view of a cylindrical structure assembled from the modular blocks shown in FIG. 46 ;
FIG. 48 is a perspective view of a structure assembled from a combination of curved and straight modular blocks;
FIG. 49 is a perspective view of trapezoidal modular block;
FIG. 50 is a perspective view of a structure assembled from the trapezoidal modular blocks shown in FIG. 49 ;
FIG. 51 is perspective view of a lobed modular block;
FIG. 52 is a perspective view of a wall structure assembled from the lobed modular blocks shown in FIG. 51 ;
FIG. 53 is a perspective view of the wall structure of FIG. 52 in a pivoted position;
FIG. 54 is a perspective view of a structure assembled from different shapes of modular blocks;
FIG. 55 is a perspective view of a modular block constructed in accordance with another alternative embodiment of the present invention;
FIG. 56 is an exploded perspective view of the block shown in FIG. 55 ;
FIG. 57 is a perspective view of a variation of the block shown in FIG. 55 ;
FIG. 58 is a perspective view of a key for use with the block of FIG. 55 ;
FIG. 59 is another perspective view of the key shown in FIG. 58 ;
FIG. 60 is a perspective view of an alternative key for use with the block shown in FIG. 55 ;
FIG. 61 is another perspective view of the key shown in FIG. 60 ;
FIG. 62 is a partially exploded perspective view of a structure built up from the blocks shown in FIGS. 55 and 57 ; and
FIG. 63 is a perspective view of the structure shown in FIG. 62 showing keys being inserted therein.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views, FIG. 1 illustrates an exemplary modular block 10 constructed according to the present invention. The modular block 10 includes a top surface 12 , a bottom surface 14 , and front, rear, left and right sidewalls 16 , 18 , 20 , and 22 , respectively. An interior cavity 24 is formed in approximately the center of the modular block 10 . The interior cavity 24 includes a generally vertical portion 26 which extends between a locking recess 28 adjacent the bottom surface 14 of the modular block 10 , and a lug receptacle 30 adjacent the top surface 12 of the modular block 10 . A ledge 32 extends laterally partway into to the locking recess 28 . The lug receptacle 30 is a parallel-sided opening having an end boss 34 extending across an end wall thereof at a selected distance from the top surface 12 , and a pair of spaced-apart side bosses 36 and 38 disposed on opposite side walls thereof.
A four-faced locking lug 40 includes an inverted “L”-shaped hook 42 which is sized and shaped to engage the locking recess 28 disposed at its upper end. A lug boss 44 is disposed at each of the lower corners of the locking lug 40 . The lug bosses 44 are disposed in a pattern so that they define a lateral slot 46 around the periphery of the locking lug 40 , which communicates with a vertical slot 48 on each of the faces of the locking lug 40 .
As can be seen in FIG. 1 , the locking lug 40 is assembled to the modular block 10 by first inserting it into the lug receptacle 30 in a downwards direction. The side bosses 36 and 38 pass into opposed ones of the vertical slots 48 . Once the lug bosses 44 have cleared the side bosses 36 and 38 and the end boss 34 in a vertical direction, the locking lug 40 is then shifted laterally so that two of the lug bosses 44 are aligned with the end boss 34 , and two of the lug bosses 44 are aligned with the side bosses 36 and 38 . In this position, the locking lug 40 is prevented from being withdrawn vertically from the lug receptacle 30 .
The dimensions, material, and surface finish of the locking lug 40 may be selected to provide the desired interface with the lug receptacle 30 . For example, if an easily-disassembled joint is desired, a small clearance may be provided between the exterior of the locking lug 40 and the lug receptacle 30 . If a more permanent joint is desired, the locking lug 40 may be provided with a tighter fit in the lug receptacle 30 , for example by providing a slight interference fit, or by providing a relatively rough surface finish.
FIG. 2 illustrates the modular block 10 with the locking lug 40 assembled thereto. In the illustrated example the hook 42 of the locking lug 40 extends towards the left sidewall 20 of the modular block 10 . However, it will be appreciated that the locking lug 40 may be assembled to the modular block 10 so that it points in any one of four directions.
The modular block 10 and the locking lug 40 may be constructed of any material which is suited to the application for which the modular block 10 is to be used and which can be formed into the necessary dimensional features. For example, the modular block 10 may be used as a toy, a modeling element, or a light structural element, in which case it may be molded from a material such as plastic resin. The modular block 10 may also be used for heavier structural applications, in which case it may be formed from materials such as concrete, wood or engineered wood materials, pressed fiber, metals, or fiber composite materials. Specific applications of the modular blocks 10 are discussed in more detail below.
FIGS. 3A-3G illustrates the two identical modular blocks 10 and 10 ′ to form a larger structure. Modular block 10 is provided with a locking lug 40 having a hook 42 as described above. As shown in FIGS. 3B , 3 C and 3 D, the hook 42 is inserted into the locking recess 28 ′ of the block 10 ′ and then shifted laterally so that the hook 42 is disposed behind the ledge 32 ′ of the locking recess 28 ′. This prevents the modular blocks 10 and 10 ′ from being disconnected in a vertical direction.
To secure the blocks together, a key 50 is inserted into the vertical portion 26 ′ (see FIGS. 3E and 3F ). The key 50 is an elongated member sized to fit into the vertical portion 26 ′ of the cavity 24 ′ (identical to cavity 24 ). As shown in FIG. 3G , the presence of the key 50 prevents lateral motion of the hook 42 relative to the locking recess 28 ′. The key 50 may be provided with a cut-back edge 52 that engages a shelf 54 of the lug receptacle (best seen in the identical block 10 of FIG. 2 ), to prevent the key 50 from falling out of the bottom of the modular blocks 10 and 10 ′. As noted above with respect to the locking lug 40 , the dimensions, materials, and surface finish of the key 50 may be selected to prevent unintended withdrawal.
As shown in FIG. 2 , the modular block 10 includes an array of laterally-extending corner slots 56 formed in each of its vertical edges. A corner hole 58 passes through the modular block 10 near each of its vertical edges and thus intersects the corner slots 56 formed along each vertical edge. FIG. 4A illustrates components used to connect two or more modular blocks 10 together laterally, including a connector pin 60 , and various connector plates 62 , 64 , 66 , and 68 . The connector pin 60 is an elongated pin sized to fit the corner hole 58 . It may include an enlarged head 70 to prevent it from falling through the modular block 10 . Each connector plate is a flat member having a thickness sized to fit in one of the corner slots 56 of a modular block 10 , and one or more connector pin holes 72 . In the illustrated example, the connector plate 62 has a single hole and is sized to fill in a corner slot 56 but not to perform any joining function. The connector plate 64 is rectangular and has two connector pin holes 72 therein. The connector plate 66 is “L”-shaped and has three connector pin holes 72 . Finally, the connector plate 68 is square and has four connector pin holes 72 therein.
FIG. 4B illustrates several modular blocks 10 , 10 ′ and 10 ″ connected together. The modular blocks 10 , 10 ′ and 10 ″ meet at a common vertical edge 74 , and connector plates 68 are inserted into corner slots 56 of each of the modular blocks 10 , 10 ′, and 10 ″. A connector pin 60 is then inserted into the corner holes 58 of each of the modular blocks 10 , 10 ′, and 10 ″. This secures each of the modular blocks 10 , 10 ′, and 10 ″ to the connector plates 68 and thus secures the modular blocks 10 , 10 ′, and 10 ″ to each other, in both lateral and vertical directions.
FIG. 5A illustrates a modular block 10 along with a connector pin 60 , connector plates 62 - 68 , and a finish element 76 . The finish element 76 has a planar inner side 78 which is sized and shaped to mate with a side wall of the modular block 10 . The inner side 78 includes one or more connector tabs 80 with connector pin holes 72 therein. The connector tabs 80 are positioned and sized to fit into corner slots 56 of the modular block 10 . The finish element 76 has an exterior surface 82 with one or more sides or facets which are formed into a desired shape. In the illustrated example, the exterior surface of the finish element 76 is shaped to form a portion of a cylinder.
FIG. 5B illustrates several modular blocks 10 , 10 ′, 10 ″, and 10 ′″ connected together with several finish elements 76 , using the connector plates 68 , connector tabs 80 , and connector pins 60 as described above to form a solid structure with a cylindrical outer surface. As can be observed from FIG. 5B , the use of finish elements 76 allows the creation of structures that are essentially modular, but which have arbitrary external shapes.
FIG. 6 illustrates a plurality of building elements 84 . Each of these building elements 84 has multiple “L”-shaped hooks 42 extending from an upper surface thereof, and multiple locking recesses 26 on a lower surface thereof. The building elements 84 can be made as a single element, or built up from individual modular blocks 10 . The direction that each hook 42 faces can be arbitrarily selected to suit a particular application. In FIG. 6 , each hook labeled 42 A is facing towards the left of the page, each hook labeled 42 B is facing towards the bottom of the page, each hook labeled 42 C is facing towards the right of the page, and each hook labeled 42 D is facing towards the top of the page. If the eight hooks 42 on each building element 84 are divided into groups of four, there are then 16 possible combinations of hook directions. FIG. 7 illustrates a structure which is built up from building elements 84 having hooks 42 facing in different directions, while FIG. 8 illustrates a structure which is built up from building elements having hooks 42 all facing in a single direction.
FIG. 9 illustrates an example of a truss structure 86 which may built up from the modular blocks 10 described above. The modular blocks 10 are connected side-by side and vertically to form longitudinal members 88 , lateral members 90 , and vertical members 92 . Tapered blocks 94 are disposed at the upper ends of the vertical members 92 so that the uppermost longitudinal members 88 will be at the proper angle.
FIG. 10 illustrates a ladder truss-type structure 96 having longitudinal members 98 and lateral members 100 which may be built up from modular blocks 10 described above.
FIG. 11 illustrates a modular block 10 alongside additional modular blocks 110 and 112 . The modular blocks 110 and 112 are substantially identical in construction to the modular block 10 , and include hooks 114 and 116 , and locking recesses 118 and 120 , respectively. The modular blocks 110 and 112 differ from the modular block 10 in their size. This may vary from a size small enough to construct items such as electronic circuit boards, to as many as several feet on a side for elements for constructing buildings.
FIG. 12 illustrates a modular block 122 which is designed to serve as an “adapter” for connection to different-sized modular blocks. The modular block 122 includes a single locking recess 124 on its lower side. Four “L”-shaped hooks 126 protrude from the upper surface of the modular block 122 . As shown in FIG. 13 , this allows the modular block 122 to be connected to additional modular blocks 128 and 130 which are each one-quarter of the size of the modular block 122 .
FIG. 14 illustrates another modular block 132 which is designed to serve as an “adapter” for connection to different-sized modular blocks. The modular block 132 includes a single “L”-shaped hook 134 protruding from its upper surface. Four locking recesses 136 are disposed on its lower side. As shown in FIG. 15 , this allows the modular block 132 to be connected to additional modular blocks 138 which are each one-quarter of the size of the modular block 132 .
FIGS. 16 and 17 illustrate an exemplary modular block 200 constructed according to the present invention. The modular block 200 is generally rectangular and includes a top surface 212 , a bottom surface 214 , and front, rear, left and right sidewalls 216 , 218 , 220 , and 222 , respectively. A plurality of generally cylindrical core passages 224 of various sizes pass through the modular block 200 from top to bottom. As shown in more detail in FIG. 18 , each core passage 224 has an enlarged-diameter counterbore 226 formed at its upper end. As shown in more detail in FIG. 19 , each core passage 224 has a plurality of semi-cylindrical key slots 228 formed around the periphery of its lower end.
FIG. 20 illustrates an exemplary locking assembly 230 , which includes a core 232 , a locking rod 234 , one or more core keys 236 , and a rod key 238 , all of which are described in more detail below. The locking assembly 230 is received in one of the core passages 224 of a modular block 200 to enable the modular block 200 to be connected to other blocks, as shown in FIG. 21 . The locking assembly 230 fits in the core passage 224 so that the upper end of the core 232 fits flush with the top surface 212 of the modular block 200 , as shown in FIG. 22 , and the lower end of the core is flush with the bottom surface 214 of the modular block 200 , as shown in FIG. 23 .
FIGS. 24A through 24E illustrate the assembly sequence of the locking assembly 230 . Referring to FIG. 24A , the generally cylindrical core 232 has an enlarged boss 240 formed at its upper end which is sized and shaped to fit into the counterbore 226 of the core passage 224 . The core 232 has a through-bore 242 passing along its length. Approximately one-half of the through-bore 242 defines a series of alternating semi-cylindrical core grooves 244 and core lands 246 . The core grooves 244 have a first inner diameter, and the core lands 246 have a second inner diameter which is smaller than the first inner diameter. The remaining portion of the through-bore 242 is formed into a semi-cylindrical passage 247 having an inner diameter somewhat larger than the first inner diameter.
FIG. 24B illustrates a locking rod 234 . The locking rod 234 is generally cylindrical. Its outer surface defines a series of alternating cylindrical rod grooves 248 and rod lands 250 . The rod lands 250 have a first outer diameter which is approximately equal to the first inner diameter of the core grooves 244 , and the rod grooves 248 have a second outer diameter which is approximately equal to the second inner diameter of the core lands 246 .
FIG. 24C shows the locking rod 234 inserted into the core 232 and shifted laterally so that the rod lands 250 engage the core grooves 244 , and the rod grooves 250 engage the core lands 246 . Thus engaged, the locking rod 234 is prevented from moving axially relative to the core 232 . The locking rod 234 is inserted approximately halfway into the core 232 , so that a space will be left in the core for receiving another locking rod 234 in a manner described below.
FIG. 24D shows a rod key 238 about to be inserted into the core 232 . The rod key is an elongated, arcuate cross-section member with a laterally-extending lip 252 at its upper end. The outer wall 254 of the rod key 238 mates with the semi-cylindrical passage 247 of the core 232 , and the inner wall 256 of the rod key 238 mates with the rod lands 250 . When the rod key 238 is fully inserted into the core 232 , it prevents the locking rod 234 from shifting laterally and thus retains it in the core.
A pair of oblong core keys 236 , best seen in FIG. 26 , are disposed in core key openings 258 near the bottom end of the core 232 so that they can slide transversely to the long axis of the core 232 . The rod key 238 has opposed chamfers 260 at its bottom end (see FIG. 25 ) which engage the core keys 236 and force them outwards as the rod key 238 is fully inserted into the core 232 .
The locking assembly 230 is attached to a modular block 200 as follows. First, the core 232 with retracted core keys 236 is inserted into one of the core passages 224 of the modular block 200 . The locking rod 234 is then inserted into the through-bore 242 and shifted laterally as described above. The rod key 238 is then inserted into the core 232 , securing the locking rod 234 in place and also forcing the core keys 236 outward. As seen in FIG. 23 , the core keys 236 engage the key slots 228 of the core passage 224 . The entire locking assembly 230 is thus securely attached to the modular block 200 and cannot be removed until the rod key 238 is removed. If desired, the materials, dimensions, and finish of the rod key 238 may be chosen to prevent its unintended removal from the core passage 224 . Furthermore, the rod key 238 may be provided with a means for assisting its removal, such as a fingernail slot or tool ledge (not shown).
FIG. 27 shows a group of modular blocks 200 , 200 ′, and 200 ″ connected together with a plurality of locking assemblies 230 . To assemble the modular blocks 200 and 200 ′ together, a locking assembly 230 is first installed into a core passage 224 so that approximately half of the locking rod 234 extends upward from the top surface 212 of the modular block 200 (see FIG. 21 ). Then, a second core 232 ′ is inserted into the upper modular block 200 ′ without a locking rod 234 or rod key 238 . The locking rod (obscured in FIG. 27 ) is inserted into the second core 232 ′ and shifted laterally so that its grooves and lands engage the grooves and lands of the second core 232 ′, similar to the manner described above with respect to FIGS. 24A-24E . At this point, the modular blocks 200 and 200 ′ are assembled in an upper-and-lower touching relationship. If desired, a second locking rod 234 ′ may be inserted into the second core 232 and engaged with the grooves and lands thereof. A second rod key 238 ′ is then inserted into the second core 232 to lock both of the locking rods 234 and 234 ′ into place in the second core 232 ′ and prevent disassembly of the modular blocks 200 and 200 ′.
FIG. 28 illustrates a connector plate 262 for being used to join two or more modular blocks 200 together side-by-side. The illustrated connector plate 262 is a flat member having a thickness sized to fit in a connector slot 264 formed in the periphery of a modular block 200 (see FIG. 29 ). One or more connector pin holes 266 are formed through the connector plate 262 . In the illustrated example, the connector plate 262 is rectangular and has a two-dimensional array of connector pin holes 266 therein.
As shown in FIGS. 29 and 30 , some of the core passages 224 in the modular block 200 intersect the connector slots 264 thereof. A connector pin 268 , is sized to fit the core passage 224 . It may include an enlarged head 270 to prevent it from falling through the modular block 200 .
FIG. 31 illustrates two modular blocks 200 and 200 ′ connected end-to-end. A connector plate 262 is inserted into connector slots 264 of each of the modular blocks 200 and 200 ′. A connector pin 268 is then inserted into core passages 224 of each of the modular blocks 200 and 200 ′, passing through the connector pin holes (obscured in FIG. 31 ). This secures each of the modular blocks 200 and 200 ′ to the connector plate 262 and thus secures the modular blocks 200 and 200 ′ to each other, in both lateral and vertical directions.
FIG. 32 illustrates another connector plate 272 for being used to join two or more modular blocks 200 together. The illustrated connector plate 272 is substantially similar to the connector plate 262 described above, differing only in the fact that it includes an array of relatively small-diameter connector pin holes 274 A, and another array of relatively larger connector pin holes 274 B are formed through the connector plate 272 . The connector plate 272 can be used to join modular blocks 200 having different-sized core passages 224 . As shown in FIG. 33 , this allows the joining of relatively large modular blocks 200 and 200 ′ with a smaller modular block 200 ″.
FIG. 34 illustrates a finish element 276 . The finish element 276 has a planar inner side 278 which is dimensioned and shaped to mate with a side wall of the modular block 200 . The inner side 278 includes one or more connector tabs 280 with connector pin holes 282 therein. The connector tabs 280 are positioned and sized to fit into the connector slots 264 of the modular block 200 . The finish element 276 has an exterior surface 284 with one or more sides or facets which are formed into a desired shape. In the illustrated example, the exterior surface 284 of the finish element 276 is shaped to form a portion of a cylinder.
FIG. 35 illustrates a modular block 200 with several finish elements 276 attached thereto. They may be secured with connector pins (not shown) as described above, to form a solid structure with a cylindrical outer surface. The use of finish elements 276 allows the creation of structures that are modular, but which have arbitrary external shapes.
FIG. 36 illustrates another type of connector plate 286 . The connector plate 286 is a flat member having a thickness sized to fit in a connector slot 264 formed in the periphery of a modular block 200 . An array of connector pin holes 288 are formed through the connector plate 286 . One or more cylindrical studs 290 , each having at least one cylindrical land 292 and one cylindrical groove 294 , are attached to the connector plate 286 and are extend parallel to the plane thereof. The installation of the connector plate 286 into a connector slot 264 , as shown in FIG. 37 , gives the side of a modular block 200 the same connectivity as the top of the modular block 200 . More particularly, the studs 290 perform the same function as the locking rods 236 so that a modular block 200 ′ can be connected to the side of a modular block 200 (see FIG. 38 ).
FIG. 39 illustrates how various sizes of modular blocks 200 , 200 ′, 200 ″, 200 ′″, and 200 ″″ may be connected to each other by using appropriately-sized locking assemblies 230 in the core passages 224 . Exemplary locking assemblies 230 , 296 , and 298 , varying only in the size of their constituent components, are shown in FIGS. 40 , 41 , and 42 , respectively. The use of these different-sized locking assemblies 230 , 296 , and 298 is enabled by the provision of different-sized core passages 224 in the modular blocks 200 . As shown in FIG. 43 , these core passages 224 are laid out in a regular grid pattern within the modular block 200 .
FIGS. 44 and 45 illustrate an example of how a complex structure, in this case a wheeled vehicle, can be built up from the components described above, including modular blocks 200 , locking assemblies 230 , finish elements 276 , connector plates 286 , and connector pins 268
The modular blocks need not be square or rectangular. For example, FIG. 46 illustrates a curved modular block 300 . The curved modular block 300 includes a top surface 312 , a bottom surface 314 , and front, rear, left and right sidewalls 316 , 318 , 320 , and 322 , respectively. The front and rear sidewalls 316 and 318 are curved into parallel arcs. A plurality of generally cylindrical core passages 224 pass through the curved modular block 300 from top to bottom. As shown in FIGS. 47 and 48 , these curved modular blocks 300 can be used solely with other curved modular blocks 300 , or with rectangular modular blocks 200 to form structures with a desired shape.
FIG. 49 illustrates a trapezoidal modular block 400 . The trapezoidal modular block 400 includes a top surface 412 , a bottom surface 414 , and front, rear, left and right sidewalls 416 , 418 , 420 , and 422 , respectively. The left and right sidewalls 420 and 422 are angled in opposite directions. A plurality of generally cylindrical core passages 224 pass through the curved modular block 300 from top to bottom. As shown in FIG. 50 , these trapezoidal modular blocks 400 can be used with other trapezoidal modular blocks 400 to produce polygonal structures.
FIG. 51 illustrates a lobed modular block 500 which includes a top surface 512 , a bottom surface 514 , and a continuous sidewall 516 . The sidewall 516 is curved into a shaped having a pinched-in “waist” 518 disposed between two cylindrical lobes 520 . A generally cylindrical core passage 224 passes through the lobed modular block 500 from top to bottom at the center of each lobe 520 . As shown in FIGS. 52 and 53 , these lobed modular blocks 500 can be used to build up wall-like structures which can pivot about the locking rods 500 which hold them together.
Any of the various shapes of modular blocks described above may be attached to any other shape as long as a core passage is available. An example of a structure built up from various block shapes is shown in FIG. 54 .
FIG. 55 illustrates another alternative modular block 600 constructed according to the present invention. The modular block 600 includes a top surface 610 , a bottom surface 612 , and front, rear, left and right sidewalls 614 , 616 , 618 , and 620 , respectively. An interior space 621 is defined along the central portion of the modular block 600 . As shown more clearly in FIG. 56 , the modular block 600 is built up from two side members 622 A and 622 B, and one or more locking lugs 624 . Each of the side members 622 has an inner surface 626 and an outer surface 628 . The inner surface 626 of each side member 622 is generally planar and has a plurality of key grooves 623 formed therein. Because the inner surfaces 626 are identical, the side members 622 may be produced in large quantities by providing a workpiece with a flat surface, machining long, continuous grooves in the flat surface, and then cutting the workpiece into individual side members 622 .
Each of the locking lugs 624 includes upper and lower notches 630 A and 630 B formed near its upper and lower ends. These notches 630 are positioned and sized so as to define “L” shaped upper and lower hooks 632 A and 632 B, respectively. The hooks 632 are sized to engage the notches 630 .
Referring again to FIG. 55 , the locking lugs 624 are assembled to the modular block 600 by clamping them between the side members 622 A and 622 B. It will be appreciated that the locking lug 624 may be assembled to the modular block 600 so that it points in any one of four directions. In FIG. 55 the upper hooks 632 A of the locking lugs 624 extend towards the front endwall 614 of the modular block 600 , whereas in FIG. 57 , the upper hooks 632 A′ of the locking lugs 624 ′ extend towards the right sidewall 620 ′ of the modular block 600 ′. The components may be secured together by adhesives, welding, thermal or sonic bonding, fasteners, or any other method that will create a unitary whole. The entire modular block 600 may also be formed as an integral component, for example by casting it from a mold.
The modular block 600 and the locking lug 624 may be constructed of any material which is suited to the application for which the modular block 600 is to be used and which can be formed into the necessary dimensional features. For example, the modular block 600 may be used as a toy, a modeling element, or a light structural element, in which case it may be molded from a material such as plastic resin. The modular block 600 may also be used for heavier structural applications, in which case it may be formed from materials such as concrete, wood or engineered wood materials, pressed fiber, metals, or fiber composite materials. In the illustrated example, the modular block 600 includes an exterior fascia 601 intended to present a finished appearance. The fascia 601 may be formed as an integral part of the modular block 600 , or it may be added to the exterior of the modular block 600 , for example by building up a layer of mortar, joint compound, or the like, and applying an appropriate finish thereto.
FIGS. 58 and 59 illustrate a key 634 to be used with the modular blocks 600 . The key 634 is an elongated member sized to fit into the interior space 621 . The key 634 has an upper end 636 with an alignment pin 638 protruding therefrom, and a lower end 640 with a complementary alignment hole 642 formed therein. The key 634 also includes at least one alignment rail 644 adapted to engage the key grooves 623 . In the illustrated example, the body of the key 634 is an “H” shaped cross-section, and the alignment rail 644 is formed by positioning a dowel between the uprights of the “H” section. This simplifies manufacture of the key 634 .
FIGS. 60 and 61 illustrate an alternative key 646 . The key 646 is substantially similar to the key 634 and has an upper end 648 with an alignment pin 650 protruding therefrom, and a lower end 652 with a complementary alignment hole 654 formed therein. The key 646 also includes at least one alignment rail 656 adapted to engage the key grooves 623 . In the illustrated example, the body of the key 656 is generally rectangular, and the alignment rails 656 are formed by positioning dowels within slots 658 in the surface of the key 656 .
FIGS. 62 and 63 illustrate how a plurality of modular blocks 600 may be assembled to form a larger structure. A first modular block identified as 600 A is positioned down over the locking lugs 624 of one or more other modular blocks 600 B, 600 C, and then shifted laterally so that the hooks 632 of the modular blocks 600 B and 600 C engage the notches (not visible in FIG. 62 ) in the locking lugs 624 of the first modular block 600 A. This prevents the modular blocks 600 A, 600 B, and 600 C from being disconnected in a vertical direction. In creating the assembled structure, the orientation of the locking lugs 624 are preferable chosen so that the hooks 632 will all be facing in the same direction regardless of the orientation of the modular blocks 600 . For example, in FIG. 62 , the modular block identified as 600 D has its hooks 632 facing perpendicular to its long axis.
To secure the modular blocks 600 together, one or more keys are inserted into the central spaces 621 , with the alignment rails 644 engaging the key grooves 623 of both an upper modular block 600 A, and the modular block 600 C below it (see FIG. 63 ). The engagement of the key 634 prevents lateral motion of the hook 632 relative to the notches 630 . A larger key 646 has multiple alignment rails 656 and therefore holds together two adjacent modular blocks 600 A and 600 E by engaging key grooves 623 in each of the blocks 600 A and 600 D. The dimensions, materials, and surface finish of the keys 634 and 646 may be selected to prevent unintended withdrawal.
The modular blocks (for example items 10 , 200 , 300 , 400 , 500 , and 600 ) described above may be used for any type of construction which requires or would benefit from a modular characteristic. Several non-limiting examples of possible applications for theses blocks will now be set forth, without regard to a particular embodiment of the blocks themselves. Of course, the modular blocks can be used as toys or as small-scale modeling elements when produced in a proper size, say a few centimeters on a side.
When produced in larger sizes, they may be used for residential or commercial building elements such as walls, roofs, floor, retaining walls, and windows (if made from transparent or translucent material). They may also be used to construct industrial structures such as factory floors, machine tool bases and machine bodies.
The modular blocks can also be used to build marine structures such as piers, barges, underwater structures, and boat hulls.
On a smaller scale, the modular blocks may be used to build up three-dimensional circuit cards, or if made of bio-compatible materials, they may be used to form three-dimensional frames for bone or organ tissue construction. If reduced to a sufficiently small scale, they can be used for nanostructures.
The modular blocks may be formed out of armor material or projectile-resistant material, such as KEVLAR aramid fibers. These armored blocks can be used to form containers to ship military supplies. After the supplies are received at the destination, the containers can then be disassembled into modular blocks. These blocks can then be used to construct custom made protective shields for personnel or equipment. Shipping containers may also be made from more conventional construction materials and then used to ship food, water, or other supplies to disaster areas. After the supplies are received, the shipping containers may be disassembled into modular blocks and then used for low-cost buildings that can be quickly erected.
The foregoing has described a modular block and a method of construction using such modular blocks. While specific embodiments of the present invention have been described, it will be apparent to those skilled in the art that various modifications thereto can be made without departing from the spirit and scope of the invention. Accordingly, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation. | A modular block apparatus includes first and second blocks, each block having a generally upwardly protruding locking member and an internal recess sized to receive the locking member of the other block, such that the blocks can be assembled with one block above the other. The blocks are secured together in a vertical direction by relative lateral movement of the locking member and the internal recess. A locking device is provided to prevent relative lateral movement of the locking member and the internal recess so as to retain the blocks in a connected condition. The locking member may be an integral hook, a separate hook, or a cylindrical locking rod. If a hook is used, its orientation relative to the block may be varied. A variety of structures may be built up from the modular blocks. | 4 |
This is a 371 of PCT/EP02/07563 filed 8 Jul. 2002 (international filing date).
The invention relates to equipment for separating liquids and solids in centrifuges, in particular disk separators with automatic discharge. The invention relates in particular to a paste deflector ring with an annular impact wall for a self-discharging centrifuge and to the self-discharging centrifuge itself.
BACKGROUND OF THE INVENTION
Disk separators are centrifuges equipped with a central inlet for the suspension, conical disks which are located in the drum and which act as separators for fine particles as a result of the centrifugal force which is present and the short sedimentation paths. The particles which have been separated out slide along the disks into the solids collection space toward the maximum diameter of the drum. The clarified liquid is discharged over an overflow weir without pressure or under pressure by means of what is known as a gripper designed as a pump impeller.
For low solids contents, disk separators with a closed drum which have to be emptied by hand are in use. For higher solids contents, the drums are equipped with an emptying system which enables the entire contents of the drum comprising solids and liquid to be discharged as a slurry.
Disk separators with a standing or suspended drum are known.
German laid-open specification DE 198 46 535 A1 has disclosed a centrifuge with a suspended drum in which a tubular bag is fitted beneath the drum in order to collect the solid. The vessel in the centrifuge is of cylindrical design in the region of the centrifuging zone of the drum.
This has the drawback that the solids which are centrifuged out can remain stuck in the region of the centrifuging zone, making central collection of the solids impossible.
It is also known that with solid pastes with good flow properties, by achieving an extremely short drum opening time, what are known as partial sludge removal operations are possible, allowing a higher solids concentration to be achieved in the paste which is discharged.
In recent times, it has been attempted to produce a highly concentrated paste by extracting the liquid fraction in the drum before it is emptied and to discharge this highly concentrated paste through a controllable gap which is larger than has hitherto been customary.
For system reasons, the discharge of paste takes place with centrifugal acceleration in the horizontal direction onto a circular periphery, and the paste discharged could be collected in an annular vessel. However, it is desirable for the paste to be collected in a vessel located beneath the drum. This is preferably possible with a suspended drum in one embodiment of a centrifuge. The paste then has to be deflected from the horizontal direction downward into the vessel.
SUMMARY OF THE INVENTION
The invention relates to a device comprising a paste deflector ring and a paste container which is connected to it or can be released and is able to receive the paste from a plurality of drum emptying operations. This ring is designed in such a way that deflection entails the minimum possible product losses.
The subject matter of the invention is a paste deflector ring having an annular impact wall for a self-discharging centrifuge, characterized in that the setting angle α of the tangent of the impact wall of the deflector ring positioned opposite the discharge slot of the centrifuge with respect to the horizontal is from 3 to 60°, preferably 10 to 30°, as seen over the entire opening width of the discharge slot.
This allows gentle deflection, in particular with low shear forces, of the solid which has been centrifuged out of the discharge slot into the collection vessel of the centrifuge.
DETAILED DESCRIPTION
A particular deflector ring is characterized in that the inner contour of the impact wall immediately below the impact surface, in particular as seen over any desired longitudinal section through the deflector ring, is of circular or parabolic design.
This makes the deflection even more gentle on the product and further reduces the shear forces.
In a preferred form, the deflector ring is designed in such a way that the impact wall, in the region below the discharge slot, has a curved inner contour, as seen in geometric longitudinal section, with a radius of curvature of >20 mm, preferably of 30 to 50 mm.
The latter curved wall surface may also be designed according to a curve, with a radius which varies over the path length.
In a particularly preferred embodiment, the impact wall of the deflector ring, in the region above the opening width of the discharge slot, has a setting angle γ with respect to the horizontal of 3 to 30°, preferably from 5 to 15°.
A preferred variant of the deflector ring is characterized in that the tangent of the inner contour of the impact surface, in the region below the deflecting contour of the deflector ring, has a setting angle β of up to 30°, preferably from 5 to 15°, with respect to the vertical, as seen in geometric longitudinal section. The vertical is in this case parallel to the axis of rotation of the drum.
This results in particularly favorable guidance of the product which has been centrifuged out toward the center of the collection vessel.
In a preferred variant, the deflector ring has a detachment edge, which may be undercut, at its lower end.
The deflector ring is in particular integral with a collection vessel or is particularly preferably releasably connected to the collection vessel of the centrifuge.
In a preferred embodiment, the deflector ring is designed with jacket cooling.
The cooling jacket is, for example, a double wall on the outer periphery of the deflector ring, through which a heat-transfer medium can flow.
In a preferred embodiment, the surface of the deflector ring which comes into contact with product is provided with a coating with sliding properties, in particular made from PTFE or metal alloys.
In a further preferred variant, the deflector ring has one or more nozzles for spraying in liquid nitrogen.
These nozzles are in particular distributed over the periphery of the deflector ring below the impact surface which corresponds to the opening width of the discharge slot.
The subject matter of the invention is also a self-discharging centrifuge for the process engineering treatment of highly concentrated pastes, at least comprising an optionally coolable housing, a feed line for the suspension, a discharge line for the clarified liquid, a suspended drum, which is connected to a drive part at the top and has two or more discharge slots, a collection vessel, which if appropriate can be detached from the housing, and a discharge device for the paste, characterized in that the centrifuge includes a deflector ring according to the invention.
The collection vessel is preferably cylindrical or designed to taper conically toward the bottom.
The conical taper of the collection vessel makes it easier to discharge, for example, frozen product from the vessel. The upper edge of the vessel is in particular designed in such a way that a flow with little swirling is formed below the detachment edge which is preferably fitted as part of the deflector ring.
Likewise in a preferred embodiment, the inner surfaces of the collection vessel which come into contact with product are provided with a coating with sliding properties, in particular made from PTFE or metal alloys.
A bag made from flexible material is particularly preferably fitted into the collection vessel and can be fixed to the vessel walls in particular by means of a pressure reduction.
Suitable materials for the bag are all film plastics, in particular polypropylene, polyethylene or polyvinyl chloride.
In a preferred further form of the centrifuge, the collection vessel is designed with a temperature-control device, in particular with jacket cooling.
The collection vessel preferably also has means for transporting the collection vessel, in particular by means of floor conveyor devices.
The upper opening of the collection vessel is particularly preferably designed as a partial flange.
As a result, the collection vessel can, for example, be closed by means of a cover and is designed in such a way that it can be docked to other process engineering apparatus, in particular to a dissolving tank.
For use in the biotechnology sector, e.g. during the separation of pastes or clarification of liquids in human blood plasma fractionation, the collection vessel is designed with the capacity for jacket cooling.
To improve the cooling action, one or more nozzles may be fitted, through which liquid nitrogen can be introduced into the gas space in the vicinity of the rotating drum, in order to prevent the discharge space from being heated by air friction.
There are known disk separators which can be cleaned automatically by cleaning-in-place. For this purpose, during certain in some cases special operating states, the separator is rinsed with various cleaning liquids. Special CIP nozzles may be fitted to assist with the cleaning. When designing the components and the seals between the components, it should be ensured that they are readily accessible during the cleaning.
The vessel may be made from metallic or nonmetallic materials. The vessel may be arranged detachably or non-detachably in a frame which is transported or can be stacked by means of floor conveyor vehicles.
The vessel may be provided with a cover or may be equipped with an automatic opening slide and may be suitable for feeding dissolving tanks.
The vessel may be equipped with a slurrying or melting device which enables it to convey the contents into the dissolving tank as a free-flowing suspension.
Like the deflector ring, the vessel may also be equipped with the capacity for jacket cooling, for example for use in biotechnology.
The invention is explained in more detail below, by way of example, with reference to the figures, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a longitudinal section through a modified centrifuge 1 .
FIG. 2 shows an enlarged detail of the longitudinal section shown in FIG. 1 .
EXAMPLES
The discharge of a biological paste which is formed during the fractionation of human blood plasma takes place from a centrifuge drum 14 having an external diameter of 468 mm at a drum rotational speed of 7000 rpm, with the blood plasma paste being deflected by a paste deflector ring 4 . The centrifuge 1 has a drive part 13 for driving the drum 14 , with a feed line 11 for the plasma. The drum 14 is suspended in a dividable lower part of the centrifuge 1 which comprises the jacket housing 10 , with feed lines 19 and discharge lines 22 for a cooling liquid and lines 9 for introducing liquid nitrogen, the deflector ring 4 and the collection vessel 7 , with flexible collection bag 17 inserted therein. The collection vessel has a cooling jacket 16 with feed lines 20 and discharge lines 21 and also welded-on transport brackets 18 . The drum 14 also has an outlet 12 for the clarified liquid. FIG. 2 shows the deflector ring 4 in detail. The impact wall 2 of the paste deflector ring 4 is at an angle α=15° (cf. FIG. 2 ) with respect to the horizontal in the region of the discharge slot 3 . The angle y above the opening width of the discharge slot 3 is likewise inclined by 15° with respect to the horizontal, so that the impact wall 2 , itself and the region above it form a straight line in projection. Below the impact wall 2 , the discharged paste is deflected toward the base of the collection vessel 7 by a circular contour, as seen in longitudinal section, with a radius of curvature r of 45 mm. To guide the discharged solids away from the vessel wall toward the center of the base, the adjoining surface 5 is inclined at an angle β=10° with respect to the vertical. At its lower end, the paste deflector ring 4 has a detachment edge 6 .
With this geometry, it was possible to achieve virtually complete deflection of the paste. By way of example, after two discharges from the centrifuge drum, 98.3% of the discharged mass of solids was located in the collection vessel 7 beneath it and only 1.7% was still on the surface of the deflector ring. A further test using a different biological paste, after six discharges, showed a mass of solids of 99.5% in the collection vessel, corresponding to a loss of 0.5% on the surface of the paste deflector ring. | The invention relates to a deviation ring for paste comprising an annular rebound wall ( 2 ) for a self-distributing centrifuge ( 1 ). The invention also relates to a corresponding self-distributing centrifuge ( 1 ). In the deviation ring, the angle of incidence ? of the tangents of the rebound wall ( 2 ) of the deviation ring ( 4 ), opposite the distribution slit ( 3 ) of the centrifuge ( 1 ), in relation to the horizontal, is between 3 and 60° over the entire opening width of the distribution slit ( 3 ). | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority benefit under 35 U.S.C. §119(e) of applicants' copending U.S. provisional patent application No. 60/089,324, filed Jun. 15, 1998.
BACKGROUND OF THE INVENTION
This invention relates to security devices bearing holographic images, of the type commonly applied to personal identification cards, various types of documents or other substrates, and to methods of making such devices.
As described for example in U.S. Pat. Nos. 5,145,212 and 4,913,504, to protect a credit card or other article or document of value against counterfeiting, a label or like device bearing a relief holographic image may be applied thereto. Holographic images are inherently extremely difficult to replicate effectively; moreover, in the described security device, the relief image is cast on a surface facing the substrate, so as to be inaccessible for taking impressions. Owing to this combination of characteristics, devices of the type described have won very wide acceptance.
Notwithstanding the success of such known holographic image-bearing security devices, it would be desirable to provide enhanced or additional security features in these devices, and to do so in a simple and economical manner, preferably capable of implementation with a minimum of modification in existing types of production lines.
SUMMARY OF THE INVENTION
An object of the present invention is to provide holographic image-bearing security devices, e.g. labels, for application to cards, documents and/or other substrates, characterized by a new and improved feature for making attempted tampering evident. Another object is to provide tamper evident security labels or overlaminates which combine both a readily verifiable overt security feature through the use of a holographic image and a covert security feature through the use of an invisible pattern that only becomes evident upon an attempt to delaminate the device from the surface to which it is adhered.
A further object is to provide a relatively simple and cost effective method of making tamper evident security devices of the type bearing holographic images. A still further object is to provide such a method of mass producing tamper evident holographic security products by radiation casting techniques.
To these and other ends, the present invention in a first aspect broadly contemplates the provision of a security tamper evident holographic label or like device affixable to a substrate such as a card, document or other article. The security device of the invention comprises a clear protective layer having opposed surfaces; a thin patterned layer of a clear resin cast onto a surface of the protective layer in a pattern such that some portions of that protective layer surface are covered, and other portions are not covered, by the patterned layer; a holographic image layer of a resin bearing a holographic image and having opposed surfaces of which one faces toward, and is bonded to, the patterned layer and portions of the protective layer surface that are not covered by the patterned layer, the bond of the image layer to the not-covered portions of the protective layer surface being stronger than the bond of the image layer to the patterned layer; a reflective layer strongly attached to the image layer; and an adhesive layer, bonded to the reflective layer, for affixing the device to a substrate.
This article, when adhered to a identification card or other base substrate by the adhesive layer, will exhibit no discernible security feature to the unaided eye owing to the thinness of the clear security patterned layer. If delamination of the article is attempted, however, the holographic image layer will be broken at the weakest interfacial bond, which is between the patterned layer and image layer surfaces, making evidence of tampering visible in the form of a break pattern identical to that of the clear patterned layer.
As an important particular feature of the invention, for achieving the foregoing and other advantages, both the patterned layer and the holographic image layer of the device are constituted of ultraviolet cured resin. The patterned layer and the image layer can be made of the same type of ultraviolet cured resin, or can be made of exactly the same resin.
In a second aspect, the invention contemplates the provision of a method for making a security device as described above, including the steps of providing a clear protective layer having opposed surfaces; radiation casting, on one of the surfaces of the protective layer, a thin patterned layer of a clear radiation curable resin, the patterned layer being cast onto the protective layer in a pattern such that some portions of the protective layer are covered, and other portions are not covered, by the patterned layer; radiation casting a second layer of a clear radiation curable resin bearing a holographic image onto the patterned layer and portions of the protective layer that are not covered by the patterned layer, the materials of the protective layer, patterned layer and second radiation curable resin layer being such that the last-mentioned layer bonds more strongly to the not-covered portions of the protective layer surface than to the patterned layer; strongly attaching a reflective layer to the last-mentioned image layer; and bonding an adhesive layer to the reflective layer, for affixing the device to a substrate. The protective layer and the patterned layer are subjected to a corona treatment before the holographic image layer is cast thereover.
Further features and advantages of the invention will be apparent from the detailed description hereinbelow set forth, together with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic side elevational sectional view, not to scale, of a security label embodying the present invention in a particular form, attached to a substrate such as a personal identification card, in untampered condition;
FIG. 2 is a similar but exploded view of the security label of FIG. 1, again shown in untampered condition; and
FIG. 3 is a similar view of the same label after tampering.
DETAILED DESCRIPTION
Referring to the drawing, and in particular to FIGS. 1 and 2 thereof, the security label 10 there shown has a clear radiation cured patterned layer 12 cast “partly” (in a designed pattern) onto a surface of a clear protective layer 14 , another clear radiation cured layer 16 bearing a cast holographic image, a reflective layer 18 , and an adhesive layer 20 for securing the label to a substrate such as a card, document or other article 22 . The pattern of layer 12 is such that some portions of the surface of layer 14 are covered by the material of layer 12 and other portions are not. The direct bond between the holographic image layer 16 and the protective layer 14 (i.e. in protective layer surface portions 24 where the protective layer surface is left exposed by patterned layer 12 ) is stronger than that between layer 16 and the patterned layer 12 , so that attempted delamination will break the holographic image layer at the weakest interfacial bond, to form a break pattern identical to the pattern of layer 12 .
Typically the cast holographic image is a relief holographic image as described in the aforementioned U.S. Pat. Nos. 5,145,212 and 4,913,504, and is cast in the surface of layer 16 facing away from layers 12 and 14 , the reflective layer 18 being formed thereafter by vapor deposition or sputtering of aluminum or other highly reflective materials over this cast surface (again as set forth in the last-mentioned patents) prior to application of the adhesive layer 20 .
As thus embodied, important particular features of the invention reside in the provision of a clear patterned layer between a clear protective layer and a holographic image layer to provide a differential adhesion pattern at that location. The patterned layer 12 is sufficiently thin so as to be undetectable (in the untampered label) upon visual inspection.
In the illustrated embodiment of the invention, the bond strength between the image layer 16 and the exposed (unpatterned) portions 24 of the surface of protective layer 14 is greater than the shear strength of the image layer 16 and the reflective layer 18 ; the bond strength between the adhesive layer 20 and the reflective layer 18 is also greater than the shear strength of the image layer 16 and the reflective layer 18 ; the bond strength between the image layer 16 and the exposed (unpatterned) portions of the surface of protective layer 14 is greater than the bond strength between the adhesive layer 20 and the reflective layer 18 ; and the shear strength of the protective layer 14 is greater than the shear strength of the image layer 16 and the reflective layer 18 .
In a typical holographic label or overlaminate using radiation casting techniques, the product can be viewed as a two-layer system comprising a clear protective layer and a much thinner holographic layer cast directly onto the protective layer. The holographic image is subsequently made more visible by coating the holographic image side of the label with an ultra thin layer of reflective material. An adhesive layer is finally applied to the reflective side of the label to render the entire system functional as a pressure sensitive holographic label or a holographic overlaminate product. The present invention achieves the objective of adding a covert security feature, to the typical construction just described, in the form of a tamper evident pattern that remains invisible until the product has been tampered with.
In its method aspects, the invention achieves the further objective of adding the covert security feature in an efficient and cost effective manner during the mass production of the security device. To this end, two simple but very effective additional operational steps are introduced just prior to the casting of the holographic image layer 16 onto the protective layer 14 and the pattern layer 12 . These steps comprise first casting directly onto the clear protective layer 14 a very thin and clear patterned layer 12 that partly covers the protective layer, following by subjecting the resulting two-layered film to corona treatment. The patterned layer is a clear UV-curable liquid resin that bears no image and is chosen to exhibit practically the same or similar refractive index to that of the clear polymeric protective layer so that it will remain invisible to the unaided eye in the final construction. Preferably, this patterned layer is chosen to bond strongly to the protective layer.
The pattern design of layer 12 on layer 14 can assume a variety of forms and shapes, from the common checkerboard pattern to a number of designed graphics, indicia, text or the like. As will be understood, the pattern is constituted of areas in which the patterned layer is present (covering portions of the protective layer surface) and areas in which the patterned layer is absent (leaving other portions 24 of the protective layer surface exposed for direct bonding to the subsequently cast image layer 16 ).
After the UV casting of the patterned layer and the corona treatment of both the protective and patterned layers, the holographic image layer 16 is cast directly over the patterned layer and the protective layer. The holographic image layer is a UV curable resin made of the same type of resin as that of the patterned layer or is made of exactly the same resin as the patterned layer. The image layer is of the same order of thickness as that of a typical UV cast hologram but must fully cover the protective layer as well as the thinner patterned surface so that the final holographic image that becomes visible due to the subsequent addition of an ultra thin coating of a reflective material 18 will remain evenly smooth and effectively render invisible the security pattern of the patterned layer 12 .
The UV curable resin used to cast the holographic image layer 16 is chosen to exhibit a sufficiently high bond strength toward the protective layer 14 to exceed the weaker bond between the corona treated patterned resin and the image resin. Corona treating the patterned layer prior to casting the image layer on top of it, regardless whether the patterned layer is made of the same resin as the image layer or not, will reduce the bond strength between the said two UV curable resin layers and consequently produces an increase in the bond strength differential between the image layer 16 and the protective layer 14 on one hand and the image layer 16 and the patterned layer 12 on the other hand. The aforesaid bond strength differential can also be further improved if, in addition to corona treatment, the bond strength between the holographic image layer 16 and the protective layer 14 is made even stronger by choosing a combination of protective layer material and holographic layer chemicals that exhibit an inherently greater bond strength among them. The latter case is particularly helpful when the final product is an overlaminate which makes use of a heat-activated adhesive instead of a pressure sensitive label.
It is this bond strength differential that allows the final product to assume the tamper evident characteristic if tampered with. That is, when stress is applied to remove the label from the surface to which it has been attached by means of an adhesive layer 20 , portions of the image layer 16 that come in direct contact with the patterned layer 12 will be readily detached from the patterned portions because of the weaker interfacial bond between the two UV cured resins. On the other hand, in areas where the image layer 16 is directly cast over the non-patterned portions 24 of the protective layer 14 , the image layer will remain attached to the protective layer 14 because its bond strength towards the protective film is greater than the adhesive strength between the reflective layer 18 and the base substrate 22 . Since the tear strength of the thin UV cast image layer is lower than the adhesive strength between the image layer and the base substrate, the image layer will break in the exact pattern as the patterned layer during the delamination process (as shown in FIG. 3 ), leaving parts of the image behind on the base substrate and other parts of it on the delaminated portion.
The simplicity of this method resides in part in the fact that it requires the addition of only one single extra casting step in the UV casting operation, i.e., for casting the patterned layer 12 . It becomes even more straightforward if done in-line if the casting equipment has multiple casting stations.
Another advantage of this method from the standpoint of simplicity is that the patterned layer and the image layer can be made of exactly the same UV cured resin. This further simplifies the manufacturing of the product since there is no downtime due to cleaning between the two casting operations.
By way of illustration of suitable materials for the tamper evident device of the invention, the protective layer 14 may be a clear plastic film (available from commercial suppliers) e.g. a film of PET, polypropylene, polycarbonate, styrenic, vinyl, acetate, etc. The patterned layer 12 may be constituted of a UV curable resin based on acrylic, urethane and/or epoxy chemicals. Similarly, the holographic image layer 16 may be constituted of a UV curable resin based on acrylic, urethane and/or epoxy chemicals.
In a currently preferred combination of materials, the protective layer 14 is an optically clear, tough plastic film such as polyester, polycarbonate or polypropylene film, while a combination of acrylic and urethane-based UV curable oligomers having mono and multi-functionalities is used for the patterned layer 12 and the image layer 16 . A typical or exemplary formulation for these two (patterned and holographic image) layers contains high speed UV initiator and monofunctional UV curable monomer as diluent.
An exemplary range of thickness of the patterned layer 12 is between about 0.5 microns and about 2.5 microns. A currently preferred value for this thickness is approximately 2 microns.
More particularly, in currently preferred practice, the resins (varnishes) used in the patterned and the holographic image layers are made of chemical ingredients originating from the same classes of UV curable chemicals. The common classes of UV materials generally include those in the acrylic, urethane and epoxy groups. A varnish typically contains either oligomers from the acrylic, urethane or epoxy groups or from a mixture of the above groups of chemicals. The choice of chemicals is dictated by the substrate onto which the varnish is cast as well as its final properties. In general, there is a set of structure-property guidelines typically found in radiation curable resins. See United Kingdom published patent application No. 2,027,441-A.
The preferred method of casting the patterned layer 12 on the protective film 14 is by a combination of gravure roller and transfer roller (not shown). First the gravure roller is brought in contact with the liquid varnish while it is in a continuously rotating mode. A transfer roller on which a desired pattern has been engraved is simultaneously brought in contact with the rotating gravure cylinder. The raised patterned areas on the transfer roller become wetted with the liquid varnish. The protective film is brought in contact directly with the rolling transfer roller via a nip roller and is therefore set in a continuously advancing motion. The film becomes continuously coated with the liquid varnish in the same pattern design as the pattern design on the transfer roller. The thickness of the coated varnish is mainly related to the cell gravure cylinder, the viscosity of the liquid varnish as well as the speed of the film as it passes through the line. The liquid varnish is then cured as it passes directly under a UV light source, forming an ultra-thin patterned layer 12 of UV cured resin on top of the protective layer 14 .
The casting of the holographic image layer 16 onto the newly formed double-layered film which is composed of the protective film 14 and patterned layer 12 attached to it, is very similar to the casting of the patterned layer 12 . First, the double-layered film is coated with a second liquid UV varnish by gravure and transfer roller as described before. This time, the transfer roller does not have any pattern on it. The second liquid varnish covers the entire film surface including the patterned areas as well as the unpatterned areas of the protective film. Its preferred thickness after curing is approximately 3 to 5 microns. The coated film subsequently passes over an image cylinder with the liquid varnish facing the image grooves while it is simultaneously cured by exposure to a UV light located directly above the image cylinder. The liquid varnish is cured by the UV beam as the latter passes through the clear protective and patterned layers. In this casting process, the cured varnish retains the holographic image grooves as it replicates the grooves from the image cylinder. The final film is a three-layered film made of a protective layer, a patterned layer and a holographic image layer. Each layer is made of polymeric materials chosen to exhibit refractive index values very close to one another. As long as the image layer fully covers the ultra-thin patterned layer beneath it, it will not make the patterned layer apparent even after the hologram has been coated with a high reflective metal for ready visibility.
It is to be understood that the invention is not limited to the features and embodiments herein specifically set forth, but may be carried out in other ways without departure from its spirit. | A method for producing a tamper evident security holographic label and overlaminate using UV casting techniques, and a security device so produced, comprising a clear protective layer; a thin layer of clear UV cured resin cast partly onto the protective layer following a designed pattern; another layer of UV cured resin bearing a cast holographic image, wherein the bond of the holographic image layer is stronger toward the surface of the protective layer than it is toward the surface of the pattern layer; a reflective layer strongly attached to the adjacent holographic layer; and an adhesive layer bonded to the reflective layer. Such a composite product when adhered to a base substrate via the adhesive layer will show no visible security feature to the unaided eye due to the thin nature of the clear security pattern. But upon delamination attempts, the ultra-thin holographic image layer will be broken at the weakest interfacial bond which is between the two UV cured resin surfaces, providing visible evidence of tampering in the form of a break pattern identical to that of the clear pattern layer. | 8 |
This application is a division of application Ser. No. 111,870, filed Jan. 14, 1980, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to firearms. More specifically, this invention relates to handguns capable of firing high-powered ammunition.
Conventional handguns have employed a rebound assembly comprising a strut which engages the hammer after firing and returns the hammer to the at-rest or safety position. The struts have generally employed a bifurcated engaging means whereby an engagement is made at two contact points generally symmetrical to the pivot point of the hammer pin and the hammer is "rocked" into a safety position. This type of rebound cam assembly is exemplified in U.S. Pat. No. 3,988,849.
Additionally, prior multibarrel handguns have provided means for sequentially firing the barrels. This sequential firing has been frequently accomplished in part by means of mounting a firing element on a ratchet, which rotates on the hammer so as to sequentially align with the firing pins during firing.
Unfortunately, multibarrel handguns employing sequential firing mechanisms have exhibited firing malfunctions, such as a machine gunning effect whereby one pull of the trigger results in a rapid sequential firing of all of the barrels of the firearm. The result of this rapid sequential fire is exacerbated with high-power ammunition and frequently results in violent recoil forces often endangering the firearm user and severely affecting the accuracy and effectiveness of the handgun.
SUMMARY OF THE INVENTION
This invention provides a new and improved strut assembly means whereby the strut is forceably engaged with the hammer assembly at only one point prior to firing and the hammer assembly is permitted to return to the at-rest or safety position when the strut is stopped against the hammer pivot. This feature considerably reduces the chances of misfire, since the conventional rocking engagement of the cam strut frequently compresses the strut spring on the rebound resulting in a diminished forward hammer thrust. The diminished forward thrust can result in a misfire. Additionally, the improved strut assembly permits the attainment of a neutal positioning of the hammer after firing.
This invention further provides a new and improved method for indexing and rotating the ratchet on a multibarrel firearm in part by employing notches on a ratchet both to facilitate the rotation of the ratchet and to position the firing lug on the ratchet in alignment with an associated cartridge chamber. This improvement allows for easier alignment during assembly process, makes the operation of the firearm more efficient during the firing process and reduces the manufacturing expense, since fewer assembly elements are necessary.
This invention further provides for a new and improved mechanism which acts to eliminate machine gunning by means of an outwardly projecting lug on the trigger assembly. The lug prevents the pawl or hand which rotates the ratchet and hence the firing plate, from rotating the firing lug to a new position so as to align with a chamber containing an unfired cartridge until the trigger has been fully returned to the safety or at-rest position.
An object of the invention is to provide a new and improved means for aligning the firing lug with the firing pins or cartridge chambers in a multibarrel handgun.
Another object of the invention is to provide a new and improved means of sequentially firing a multibarrel handgun.
A further object of the invention is to provide a mechanism for preventing the machine gunning effect upon initial firing of the handgun.
A still further object of the invention is to provide certain improvements in the form, construction and arrangement of the several parts whereby the above-named and other objects may effectively be attained.
The invention accordingly comprises the features of construction, combinations of elements, and arrangement of parts which will be exemplified in the constructions hereinafter set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of a four-barrel handgun;
FIG. 2 is a vertical sectional view along the lines 2--2 of FIG. 1 showing the gun in an at-rest position, parts being broken away;
FIG. 3 is a vertical sectional view along the line 3--3 of FIG. 2 looking toward the rear of the handgun;
FIG. 4 is a detailed vertical sectional view along the line 4--4 of FIG. 2 looking toward the front of the handgun;
FIG. 5 is a detailed sectional view of the ratchet and part of the hammer assembly along the line 5--5 of FIG. 3; and
FIG. 6 is a detailed view similar to FIG. 2 showing the hammer and trigger in cocked position, parts being broken away.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the handgun has a frame 10 which includes the grip portion 14, the breech portion 16, the barrel portion 12, trigger guard 18 and the barrel mounting portion 20. The frame 10 is centrally recessed as indicated at 19 to receive the trigger assembly 17, hammer assembly 59 and the strut assembly 58. A pair of mounting slots 135, which open outwardly and upwardly from the barrel mounting portion 20, receive a pair of mounting tongues 132 of the barrel assembly 12.
The barrel assembly 12 consists of four cylindrical barrels 15 extending the length of the assembly from an exit end 116 to a cartridge chamber at the cartridge receiving end 117, said barrels being arranged in pairs side by side, with one pair being mounted on top of the other. The barrel assembly 12 is mounted on the a pair of mounting tongues 132, which are pivoted on a barrel pivot pin 130 inserted through the barrel mounting portion 20 and mounting slots 135. A front sight 140 is mounted at the top of the exit end 116 of the barrel assembly. A release groove 115 is formed in the top of the barrel assembly at the cartridge receiving end 117. Said release groove is adapted to receive a latch plate 118.
An extractor bore 123 which is parallel to the barrels 15 and centrally positioned with respect to said barrels 15 opens rearwardly to a central recess 119 in the cartridge receiving end 117. The extractor bore 123 slidably receives an extractor guide 122, orthogonally connected to an extractor plate 120, so that the guide 122 and plate 120 may be received in the central recess in general alignment with the barrels and cartridge chambers at the cartridge receiving end 117. The vertical extractor plate 120 extends below the barrels 15 to connect to a horizontally disposed extractor push rod 126. The extractor push rod 126 is slidably retained on the barrel assembly by means of a guide pin 127, which supports the extractor push rod 126 between the mounting tongues 132. The extractor push rod 126 is provided with a recess 125 to receive the pin 127, the horizontal dimensions of said recess 125 defining the limits of the sliding of the push rod 126, and hence the movement of the extractor plate with respect to the barrel assembly. As the barrel assembly 12 is pivoted from its closed position to an open position, the end of the barrel mounting portion 20 contacts with the push rod end 129 imparting a sliding movement to the extractor 126, and causing the extractor plate 120 to move rearwardly with respect to the barrels at the cartridge receiving end 117, thus facilitating the removal of spent cartridges from the cartridge chambers.
In a closed position, the cartridge receiving end 117 is adjacent the breech portion 16. The barrel assembly is secured in a closed position by the engagement of the latch plate 118 in the release groove 115 of the barrel assembly. The latch plate 118 is biased toward a forward position by means of a spring 114. The barrel assembly is opened by forcing a latch release 112 toward the rear of the frame, thus removing the latch plate from the release groove 115 and allowing the barrel assembly 12 to be pivoted to an open position.
A trigger 22 is slidably mounted, at its top in a mounting groove 32 and at its bottom in a trigger guard groove 31, said grooves being horizontally disposed. At the rear, the trigger 22 has a difurcated end consisting of an upper segment 21 and a lower segment 23. A trigger groove 24 formed in the bottom of the trigger 22 extends through the bottom of the lower segment 23 and is adapted to receive a trigger spring 28. The trigger spring 28 is mounted on one end around a trigger spring guide rod 26, which is held in a rod recess 55 of the frame 10 by the force of the spring. The other end of the trigger spring 28 extends into the trigger groove 24, so as to urge the trigger toward the front of the handgun. The forward movement of the trigger is limited by the trigger groove end 51 and the mounting groove end 52. Thus, the trigger is supported in the frame for movement between a ready position, shown in full lines in FIG. 2, and a firing position shown in FIG. 6.
The upper edge of the rear segment 21 of the trigger is recessed to form a bottom surface 29 having at its forward end a notch 30 and a rearwardly facing end wall 27 adjacent to a trigger top surface 25. An outwardly projecting lug 35 is mounted on the side near the rear end of the upper segment 21 of the trigger.
The hammer assembly 59 comprises a hammer 60 pivotally mounted at its lower end on a hammer pivot pin 62, extending through each side of the frame 10 and through a pivot bore 64 in the hammer. Near the top of the hammer 60 a horizontally disposed hammer bore 65 extends from the percussion side to the back side of the hammer 60. A sear plunger bore 67 opens upward into the hammer bore 65. The sear plunger bore 67 is adapted to receive a sear plunger 43 in the form of a ball, which is received beneath a sear plunger spring 45, so that the sear plunger 43 is urged in a downward direction.
A detent bore 96, parallel to the hammer bore 65, opens outward on the percussion side of the hammer. The detent bore is adapted to receive a ball detent mechanism which includes a spring 97 and a detent 99 in the form of a ball urged by the spring in an outward direction toward the front of the handgun.
The firing element or ratchet 90 comprises a disc 93 integral with a hub 98, which is rotatable in the hammer bore 65. Opposite the hub 98, the circular ratchet rim 92 has on its outer circumference a radially projecting firing lug 91.
The ratchet, and in particular the firing lug 91, is adapted to make contact with firing pins 104 in a breech block 100 hereinafter described. The outside diameter of the ratchet rim is generally commensurate with the diameter of the firing pin retainer washer 106, hereinafter described. The inside diameter of said rim is greater than the diameter of the head of retaining pin 108, hereinafter described, and the height of said rim is greater than the longitudinal dimension of the head of pin 108.
Four symmetrically spaced notches 94 around the circumference of the ratchet disc face toward the hub side of the ratchet. The ratchet is mounted on the hammer 60 by inserting the ratchet hub 98 through the hammer bore 65 and securing the end of the hub by means of a retaining ring 95, so that the ratchet rim faces toward the front of the handgun. The notches are in circumferential positions to receive the ratchet plunger as it is urged forward, and the ratchet is in general alignment with the breech block 100 when the hammer is in the at-rest position as shown in FIG. 2.
Below the sear plunger 43, a sear recess 41 opens downward and extends through both the percussion side and the back side of the hammer. The sear 40 is received in the sear recess 41 and pivotally connected to the hammer by means of a sear pivot pin 42. The sear 40 extends through the concussion side and is disposed in a generally horizontal position. The sear 40 has an upper sear cam surface 44 and a bottom surface 48 adjacent to a sear end surface 46. The sear is urged downward by means of the sear plunger 43 being forced against the sear cam surface 44. In the at-rest position, as shown in FIG. 2, a sear edge 49 which is at the intersection of the sear end surface 46 and the sear bottom surface 48, rests on the trigger recess bottom 29.
A strut slot 57 formed in the bottom of the hammer 60 opens outwardly through the back side, so as to receive a hammer strut 70. The hammer strut 70 comprises a generally "T" shaped yoke 73 on one end and a strut retaining end 76 at the other end. The front of the yoke contains a strut seat 71 and a stop seat 72, the seat 71 being forced against a pin 61 located on the hammer above and parallel to the hammer pivot pin 62 by the strut spring 75. The rear end of said strut spring 75 is fitted on a base 78, in a recess 54 in the rear portion of the frame 10. The strut extends through the central axis of the spring 75 with the end 76 being retained in the recess 79 in the base, so that the bias of the spring 75 urges the strut 70 in a forward direction, with the seat 72 biasing against the pin 62 when the trigger and hammer are in an at-rest position, as shown in FIG. 2.
An indexing pawl or hand 80 is pivotally connected to the frame 10 by a pivot pin 82 and is urged in a forward direction by a torsion spring 86 mounted on the pivot pin 82 so that one end of the spring bears against a spring retainer 84 and the other end against the interior of the frame, thus urging the pawl or hand in a forward direction. The free end of the pawl is adapted to engage in the notch 94 when the hammer and trigger are in an at-rest position, as shown in FIG. 2.
The breech block 100 vertically disposed between the barrel assembly 12 and the central recess 19 is in general horizontal alignment with the ratchet 90. Four horizontal symmetrically placed stepped concentric bores 102 in the breech block are axially aligned with the centers of the respective barrels 15 at the cartridge receiving end 117 when the barrel assembly 12 is in the closed position.
A firing pin 104 is received in each of the firing pin bores 102. The head of each firing pin is cut away at 107 so that the firing pins may be secured in the breech block by means of a firing pin retaining washer 106, which is fastened to the breech block by a threaded retaining pin 108, as shown in FIGS. 4 and 6. The firing pin/retaining washer configuration allows for a small degree of movement of the firing pin 104 in the firing pin bore 102. The firing pins are in general alignment with the ratchet 90 when the hammer is in a firing position, which position is not shown in the drawings.
During firing, the firing lug 91 on the ratchet makes contact with one of the four firing pins 104. The ratchet may be suitably rotated so that the firing lug is in successive sequential alignment with each of the firing pins 104. It may thus be seen that it is necessary that the firing plate 91 be positioned in one of four circumferential positions on the ratchet, so as to obtain required alignment between the firing lug 91 and each firing pin 104.
The rotation and incremental positioning of the ratchet is accomplished by means of the unique utilization of the notches 94 to both facilitate rotation and secure correct positioning. Th ratchet plunger, situated in the hammer shaft, forces a plunger ball into one of the four notches 94 circumferentially arranged around the ratchet. The plunger 99 will engage each of the notches upon rotation of the notch to a position in the vicinity of the plunger bore 96, thus securing the firing lug 91 at one of four positions or striking locations, each of which will be in alignment with a corresponding firing pin 104 of the breech block 100. The seating of the plunger in the bottom of each notch effects fine adjustment of the ratchet in each of the four operative positions.
Each notch 94 is defined by a slant surface 103 which is inclined outwardly and away from a surface 105 which is perpendicular to the face of the disc 93 and extends radially outward. When a notch is aligned with the plunger 99, the plunger is forced into the notch. Because of the relatively lower resistance to disengagement by the slant surface 103 as opposed to the surface 105, rotatitonal movement of the ratchet is unidirectional.
In operation, the barrel assembly 12 is moved to an open position by forcing the latch release 112 toward the rear of the gun and pivoting the barrel assembly on the barrel pivot pin 130. Cartridges are placed in each of the cartridge chambers at the cartridge-receiving end 117 of the barrel assembly. The barrel assembly is then pivoted back to a generally horizontal position and the latch plate 118 is secured in the release groove 115.
The hammer strut 70 does not exert biasing force upon the hammer 60 when the gun is at rest, as shown in FIG. 2. The hammer is supported for limited free pivotal movement about the axis of the pin 62 and generally toward and away from the breech block, as it appears in FIG. 2. Thus, the firing pins are slidably movable within the breech block free of influence of the hammer 60 and strut assembly 58. This arrangement allows any firing pin which may project beyond the face of the breech block to be freely cammed rearwardly within the breech block and to a position flush with the breech block face when the barrel assembly is pivoted to and latched in its closed position.
The handgun is fired by drawing the trigger 22 toward the rear of the handgun from an at-rest position as exemplified in FIG. 2 to its firing position, which is exemplified in FIG. 6. The forcing of the trigger toward the rear of the handgun results in a relative position change in the hammer 60, the strut 70, the sear 40, the pawl 80 and the ratchet 90, all of which act in a coordinated movement so as to fire the handgun.
In the at-rest position shown in FIG. 2, the sear edge 49 rests on the bottom 29 of the trigger recess. As the trigger slides rearward, the sear edge 49 slides into the recessed notch 30 of the trigger. Further movement of the trigger results in contact between the sear end 46 and the recess end 27. The sear plunger 43 urges the sear 40 downward thus securing a firm engagement of the sear end 46 and the sear edge 49 with the recess edge 27 and the recess notch 30. Further movement of the trigger exerts a rearward force on the hammer 60, which is pivotally engaged to the frame by the pivot pin 62 resulting in a rearward pivot of the hammer toward the back of the frame to its releasing position.
As the hammer pivots around the pivot pin 62, the stop seat 72 loses contact with the pivot pin 62 while contact remains with the strut seat 71 and the pin 61, as shown in FIG. 6. The strut spring 75 is further compressed, and the strut retaining end 76 is forced further into the recess 79.
In the at-rest position of FIG. 2, the pawl 80 is engaged in the notch 94 near the bottom of the ratchet, the pawl being biased in a forward direction. As the hammer pivots, the notch surface 83 of the pawl is forced against the surface 105 of a lower notch 94. Further pivoting of the hammer results in the pawl 80 being forced in an upward direction with respect to the hammer and the ratchet thus imparting a rotational movement to the ratchet. The path of the pawl-engaging surface travels upward through a pawl slot 63 extending through the top of the hammer so that the slot is aligned with an upper-fixed position of a notch. At the top of the path, the surface 105 is parallel and adjacent the sides of slot 63 so that the pawl no longer engages the surface in an oblique upward type of contact, but slides upwardly along the surface 105, thus terminating the rotational force created by the notch-engaging surface 83 on the pawl-receiving surface of the notch 94. Upon termination of rotation, the ratchet plunger 99 engages notch 94 and holds the ratchet in a new fixed position. The end of the pawl or hand is now biased to slide down and engage the next lower notch at such time as the hammer resumes a forward pivot position.
The pivoting of the hammer also results in a relative change in position of the sear 40 with respect to the trigger 22. Being pivotally connected to the hammer 60 the sear 40, upon rearward pivot of the hammer, will eventually assume a position in which the sear bottom 48 is generally lower than that of the trigger recess bottom 29. Thus, the sear bottom 48 will ride up and come into contact with the recess bottom 29, and the position of the sear edge 49 will rise relative to the recess end 27. Further movement of the trigger will result in a position where the sear edge 49 will clear the top of the recess end 27 and will thus slide along the trigger top surface 25, so that the sear bottom 48 rests on the top surface 25. At this point, the force acting to pivot the hammer toward the rear, which force is exerted on the hammer 60 by means of the force of the movement of the trigger transferred rearward through the sear, is terminated by virtue of the release of the engagement of the sear end and the recess end.
The dominant force is now exerted by the strut spring 75 acting against the yoke 73 to force the strut seat 71 against the pin 61. The latter force thrusts the hammer in a forward pivoting direction to a striking position resulting in one of the firing pins 104 being struck by the forward thrust of the previously aligned firing lug 91 thereby firing one of the cartridges. The hammer is free to return to the at-rest position as shown in FIG. 2.
A machine-gunning effect is prevented by a disabling means or lug 35 which projects outwardly from the side of the rear end of the upper segment 21 of the trigger. The lug prevents the pawl or hand 80 from returning to a position so as to engage a lower notch 94 while the trigger is in a "fired" position; therefore, the ratchet 90 and hence firing lug 91 secured in position by the ratchet plunger 99 cannot be further rotated to align and contact another firing pin until the trigger is moved to its at-rest position and pulled a second time.
The barrel assembly 12 may be opened by pivoting the barrel assembly on the barrel pivot pin 130. The opening of the barrel assembly causes the extractor guide and hence the extractor 120 to move relative to the barrels 15, thus forcing the ends of the spent cartridges from the barrel.
It will thus be seen that the objects set forth above among those made apparent from the preceding description are efficiently obtained, and since certain changes may be made in the above construction without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | A new and improved handgun providing a strut assembly which engages the hammer assembly at two contact points, one of which is at the hammer pivot point which acts as a stop. An improved sequential firing mechanism is disclosed making use of notches on a ratchet engaged by a detent to secure proper alignment and positioning of the hammer firing mechanism with the firing pin. The invention also provides a safety mechanism for preventing the accidental firing of additional shots in a multibarrel handgun. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/100,447 entitled “An Advertising Request and Rules-Based Content Provision Engine, System and Method,” filed Sep. 26, 2008, the entire disclosure of which is incorporated by reference herein as if set forth in its entirety.
[0002] This application is related to U.S. patent application Ser. No. 11/981,837, filed Oct. 31, 2007, which is related to concurrently filed U.S. patent application Ser. No. 11/981,646, filed Oct. 31, 2007, and which claims the benefit of U.S. Provisional Application Ser. No. 60/993,096, filed Sep. 7, 2007, the entire disclosures of which are incorporated by reference herein as if set forth in their entireties, respectively.
FIELD OF THE INVENTION
[0003] The present invention is directed to an advertising engine and, more particularly, to an advertising request and rules-based content provision engine, and a method of making and using same.
BACKGROUND OF THE INVENTION
[0004] In the current art, a true marketplace for endorsed advertising is not available. This is due, in part, to the lack of a convenient clearinghouse that might allow for application of rules preferred by prospective endorsers before such prospective endorsers would allow use of an endorsement. For example, the process of gaining approval from an endorser requires the tracking down of the desired media content, figuring out who and how to contact the agent representing that endorser, scheduling meetings and possibly traveling to meet and discuss the licensing opportunities with the agent, and passing back and forth unfamiliar contractual forms including language that is unique for that agent. It goes without saying that the propensity for “red tape” is extremely high.
[0005] Thus, there exists a need for an apparatus, system and method that would provide a convenient clearinghouse and approval mechanism for application of rules preferred by prospective endorsers before such prospective endorsers would allow use of an endorsement to streamline the approval process for licensing media assets.
SUMMARY OF THE INVENTION
[0006] The present invention includes an approval engine for pre-approving media content. The approval engine includes an ad generator and an ad generator interface by which a user can interact with the ad generator, where the user requests at least one content item not owned by the user for inclusion in a creative. The approval engine also includes a content provision rules engine that includes a plurality of rules asserted by the owner of the requested content to govern the inclusion of the content in the creative, where ones of the plurality of rules includes a minimum price. The content provision rules engine further includes a content provision interface by which the owner of the requested content can interact with the content rules engine to assert the plurality of rules. The user then receives authorization to include the requested content upon meeting the requirements of each of the plurality of rules asserted by the owner prior to the content request made by the user.
[0007] Thus, the present invention provides an apparatus, system and method that would provide a convenient mechanism for application of rules preferred by prospective endorsers before such prospective endorsers would allow use of an endorsement.
BRIEF DESCRIPTION OF THE FIGURES
[0008] Understanding of the present invention will be facilitated by consideration of the following detailed description of the embodiments of the present invention taken in conjunction with the accompanying drawings, in which like numerals refer to like parts and in which:
[0009] FIG. 1 is illustrative of the invention; and
[0010] FIG. 2 is a flow chart of a content approval method, according to an aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0011] It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for the purpose of clarity, many other elements found in typical advertising engines, systems and methods. Those of ordinary skill in the art will recognize that other elements and/or steps are desirable and/or required in implementing the present invention. However, because such elements and steps are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements and steps is not provided herein. The disclosure herein is directed to all such variations and modifications to such elements and methods known to those skilled in the art. Furthermore, the embodiments identified and illustrated herein are for exemplary purposes only, and are not meant to be exclusive or limited in their description of the present invention.
[0012] The present invention is and includes a clearinghouse that allows for the use of approved, copyrightable, and/or public persona content by non-owners of such content, such as pre-approved photographs, audio, video files, data files, printed text, logos and trademarks, publicity announcements, metatagsDand metatag streams, and the like. The present invention provides for the use of brand recognition to create brand affinity, at least in that the present invention allows for the use of known and relevant brands in association with endorsed or advertised brands, which endorsement or advertisement is requested by an advertisement requester.
[0013] FIG. 1 is illustrative of the present invention. As shown in FIG. 1 , the present invention includes at least an advertisement/endorsement generator (hereinafter ad generator) 10 , an ad generator interface 12 , a content provision rules engine 14 , a content provision interface 16 , an approval engine 18 , and an approval engine interface 20 .
[0014] In this exemplary embodiment, the ad generator may provide, via the ad generator interface, the capability for a user (also referred to as the ad requester) to create an advertisement, announcement, data file, or the like, with or without an association with an endorser, affiliate, affiliated product, or the like, such as using external content or content from one or more vaults associated with the content provision rules engine discussed further below. The ad generator may provide, for example, a multiplicity of advertisement templates, from among which a user may select a desired advertisement format. Such format may include, for example, a requested endorsement or affiliation. Such endorsement or affiliation may be recommended to the user, such as by endorser or affiliation type, or specific endorsers or affiliates, which specific endorsers or affiliates may be exemplary, a totality of specifics, or menu based or categorically driven. Such suggested endorsers or affiliates may be presented to the user in order to minimize the cost of use of that endorsement or affiliation to the ad requester, in order to maximize the cost of use for that endorsement or affiliation, based on a cost of use range selected by a user, or other similar presentation methodologies, certain of which may be entered by the content provider to the content provision rules engine as discussed below. Through the use of the ad generator via an easy to use ad generator interface, the user may simplistically generate an advertisement or announcement for endorsement or affiliation.
[0015] The content provision rules 34 may be accessible to a content-providing user (also referred to as the “owner” of the content, although the providing user may not own the content, but must have a right to control the content) via the content provision interface communicating with the content provision rules engine. The content provision rules engine may allow for the selection by a content provision user of what usages and approvals for usage will be allowable for the content made available by the content provision user. The content 36 provided by the content provision user may be entered directly for storage in the vault(s) through the content provision interface by the content provision user, or may be provided via a link to the content, which link is external to the content provision rules engine and interface, but which link may allow the content rules engine to draw the content from any source in any format. As such, the content provision rules engine may include a normalization engine whereby content may be discerned in any format, or any human or computer language, from any source and normalized to the preferred format employed by the content provision rules engine. As discussed above, the provided content may be audiovisual content, metatag or metatag stream content, or the like.
[0016] The usages allowable for the content provided by the content provision user, as per the rules selected or entered, may include usage with regard to particular products, causes, announcements, particular geographies, or the like. Further, such usages may be provided with a cost per use, a cost per bundle of uses, or a cost for permanent usability, for example. The allowable permissions may provide automatic approval for usages entered as being within pre-approved categories, or may provide that certain or all usage requests be forwarded back to the content provision user via the approval engine and approval engine interface for approval. Further, the content provision user may enter that its endorsement or affiliation be available only as a premier use, such as in cases where the rules engine endeavors to upsell an ad requester from a requested level of cost of content to more expensive content. Such premier usages may allow a content provision user to maintain the goodwill and good name of premium brands. As such, the rules engine may include allowances as to which parties using the ad generator should even be offered the content provided for use in endorsements or affiliations.
[0017] For example, the content provider may allow for affiliations, endorsements or sponsorships from certain specific entities or certain types of entities, and such affiliations, sponsorships or endorsements may be presented to the ad requester, and may be used, for example, for an additional fee. Such an “upsell” rule 34 may be particularly useful in the event the ad requester has entered only the brand of the ad requester, and not requested additional third party content. In such a case, research, such as third party research, may be imported by the content provision engine to assess whether the ad requested could be improved by an “upsell”, which may be an endorser, affiliate, partner or sponsor available (based on the content provision rules) for the type of ad requested. Such upsell decisions may be based on geography, product type, recognition of the brand in the ad requested, and similar factors. For example, and ad requested for television in Los Angeles for “Super Soap” may be improved if the ad requester is offered an affiliation with Bath and Body Works, and may be further improved (in part due to the geography of the ad in Los Angeles) by an endorsement of the Bath and Body Works affiliation by a famous Los Angeles actress. Likewise, an after-shave commercial may work well as an advertisement during a football game, but after-shave in conjunction with a fantasy sports site sponsor may work even better for the success of the ad.
[0018] Thereby, the upsell can be offered to further improve the effectiveness of the ad requested, based on content available via the content provision rules, and/or research that may, or may not, be presented to help convince the ad requester of the propriety of selecting the upsell. For example, such research may include brand recognitions, recognition comparisons, available affiliates, sponsors, endorsers or partners that historically improve brand recognition in particular areas (and that are authorized to be in such an upsell by the content provisions rules).
[0019] The example above is by no means limiting with respect to an upsell. Myriad other research may be incorporated for an upsell, as will be apparent to those skilled in the art in view of the disclosure herein. For example, inferences about customers of certain products may be made based on the time of day an audio/visual work to be associated with the requested ad is generally accessed by viewers, sites from which viewers access such content, geographical location of frequent viewers, and the like, and such inferences may be used to upsell an ad requester to ads in a certain geography, at a certain time, or in a certain media outlet. As such, the content provision rules, and the upsells and research associated therewith, may have access to, or be accessible from, advertising and research engines in any media outlet accessible from any communication point in the present invention. Such communication points may, of course, include networked environments, wireless network environments, television, cabled and satellite environments, personal electronic device environments, and the like. Further, the access to the present invention of such external advertising engines may allow for the publishing of new applications, in accordance with the content provisions rules, to the present invention by third party application creators.
[0020] The rules engine may allow for provision of the requested content with affiliation, sponsorship, or endorsement in the event that external research has proven that it will not hurt the person or brand that was requested by the ad requester, or in the event that such affiliation, sponsorship or endorsement will help the standing or recognition of the brand or person that was requested by the ad requester.
[0021] The approval engine provided to a content provision user via the approval interface may allow for advertisements requested by users of the ad generator to be forwarded back to the content provider for a variety of reasons, including final approval, tracking, and reporting. For example, certain advertisements or endorsements may be automatically approved based on an adherence to the rules entered into the content provision rules engine. However, even such automatically approved endorsements or affiliations may be tracked by, or reported in a requested format to, the content provider. Additionally and alternatively, requested endorsements or affiliations meeting certain criteria may be forwarded back to the content provider, or all requests may be forwarded back to the content provider, for final approval.
[0022] The approval process may also include certain pre-approvals of assets by the content provider. For example, the content provider may identify particular assets as having automatic approval for matching, and/or ultimate delivery, as an endorsed ad without further restriction based on an approval rules set, which approval rules set may be an asset in the aforementioned vault, and thus may be uniquely associated with each prospective sponsor/endorser. Pre-approvals may be authorized by both new and existing licenses between the content provider, the system, the user and/or requester of the content. Pre-approvals or automatic approval may also effectively take the form of a license renewal or extension. It goes without saying that, although the discussion herein is principally with regard to pre-approval, the discussion herein is likewise applicable to an automatic rejection.
[0023] Such pre-approval may expedite the development of a creative for a user by responding to the user request with an asset approval automatically. Pre-approval rules for a particular asset may include positive or negative restrictions. For example, pre-approval restrictions may be based on a defined geographic area, such as defining that the requested asset may be used only within the greater Chicago area, or the asset may not be used in the Commonwealth of Pennsylvania. In another example, restrictions may be based on a period of time, such as defining that the asset may be used on weekday prime-time hours, or the asset may not be used on Sundays between 12:00 p.m. and 7:00 p.m. In another example, restrictions may be based on pairing or matching with other particular assets, such as the asset may not be used in combination with any erectile dysfunction product, or alternatively, if the targeted asset is the image of a particular talent, such as Terrell Owens, the asset may be restricted from use in combination with any asset associated with another talent, such as Donovan McNabb. In other embodiments, the asset may be used only in specific combinations as defined by an approval rules set. In another example, restrictions may be based on price or cost, such as that the asset may not be used if under a threshold price. It should be appreciated that assets can be restricted or without restriction, and any restrictive rule for pre-approval may be based upon any metric as described herein and as may be associated with the subject asset. It should also be appreciated that any combination of the aforementioned restrictive rules sets, with or without use in conjunction with post or multi-step approval use, may be used to provide a pre-approval or automatic approval mechanism for users to obtain authorization from content providers. For example, the content provider for a specific asset representing Sean Merriman may allow automatic approval for users willing to pay a set price per minute for use in the greater San Diego area at non-primetime viewing hours and not during any time in which a National Football League game is being played, and which is associated only with the sale of new and/or used automobiles. It should be understood that there is no limit to the number and application for creating combinations of an approval rules set for use with the present invention. Further, needless to say, a request may, based on a rule for example, be forwarded, or forwarded upon a certain occurrence, to an asset owner or one associated with an asset owner for approval of use or the requested asset at any point in the process discussed herein.
[0024] The present invention may also include a method performing the automatic or pre-approval mechanisms as described hereinabove. For example, as shown in FIG. 2 , method 200 may be initiated by a user making a request 210 to use of a particular content item. The system then applies all approval rules 220 against the information entered by the user in the content request 210 . The rules applied at step 220 are all rules asserted by the content owner 230 that are associated with the particular content requested, and preferably, but not exclusively, only those rules that were asserted prior to the time that the request for content 210 was made. At step 240 , a determination is made whether the approval rules were met. If not, the user must either terminate the adoption of that particular content, or the user must request new content 250 to initiate the process again from the beginning. If the determination at step 240 is yes, then an approval is granted 260 by the content owner without the need for a content owner confirmation. The approved content can then be integrated 270 into an ad or creative as proposed by the user.
[0025] The present invention also allows for the avoidance of brand dilution, such as by allowing approvals of limited usage, such as in limited geographic areas, of certain endorsements or affiliations. For example, a Philadelphia athlete may feel that his or her likeness is overused in the Philadelphia area, but may be more than willing to expand that athlete's brand into California for use as an endorser of Philadelphia-themed restaurants in California who wish to use his or her likeness. Further, certain very well respected entities, such as the American Cancer Society, may wish to expand the awareness or influence of their particular causes, but may wish to do so only by affiliation with publicly acceptable causes that support their causes, or with non-profit causes, or the like. Such allowable uses, or exclusions, may be entered as content provision rules.
[0026] As such, the present invention may provide for a clearinghouse for any and all copyrightable, trademarked, and/or public persona content.
[0027] Although the invention has been described and pictured in an exemplary form with a certain degree of particularity, it is understood that the present disclosure of the exemplary form has been made by way of example, and that numerous changes in the details of construction and combination and arrangement of parts and steps may be made without departing from the spirit and scope of the invention as set forth in the claims hereinafter.
[0028] Those of ordinary skill in the art will recognize that many modifications and variations of the present invention may be implemented without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modification and variations of this invention provided they come within the scope of the appended claims and their equivalents. | The present invention includes an approval engine for pre-approving media content by which a user can interact with an ad generator and request at least one content item not owned by the user for inclusion in a creative. The approval engine also includes a content provision rules engine that includes a plurality of rules asserted by the owner of the requested content to govern the inclusion of the content in the creative, where ones of the plurality of rules includes a minimum price. The content provision rules engine further includes a content provision interface by which the owner of the requested content can interact with the content rules engine to assert the plurality of rules. The user then receives authorization to include the requested content upon meeting the requirements of each of the plurality of rules asserted by the owner prior to the content request made by the user. | 6 |
FIELD OF TECHNOLOGY
The invention relates to an image projection system comprising, in this order, an illumination system, an image display system with at least one reflective image display panel for modulating, an illumination beam to be supplied by the illumination system with image information, and a projection lens system.
BACKGROUND AND SUMMARY
An image projection system of the type described in the opening paragraph is known, for example, from U.S. Pat. No. 5,905,545. The image projection system described in this specification comprises an illumination system for supplying an illumination beam, and an image display system with reflective image display panels for modulating this light beam in conformity with image information to be projected. The display panel may be, for example, a digital micro-mirrored display (DMD) with a two-dimensional array of reflective digital light switches which are driven by means of electrodes. Small mirrors for each pixel are used to switch a pixel on or off by changing an angle of the mirrors. The pixels of the DMD can maintain their ‘on’ or ‘off’-state for controlled display times. To achieve intermediate levels of illumination between white and black, pulse-width modulation techniques are used. In the reflective DMD projection systems, the part of the light modulated by the display panel, which part must give rise to dark pixels in the image, is deflected from the light path by the reflective switches and absorbed in the optical system and is thus lost. This is at the expense of the peak brightness in the image.
It is an object of the present invention to provide an image projection system in which a relatively high peak brightness is realized.
This object is achieved by the image projection system according to the invention, which is characterized in that the illumination system comprises an extra optical system for at least partly re-illuminating the image display system with the light reflected by the image display system to the illumination system, the extra optical system comprising means for redistributing light coming from a pixel of the image display system across a plurality of pixels of the image display system.
The present invention relates to a reflective projection system in which light is incident on the display panel and modulated by the display panel before it is projected. The invention is based on the recognition that the light which is modulated by a pixel representing a dark or grey pixel in the image is deflected from the light path but is not absorbed in the display system and is again sent towards the entrance of the optical display and thus recuperated. This light will as yet have an opportunity of being incident on a pixel representing a bright pixel. In the image projection system described above, the light intended for dark or grey pixels is thus not lost but is re-used. Furthermore, to prevent ghost images from being produced during this reuse, the illumination system is provided with means for redistributing of the light.
A preferred embodiment of the image projection system according to the invention is characterized in that the extra optical system comprises a lens element and an optical fiber, the lens element being situated between an element of the reflective image display panel and an input of the optical fiber for concentrating reflected light in the optical fiber. In this way, the reflected light which is not used to form a projection image can be efficiently transported back to the illumination system. Total internal reflection in the optical fiber redistributes the recuperated light.
A further embodiment of the image projection system according to the invention is characterized in that the extra optical system comprises an optical wedge for combining the light from the radiation source and the reflected light from the reflective image display panel.
A further embodiment of the image projection system according to the invention is characterized in that the extra optical system comprises an integrating rod for receiving light from an element of the reflective image display panel, and reflecting means situated at one side of the integrating rod for reflecting the received light back to the image display panel. In this way, the integrating rod acts as a non-imaging mirror device which homogeneously distributes the light on the image display device so that small distortions are reduced in the projected picture.
A further embodiment of the image projection system according to the invention is characterized in that the image projection system comprises a further reflective image display panel for modulating a second beam provided by the illumination system, and the extra optical system comprises means for recombining the light reflected from both the reflective image display panel and the further reflective image display panel. For example, a dichroic mirror may be used to recombine the light of different colors from the respective reflective image display panels into a single light beam which can be directed to the illumination system.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the invention are apparent from and will be elucidated with reference to the embodiments described hereinafter.
In the drawings:
FIG. 1 shows a first embodiment of an image projection system according to the invention,
FIG. 2 shows a second embodiment of an image projection system comprising two integrating rods and
FIG. 3 shows a third embodiment of an image projection system comprising two reflective image display panels.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The image projection system 1 shown in FIG. 1 comprises an illumination system 3 for supplying an illumination beam. The illumination system 3 comprises a radiation source 5 and a reflector 7 . The reflector 7 at least partly surrounds the radiation source 5 and ensures that the greater part of the light emitted by the radiation source in a direction away from the system as yet reaches the system.
The illumination beam generated by the illumination system 3 is incident on the display system, represented for the sake of simplicity by a single image display panel 23 , and is modulated thereby in conformity with the image information to be displayed. The light modulated and reflected by the display panel is projected on a screen (not shown) by means of a projection lens system represented for the sake of simplicity by a single projection lens 25 .
In FIG. 1, light coming from the illumination system 3 is sent via a second reflector 9 , a first optical wedge 11 , an integrator system 13 , a first lens 15 , a folding mirror 17 and first and second relay lenses 19 , 21 towards the reflective image display panel, for example a digital mirrored display (DMD) panel 23 . DMD devices are known per se from U.S. Pat. No. 5,061,049. The mirrors of the DMD image display panel 23 reflect the light either to the pupil of the projection lens 25 or to the entrance of an extra optical system in dependence on the voltage applied across the electrodes. The extra optical system comprises, for example, in said order, an entrance mirror 27 , a third relay mirror 29 and a second optical wedge 33 . The applied voltage controls the angle of the micro-mirrors of the DMD device in conformity with the image information to be displayed. The mirrors of the DMD image display panel 23 can be set to two different states, an on-state and an off-state. The on-state of the mirror is situated, for example, at 10 degrees with respect to a normal on the DMD image display panel 23 and the off-state of the mirror is situated, for example, at −10 degrees with respect to the normal. In the on-state, a light beam impinging on the mirrors of the DMD image display panel 23 at an angle of 20 degrees with respect to the normal is reflected in a direction coincident with the normal. In the off-state, the light beam impinging on the mirrors of the DMD image display panel 23 at an angle of 20 degrees is reflected at an angle of 40 degrees with respect to the normal. This difference is sufficient for a skilled person to dimension the optical elements of the system so as to direct the light in the pupil of the projection lens 25 in the on-state of the mirrors and away from the pupil of the projection lens in the off-state of the mirror. The present invention proposes to provide the illumination system with the extra optical system for at least partly re-illuminating the DMD image display panel 23 with light reflected by the DMD image display panel. Here, light is concerned which is reflected by display elements representing dark or grey pixels in the image. The extra optical system comprises means for redistributing light coming from such a display element across a plurality of display elements. In known systems, the light reflected by such display elements is reflected from the light path by the DMD display panel 23 and is thus lost. In the image projection system according to the invention, this light is recuperated and is given another opportunity of being incident on display elements, giving rise to bright pixels in the image. In operation, in the off-state, the entrance mirror 27 directs the light coming from pixels of the display panel representing dark pixels in the image via the third relay mirror 29 and the second optical wedge 33 towards the entrance of the light-integrating system 13 .
The extra optical system may alternatively comprise, in said order, an entrance lens and an optical light guide, for example, an optical fiber made of plastic or glass.
In the embodiments of the image projection system according to the invention, shown in FIG. 1, the illumination system may not only comprise a radiation source and a reflector, but also an integrator system. The first lens 15 behind the integrator system ensures that all re-images are superimposed in the plane of the DMD image display panel.
The integrator system 13 comprises a first lens plate 31 and a second lens plate 35 and ensures a homogeneous illumination of the display panel 23 . For a detailed description of the principle of an integrator system with two lens plates, reference is made to U.S. Pat. No. 5,098,184.
Instead of two integrator plates, the integrator system may alternatively comprise a bar-shaped integrator. The illumination system is then made uniform by multiple total internal reflection on the side walls of the bar. The bar may be in the form of, for example, a quartz bar.
The display panel is, for example, a display panel which is sequentially illuminated with a red, a green and a blue beam, while it is simultaneously driven with the image having the color of the corresponding illumination. The extra optical system may also comprise, in said order, an integrating rod and a reflective means. An image projection system comprising such an extra optical system is discussed with reference to FIG. 2 .
The image projection system 1 shown in FIG. 2 comprises an illumination system 3 for supplying an illumination beam. The illumination system 3 comprises a radiation source 5 and a reflector 7 . The reflector 7 at least partly surrounds the radiation source 5 and ensures that the greater part of the light emitted by the radiation source in a direction away from the system as yet reaches the system.
The illumination beam generated by the illumination system 3 is incident on the display system, represented for the sake of simplicity by a single image display panel 23 , and is modulated thereby in conformity with the image information to be displayed. The light modulated and reflected by the display panel is projected on a screen (not shown) by means of a projection lens system represented for the sake of simplicity by a single projection lens 25 .
In FIG. 2, light coming from the illumination system 3 is sent via an integrator system, for example, a quartz rod 13 , a pair of relay lenses 40 , 42 , an aperture stop 60 , a folding mirror 17 , a third relay lens 62 and a total internal reflection (TIR) prism 44 towards the reflective image display panel, for example a DMD image display device 23 . The mirrors of the DMD image display device 23 are designed to be set at two different states. In the on-state, the mirrors of the DMD image display device 23 are designed to reflect the light beam in such a way that the reflected light beam entering the TIR prism 44 is transmitted to the projection lens 25 . In the off-state, the mirrors of the DMD are designed to reflect the incident light beam from a reflective image element back into the direction of incidence. The light is then reflected via an interface 43 of the TIR prism 44 back to the illumination system 3 . By tilting the DMD image display device 23 , the reflected light beam can be directed to the entrance of a second integrating rod 64 near the first integrating rod 13 . The other entrance of the second integrating rod 64 is provided with a reflective means, for example a reflective coating 66 for reflecting the reflected light beam back to the display system. The second integrating rod 64 and the reflective coating 66 are part of the extra optical system for redistribution of the light coming from pixels of the image display system across the pixels of the DMD image display device 23 , and, as a result, the peak brightness of the image projection device is increased. The relay lenses 40 , 42 , 62 are designed in such a way that the reflected light beam creates an image of the aperture stop 70 in the same plane as the aperture stop 68 . Furthermore, the reflective DMD display panel may be, for example, sequentially illuminated with a red, a green and a blue beam, while the display panel 23 is simultaneously driven with the image having the color of the corresponding illumination. Therefore, the illumination system 3 preferably comprises a color wheel 37 driven by a motor 39 for alternately providing the red, green and blue light beams.
The image projection system may alternatively comprise two or three display panels. An embodiment using two display panels is shown in FIG. 3 . The image projection system comprises an illumination system comprising, in said order, a radiation source 5 , a reflector 7 , an optical wedge 11 , an integrating system, for example an optical bar 13 , a total internal reflection (TIR) prism 41 , a dichroic mirror 45 for reflecting radiation with a wavelength in the red range and passing radiation in the green and blue ranges, a first reflective image display panel 47 and a second reflective image display panel 49 , for example DMD image display panels and a projection lens 25 . Furthermore, in accordance with the invention, the image projection system comprises an extra optical system for recuperating the light reflected by the first and second DMD image display panels 47 , 49 in the illumination system. This extra optical system comprises, in said order, the coupling lenses 51 , 53 , optical light guides 55 , 61 , for example, an optical fiber made of glass or plastic, and a dichroic mirror 67 for combining the reflected light from the respective first and second DMD image display panels 47 , 49 in a single beam. In operation, light from the illumination system 3 is coupled into the integrating system 13 , for example an optical rod, via the optical wedge 11 and a rotating color wheel 37 driven by a motor 39 for alternating providing yellow and magenta light beams. The optical rod 13 homogeneously distributes the light and directs the light to the total internal reflection (TIR) prism 41 . Since the angle of incidence of the incoming light at the interface 43 of the TIR prism 41 is larger than the critical angle, the prism reflects the light towards the first dichroic mirror 45 . The TIR prism 41 is situated with respect to the incoming light beam in such a way that the light beam can be properly switched by the rotary action of the mirrors of the DMD image display panels 47 , 49 . The first dichroic mirror 45 continuously reflects red light with a wavelength in the red range towards the first DMD image display panel 47 and alternately passes the green or blue light with wavelengths in the green or blue range, respectively, towards the second DMD image display panel 49 . The first DMD image display panel 47 modulates the red light, in conformity with the image information to be displayed, by reflecting the light via the dichroic mirror 45 and the TIR prism 41 in the pupil of the projection lens 25 for projection on a screen (not shown) or via the first lens 51 in the entrance pupil 57 of the first optical fiber 55 for recuperating the light which is not used for projection. The second reflective image display panel 49 alternately modulates the green or blue light simultaneously with the rotating color wheel 37 and in conformity with the image information to be displayed. The rotary action of the mirrors of the second DMD image display panel 49 directs the green or blue light via the first dichroic mirror 45 and the TIR prism 41 in the entrance pupil of the projection lens 25 for projection on the screen (not shown) or via the second lens 53 in the entrance pupil 63 of the second optical fiber 61 for recuperating the light not used for projection. The optical fibers 55 , 61 transport the red light and the respective green or blue light back to the illumination system. The second dichroic mirror 67 combines the red light coming from the output 59 of the first optical fiber 55 with the respective green or blue light coming from the output 65 of the second optical fiber 61 . The combined light is then fed back into the illumination system by the optical wedge 33 . By providing the image projection system with an integrator system ( 13 ) and an optical system ( 51 , 53 , 55 , 61 , 67 ) as described above, the light coming from pixels representing dark pixels in the image will be recuperated, as described above with reference to a single DMD image display panel and, as a result, the peak brightness of the projected image is increased.
Instead of DMD image display panels, also other reflective image display panels may be used in the projection system according to the invention, for example, an actuated mirror array (AMA) image display panel known per se from the U.S. Pat. No. 5,729,386.
Furthermore, a reflective liquid crystal image display panel may be used. When a liquid crystal display panel is used, the illumination system should provide a polarised light beam for illumination of the display system. Furthermore, an analyzer has to be situated between the liquid crystal display panel and the projection screen.
It is to be noticed that the integrating system may be omitted to save costs in exchange for image homogeneity.
It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative solutions without departing from the scope of the claims. | An image projection system includes an illumination system and an image display system with at least one reflective image display panel for modulating. An illumination beam is supplied by the illumination system with image information and a projection lens system. The illumination system has an extra optical system that at least partly re-illuminates the image display system with light reflected by the reflective image display panel to the illumination system. The extra optical system redistributes light coming from a pixel of the image display system across a plurality of pixels of the image display system. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation application of and claims priority to U.S. patent application Ser. No. 13/602,712, filed Sep. 4, 2012, entitled ROTARY VALVE SYSTEM.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The disclosed and claimed concept relates to forming a cup-shaped body and, more specifically, to providing a rotary valve for use in a cup ejection system.
[0004] Background Information
[0005] It is known in the container-forming art to form two-piece containers, e.g. cans, in which the walls and bottom of the container are a one-piece cup-shaped body, and the top, or end closure, is a separate piece. After the container is filled, the two pieces are joined and sealed, thereby completing the container. The cup-shaped body typically begins as a flat material, typically metal, either in sheet or coil form. Blanks, i.e., disks, are cut from the sheet stock and then drawn into a cup. That is, by moving the disk through a series of dies while disposed over a ram or punch, the disk is shaped into a cup having a bottom and a depending sidewall. The ram may have a concave end. The device structured to form the cup is identified as a “cupper.” In some cuppers, after the ram and dies separate, the formed cup remains disposed over the ram until ejected therefrom, typically by a jet of air. The cup may be drawn through additional dies to reach a selected length and wall thickness. Cuppers are shown in U.S. Pat. Nos. 4,343,173; 5,628,224; and 6,014,883.
[0006] Cuppers may employ an operating mechanism having a single drive shaft coupled to multiple rams, for example, it is known to have multiple rams move essentially simultaneously. Thus, one cycle of the operating mechanism produces multiple cups. It is further known to slightly stagger the impact of the rams on the sheet material and/or dies, by positioning the rams, sheet material and/or dies at slightly different elevations. At the end of the forming cycle, the cups may remain on the end of the rams. The cups may be removed therefrom by a jet of air, or other fluid, that is passed through the ram and into the space between the cup and the concave end of the ram, as shown in U.S. Pat. No. 4,343,173.
[0007] Compressed air, or another fluid, is supplied either continuously or intermittently to the ram via a compressed gas system. Each configuration of such compressed gas systems has problems. For example, if the system is structured to provide a continuous supply of compressed gas, much of the gas is wasted. That is, during the drawing of the cup and during most of the time the ram is being retracted, the cup is not free to move from the end of the ram. Thus, gas supplied to the ram during such operations is wasted. Further, the gas must be vented and such venting may be very noisy. Alternatively, the flow of gas may be controlled by one or more valves that open only when a cup is to be ejected. Given that cuppers produce thousands of cups per hour, such valves must also open and close thousands of times an hour leading to wear and tear as well as the need to replace the valves. Further, the opening and closing of the valves requires a control system or a mechanical linkage structured to time the operation of the valve to the position of the ram. Electronic control systems are expensive and mechanical systems are subject to wear and tear.
[0008] There is, therefore, a need for a compressed gas system for a copper that uses less gas and is less noisy.
SUMMARY OF THE INVENTION
[0009] The disclosed and claimed compressed gas system provides for the use of a rotary valve assembly. A compressed gas system that utilizes a rotary valve assembly uses less gas than a constant flow compressed gas system and is quieter than a compressed gas system that uses valves. The rotary valve is a disk-like body having an opening therethrough. The rotary valve body is disposed within a housing assembly wherein gas may only flow through the housing when the rotary valve body is properly aligned with a space on one side of the rotary valve body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
[0011] FIG. 1 is a partial cross-sectional view of a cupper.
[0012] FIG. 2 is a schematic view of a pressurized gas system 20 with one embodiment of the rotary valve assembly.
[0013] FIG. 3 is a front view of one embodiment of a rotary valve.
[0014] FIG. 4A is a front view of another embodiment of a rotary valve. FIG. 4B is a front view of another embodiment of a rotary valve.
[0015] FIGS. 5A and 5B are front views of another embodiment of a rotary valve. FIG. 5C shows the combination of the cooperative rotary valve bodies shown in FIGS. 5A and 5B .
[0016] FIGS. 6A and 6B are front views of another embodiment of cooperative rotary valve bodies. FIG. 6C shows the combination of the cooperative rotary valve bodies shown in FIGS. 6A and 6B . FIGS. 6D and 6E are front views of another embodiment of cooperative rotary valve bodies. FIG. 6F shows the combination of the cooperative rotary valve bodies shown in FIGS. 6D and 6E .
[0017] FIG. 7 is a schematic view of a pressurized gas system with another embodiment of the rotary valve assembly.
[0018] FIG. 8 is a schematic view of a pressurized gas system with another embodiment of the rotary valve assembly.
[0019] FIG. 9 is a schematic cross-sectional view of a rotary valve assembly.
[0020] FIG. 10 is a front view of another embodiment of a rotary valve.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Generally, and as shown partially in FIG. 1 , a cupper 10 includes at least one movable, elongated ram 12 and a corresponding die 14 . The ram 12 has a concave distal end 16 and an axial ram ejection conduit 18 that is yin fluid communication with the ram distal end 16 . An operating mechanism (not shown) moves the ram 12 axially toward, and into, the die 14 . A work piece (not shown), which may be a circular blank or a sheet of metal from which a circular blank is cut, is disposed between the ram 12 and the die 14 . As the ram 12 moves into the die 14 , the work piece is formed into a cup 2 . As the ram 12 withdraws from the die 14 , the cup 2 remains disposed over the end of the ram 12 . The ram 12 is coupled to, and in fluid communication with, a pressurized gas system 20 . The pressurized gas system 20 is structured to deliver a volume of gas to the ram distal end 16 via the axial ram ejection conduit 18 . When the volume of gas is introduced at the ram distal end 16 , the cup 2 will be ejected from the ram 12 .
[0022] Further, it is known to operate a plurality of rams 12 with a single operating mechanism. For example, a single operating mechanism may operate multiple rams 12 at substantially the same time. It is noted that the discussion below identifies four rams 12 as an example; the disclosed concept is not limited to a specific number of rams 12 . As such, multiple cups 2 will be ejected at substantially the same time. Accordingly, the pressurized gas system 20 is structured to deliver a sufficient volume of gas so as to eject a plurality of cups 2 at substantially the same time. It is noted that the plurality of rams 12 may form the cups 2 in a staggered manner. That is, the cups are formed at slightly different times so as to reduce impact forces on the operating mechanism. In such a system, the cups 2 may be ejected from the ram 12 at substantially the same time, or, the cups 2 may be ejected from the ram 12 in a staggered fashion, i.e., the cups 2 are ejected at slightly different times. For example, the cupper 10 that forms cups 2 in a staggered manner may be structured to eject all the cups 2 at a specific, single time during the cycle of the operating mechanism, or, the cups may be ejected when the ram 12 is at a certain distance from the die 14 . In the former example, the cups 2 will be ejected at substantially the same time and, in the latter example, the cups 2 are ejected at slightly different times.
[0023] As shown in FIGS. 2, 7 and 8 , the pressurized gas system 20 includes a source of pressurized gas 22 (shown schematically), a surge tank 24 , an optional controlled valve 26 , a control unit 28 , a motor 30 , at least one downstream pressure conduit 32 and a rotary valve assembly 40 . The source of pressurized gas 22 is, in one embodiment, a compressor, but any known source for pressurized gas may be used. The surge tank 24 is structured to contain a quantity of gas at a pressure between about 10 psi and 70 psi, and in one exemplary embodiment about 18 psi. The surge tank 24 includes an inlet 34 and an outlet 36 . The source of pressurized gas 22 and the surge tank 24 are coupled and in fluid communication via the surge tank inlet 34 . As is known, a plurality of conduits and valves (none shown), such as but not limited to relief valves, are used to couple the source of pressurized gas 22 and the surge tank 24 .
[0024] A tank conduit 38 is coupled to, and in fluid communication with, surge tank outlet 36 as well as rotary valve assembly housing assembly at least one inlet passage 48 (described below). Controlled valve 26 may be disposed anywhere on tank conduit 38 . The controlled valve 26 is structured to be selectively configured. That is, the controlled valve 26 may be in a first closed configuration, a second fully open configuration, or any number of partially open configurations therebetween. The controlled valve 26 may be controlled mechanically but, in a preferred embodiment, the controlled valve 26 is structured to be selectively configured electronically. Accordingly, control unit 28 is structured to provide an electronic valve configuration command, i.e., the control unit 28 is coupled to, and in electronic communication with, the controlled valve 26 . The controlled valve 26 is structured to place itself in a selected configuration in response to the electronic valve configuration command. That is, the control unit 28 is structured to configure the controlled valve 26 .
[0025] The motor 30 includes at least one drive shaft 31 having a distal end 33 . The motor 30 is structured to rotate the drive shaft 31 at a selected speed. In one embodiment, the drive shaft 31 rotates at between about 25 rpm and 425 rpm and in one exemplary embodiment between about 100 to 250 rpm. The speed of the motor 30 may be adjusted while in use. Thus, the motor 30 is structured to adjust its speed in response to an electronic motor command. Further, the control unit 28 is structured to provide an electronic motor command. Further, the motor may be started and stopped in selected orientations. For example, if operation of the cupper 10 is stopped, the motor 30 may be stopped with the rotary valve assembly 40 in a closed configuration, discussed below. Alternatively, if desired, the rotary valve assembly 40 may be stopped in an open configuration whereby fluid passes through the rotary valve assembly 40 . The control unit 28 is coupled to, and in electronic communication with, the motor 30 . Thus, the control unit 28 is structured to control the speed of the motor 30 .
[0026] The control unit 28 may also include one or more sensors 29 (one shown schematically) such as, but not limited to, a pressure sensor disposed on tank conduit 38 or at least one downstream pressure conduit 32 . The sensors 29 are in electronic communication with the control unit 28 and provide data thereto. The control unit 28 may also include a processor, memory, and programming (none shown) structured to automatically adjust the configuration of the controlled valve 26 and the speed of motor 30 in response to the sensor 29 data.
[0027] Rotary valve assembly 40 includes a housing assembly 42 and a rotary valve 44 . The rotary valve assembly housing assembly 42 defines an enclosed space 46 and has at least one inlet passage 48 , at least one outlet passage 50 , and a drive shaft passage 52 . Each of the inlet passage (s) 48 , outlet passage(s) 50 , and drive shaft passage 52 are in fluid communication with said enclosed space 46 . The rotary valve 44 is disposed in the enclosed space 46 and effectively divides the enclosed space 46 into an upstream enclosed space 54 and a downstream enclosed space 56 . As described below, the rotary valve 44 includes a rotary valve body assembly 70 (discussed below) with at least one opening 71 . The rotary valve at least one opening 71 is structured to allow selective passage of a gas from the upstream enclosed space 54 to the downstream enclosed space 56 . That is, the rotary valve at least one axial opening 71 is only in fluid communication with both the upstream enclosed space 54 and the downstream enclosed space 56 intermittently. To accomplish this, the rotary valve at least one opening 71 is intermittently in fluid communication with at least one aligned portion 58 of the upstream enclosed space 54 and at least one aligned portion 59 the downstream enclosed space 56 . As used herein, the at least one “aligned portion 58 ” of the upstream enclosed space 54 and the downstream enclosed space 56 means the portion of the enclosed space 46 wherein an upstream enclosed space 54 and a downstream enclosed space 56 exist on each side of the rotary valve 44 in a direction generally parallel to the axis of rotation of the rotary valve 44 . That is, to prevent constant fluid communication through the rotary valve 44 , the enclosed space 46 includes a substantially sealed portion 60 wherein the rotary valve assembly housing assembly 42 is very close, and may abut, at least one side of the rotary valve body assembly 70 . As there is no space between the rotary valve 44 and the rotary valve assembly housing assembly 42 in the substantially sealed portion 60 , there is no enclosed space 54 , 56 to be an “aligned portion 58 ” of the upstream enclosed space 54 or the downstream enclosed space 56 .
[0028] In the enclosed space substantially sealed portion 60 the nearness of the rotary valve assembly housing assembly 42 to the rotary valve body assembly 70 substantially prevents fluid from passing through the rotary valve at least one opening 71 . A discussion of various embodiments of the rotary valve assembly housing assembly 42 with different embodiments of the enclosed space 46 follow the discussion of the rotary valve 44 .
[0029] As shown in FIG. 3 , the rotary valve 44 includes a substantially disk shaped body assembly 70 having at least one axial opening 71 therethrough. As used herein, “disk shaped” may include an axially elongated disk or cylinder. Further, as used herein, “axial opening” means the opening 71 extends parallel to the axis of the disk shaped body assembly 70 and does not mean that the opening is disposed on the axis of the disk shaped body assembly 70 . In one embodiment, the rotary valve body assembly 70 is a substantially circular, planar body 72 having an opening 71 therethrough. The rotary valve body assembly opening 71 may be any shape, but is, as shown, preferably arcuate. Further, as shown, the rotary valve body assembly opening 71 extends over an arc of about 180 degrees; it is understood that the rotary valve body assembly opening 71 may extend over a longer or shorter arc as needed.
[0030] In another embodiment, shown in FIG. 4A , the rotary valve body assembly 70 is, again, a substantially circular, planar body 72 having a plurality of openings 71 A, 71 B, 71 C, 71 D therethrough. Each rotary valve body assembly opening 71 A, 71 B, 71 C, 71 D is disposed at a different radial distance from the center of the rotary valve body assembly body 72 . The center-point of the rotary valve body assembly openings 71 A, 71 B, 71 C, 71 D, i.e., not the mathematical “center” of the arcs which is the center of the rotary valve body assembly body 72 , may be disposed substantially on a single radius, i.e., along a single radial line r, as shown in FIG. 4A . In an alternate embodiment, shown in FIG. 4B , the rotary valve body assembly openings 71 A, 71 B, 71 C, 71 D may be staggered. That is, the center-point of each rotary valve body assembly openings 71 A, 71 B, 71 C, 71 D is disposed on a different radial line R A , R B , R C , R D . It is noted that FIGS. 4A and 4B each disclose four rotary valve body assembly openings 71 A, 71 B, 71 C, 71 D and such a rotary valve body assembly 70 could be used, with a cupper having four rams 12 . It is again noted, however, that the disclosed concept is not limited to a cupper 10 having a specific number of rams 12 . It is understood that if the cupper 10 has a different number of rams 12 the rotary valve body assembly 70 , or multiple rotary valve body assemblies 70 , will have a corresponding number of rotary valve body assembly openings 71 .
[0031] In another embodiment, shown in FIGS. 5A and 5B the rotary valve body assembly 70 includes two substantially circular, planar bodies 74 , 76 that are, preferably, about the same size and may be placed in alignment as indicated in FIG. 5A . Each rotary valve body assembly planar body 74 , 76 has at least one axial opening 75 , 77 , respectively, therethrough. Each rotary valve body assembly first and second planar body at least one axial opening 75 , 77 is disposed at a similar radius so as to at least partially overlap when the rotary valve body assembly first and second planar bodies 74 , 76 are disposed on a common axis and the rotary valve body assembly first and second planar body at least one axial opening 75 , 77 are at least partially aligned, as shown in FIG. 5B . Preferably, the rotary valve body assembly first and second planar bodies 74 , 76 are disposed on drive shaft distal end 33 . In this configuration, the rotary valve body assembly first planar body at least one axial opening 75 may move relative to said rotary valve body assembly second planar body at least one axial opening 77 between a first position, wherein the rotary valve body assembly first and second planar body at least one axial openings 75 , 77 are substantially aligned, and a second position wherein the rotary valve body assembly first and second planar body at least one axial openings 75 , 77 are partially aligned.
[0032] Further, the two rotary valve body assembly bodies 74 , 76 substantially abut each other. That is, the two rotary valve body assembly bodies 74 , 76 contact each other over one axial face so that there is, essentially, no gap therebetween. A localized gap may exist if the abutting axial faces of the two rotary valve body assembly bodies 74 , 76 are not perfectly smooth, but such a gap does not form a path for fluid communication from one side of the rotary valve body assembly 70 to the other. The rotary valve body assembly openings 75 , 77 are, preferably, arcuate and extend over an arc of about 180 degrees. In this configuration, the two rotary valve body assembly bodies 74 , 76 may be rotated relative to each other so as to adjust the size of the rotary valve at least one axial opening 71 . That is, if the two rotary valve body assembly bodies 74 , 76 are positioned so that the rotary valve body assembly openings 75 , 77 are substantially aligned, the rotary valve at least one axial opening 71 will extend over an arc of about 180 degrees. If, the two rotary valve body assembly bodies 74 , 76 are positioned so that the rotary valve body assembly openings 75 , 77 are 50% aligned, as shown, the rotary valve at least one axial opening 71 will extend over an arc of about 90 degrees. Thus, by selectively positioning the two rotary valve body assembly bodies 74 , 76 relative to each other, the size of the rotary valve at least one axial opening 71 may be adjusted.
[0033] In another embodiment shown in FIGS. 6A and 6B , and as with the embodiment wherein the rotary valve body assembly 70 includes a single circular, planar body 72 , the rotary valve body assembly 70 having two substantially circular, planar bodies 74 , 76 may also include a plurality of rotary valve body assembly openings 75 A, 77 A, 75 B, 77 B, 75 C, 77 C, 75 D, 77 D, respectively. The rotary valve body assembly openings 75 A, 77 A, 75 B, 77 B, 75 C, 77 C, 75 D, 77 D on each of the two rotary valve body assembly bodies 74 , 76 are each disposed at a different radial distance from the center of the associated rotary valve body assembly body 74 , 76 . The rotary valve body assembly openings 75 A, 77 A, 75 B, 77 B, 75 C, 77 C, 75 D, 77 D on different rotary valve body assembly bodies 74 , 76 , however, are at substantially the same radial distance from the center of the associated rotary valve body assembly body 74 , 76 . That is, for example, rotary valve body assembly openings 75 A, 77 A are each at substantially the same radial distance from the center of the associated rotary valve body assembly body 74 , 76 . In this configuration, each pair of the rotary valve body assembly openings at substantially the same radial distance, e.g., rotary valve body assembly openings 75 A, 77 A, may be aligned to create a rotary valve axial opening 71 A, as shown in FIG. 6B . Further, the rotary valve body assembly openings 75 A, 77 A, 75 B, 77 B, 75 C, 77 C, 75 D, 77 D are, preferably, arcuate so that the size of the rotary valve axial openings 71 A, 71 B, 71 C, 71 D may be adjusted as described above.
[0034] Also, as with the embodiment wherein the rotary valve body assembly 70 includes a single circular, planar body 72 , the rotary valve body assembly openings 75 A, 77 A, 75 B, 77 B, 75 C, 77 C, 75 D, 77 D may be positioned on the rotary valve body assembly body 74 , 76 so that the center-point of the resulting rotary valve axial openings 71 A, 71 B, 71 C, 71 D may be disposed substantially on a single radius, i.e., along a single radial line, or, may be staggered, i.e., disposed along different radial lines. Alternatively, as shown in FIGS. 6D-6F , the rotary valve body assembly openings 75 A, 77 A, 75 B, 77 B, 75 C, 77 C, 75 D, 77 D may be staggered. In this configuration, when rotary valve body assembly body 74 , 76 are joined the center-point of each rotary valve body assembly openings 71 A, 71 B, 71 C, 71 D is disposed on a different radial line R A , R B , R C , R D . It is noted that FIGS. 6A-6F each disclose four rotary valve body assembly openings 71 A, 71 B, 71 C, 71 D and such a rotary valve body assembly 70 could be used with a cupper having four rams 12 . It is again noted, however, that the disclosed concept is not limited to a cupper 10 having a specific number of rams 12 . It is understood that if the cupper 10 has a different number of rams 12 , the rotary valve body assembly 70 , or multiple rotary valve body assemblies 70 , will have a corresponding number of rotary valve body assembly openings 71 .
[0035] It is further noted that the rotary valve at least one axial opening 71 maybe shaped so as to produce a specific pressure profile through the rotary valve assembly 40 . For example, an arcuate rotary valve at least one axial opening 71 may have a narrow radial width at the beginning of the arcuate rotary valve at least one axial opening 71 , and a wider radial width at the end of the arcuate rotary valve at least one axial opening 71 . That is, the at least one axial opening 71 may be shaped as an arcuate “teardrop.” Other shapes for the at least one axial opening 71 may be used as well. As used herein, a “shaped” axial opening 71 is an axial opening 71 wherein the opposing edges of the opening are not substantially parallel.
[0036] The rotary valve 44 , i.e., the rotary valve body assembly 70 , is coupled to the drive shaft distal end 33 . It is noted that a single motor 30 may be used to drive more than one rotary valve 44 . For example, a single drive shaft 31 may be coupled to more than one rotary valve assembly 40 . In such a configuration, the “drive shaft distal end 33 ” shall mean any part of the drive shaft 31 that is spaced from the motor 30 . Alternatively, as shown in FIG. 7 , the motor 30 may include more than one drive shaft 31 , 31 ′, each of which is coupled to a rotary valve assembly 40 .
[0037] The at least one downstream pressure conduit 32 has an inlet 25 and an outlet 27 is coupled to, and in fluid communication with, the rotary valve assembly housing assembly at least one outlet passage 50 . The at least one downstream pressure conduit 32 is also coupled to, and in fluid communication with, the axial ram ejection conduit 18 . In a cupper 10 with a single ram 12 , the at least one downstream pressure conduit 32 may be a single downstream pressure conduit 32 . As shown in FIG. 2 , in a cupper with a plurality of rams 12 , the at least one downstream pressure conduit 32 may include, and be in fluid communication with, a manifold 90 having a manifold inlet 91 and a plurality of manifold outlet conduits 92 each coupled to, and in fluid communication with, one of the rams 12 in the plurality of rams 12 . Alternatively, in a cupper 10 with a plurality of rams 12 , the at least one downstream pressure conduit 32 may include a plurality of downstream pressure conduits 32 A, 32 B, 32 C, 32 D each coupled to, and in fluid communication with, one of the rams 12 in the plurality of rams 12 . It is noted that, for this example, it is assumed that there are four rams 12 in the plurality of rams 12 . If there are more than four rams 12 , there is a downstream pressure conduit 32 N for each ram 12 . Further, the pressurized gas system 20 may be structured to operate with more than one plurality of rams 12 . That is, the cupper 10 may have a first plurality of rams 12 operating on a first cycle and a second plurality of rams 12 operating on a second cycle. In this configuration, the at least one downstream pressure conduit 32 may include two downstream pressure conduits 32 X, 32 Y each coupled to a manifold 90 X, 90 Y, as shown in FIG. 7 , each having a plurality of manifold conduits 92 each coupled to, and in fluid communication with, one of the rams 12 in both plurality of rams 12 . Further, the at least one downstream pressure conduit 32 may include an individual conduit 32 N coupled to, and in fluid communication with, each ram 12 in both plurality of rams 12 . Further, as shown in FIG. 7 , if the motor 30 includes more than one drive shaft 31 , 31 ′, as discussed above, each drive shaft 31 , 31 ′ is coupled to a rotary valve assembly 40 , 40 ′ each of which is in fluid communication with one or more manifolds 90 X, 90 Y, 90 X′, 90 Y′. It is noted that the rotary valve 44 in each rotary valve assembly 40 , 40 ′ may be radially offset relative to each other. That is, the rotary valve assemblies 40 , 40 ′ may be structured to be open at different times.
[0038] Generally, when assembled, the drive shaft distal end 33 extends through the rotary valve assembly housing assembly drive shaft passage 52 . The rotary valve 44 , i.e., the rotary valve body assembly 70 , is coupled to the drive shaft distal end 33 within the rotary valve assembly housing assembly enclosed space 46 , thereby dividing the rotary valve assembly housing assembly enclosed space 46 into the upstream enclosed space 54 and a downstream enclosed space 56 described above. A discussion of the “aligned portion” of the upstream enclosed space 54 and the downstream enclosed space 56 may be more easily understood by providing examples. Accordingly, and as shown in FIG. 2 , in one embodiment, the rotary valve assembly housing assembly at least one inlet passage 48 and at least one outlet passage 50 are each a single passage 48 A, 50 A, respectively. Further, the rotary valve assembly housing assembly inlet passage 48 A and outlet passage 50 A are coextensive with the upstream enclosed space 54 and the downstream enclosed space 56 , respectively. Further, the rotary valve assembly housing assembly inlet passage 48 A and outlet passage 50 A are substantially aligned. Thus, the rotary valve assembly housing assembly inlet passage 48 A and outlet passage 50 A are the at least one “aligned portion” of the upstream enclosed space 54 and the downstream enclosed space 56 . Other than the portions of the rotary valve assembly housing assembly 42 that accommodate the drive shaft distal end 33 , the remaining portions of the rotary valve assembly housing assembly enclosed space 46 are disposed very close, and may abut, both sides of the rotary valve body assembly 70 . That is, other than the space defined by the rotary valve assembly housing assembly inlet passage 48 A and outlet passage 50 A, the rotary valve assembly housing assembly enclosed space 46 is a substantially sealed portion 60 . Thus, the rotation of the rotary valve body selectively provides fluid communication between aligned portions of the upstream enclosed space 54 and the downstream enclosed space 56 via the rotary valve body assembly at least one opening 71 when the rotary valve at least one axial opening 71 is in fluid communication with the at least one aligned portion 58 of the upstream enclosed space 54 and the downstream enclosed space 56 .
[0039] This embodiment operates as follows. Pressurized gas from the surge tank 24 is communicated via the tank conduit 38 to the rotary valve assembly housing assembly at least one inlet passage 48 . When the rotary valve at least one axial opening 71 is disposed within the rotary valve assembly housing assembly substantially sealed portion 60 , there is no passage for fluid communication through the rotary valve assembly 40 . In this configuration the rotary valve assembly 40 is “closed.” As the drive shaft 31 rotates, the rotary valve at least one axial opening 71 is brought into alignment with the rotary valve assembly housing assembly inlet passage 48 A and outlet passage 50 A, i.e. into alignment with the aligned portions of the upstream enclosed space 54 and the downstream enclosed space 56 . In this configuration the rotary valve assembly 40 is “open.” That is, when the rotary valve at least one axial opening 71 is brought into alignment with the rotary valve assembly housing assembly inlet passage 48 A and outlet passage 50 A gas may pass through the rotary valve assembly 40 . Thus, the gas is communicated to the at least one downstream pressure conduit 32 and then to the axial ram ejection conduit 18 whereby a cup 2 is ejected from the ram 12 . As the rotary valve at least one axial opening 71 is moved out of alignment with the rotary valve assembly housing assembly inlet passage 48 A and outlet passage 50 A, gas does not pass through the rotary valve assembly 40 . During this time, the ram 12 is actuated to form another cup.
[0040] In another embodiment, shown in FIG. 8 , the rotary valve assembly housing assembly 42 includes a space 100 on one side of the rotary valve 44 . For this example, it will be assumed that the rotary valve assembly housing assembly space 100 is disposed on the upstream side of the rotary valve body assembly 70 . That is, in this embodiment, the rotary valve assembly housing assembly 42 may be spaced from the upstream side of the rotary valve body assembly 70 . Rotary valve assembly housing assembly at least one inlet passage 48 is in fluid communication with the rotary valve assembly housing assembly space 100 . Thus, the upstream enclosed space 54 extends over the entire upstream side of the rotary valve 44 and is coextensive with space 100 . Similar to the embodiment described above, the rotary valve assembly housing assembly 42 on the downstream side of the rotary valve body assembly 70 includes an outlet passage 50 A and a portion disposed very close to, and which may abut, the downstream side of the rotary valve body assembly 70 , i.e., the substantially sealed portion 60 . Thus, the portion of the upstream enclosed space 54 on the opposite side of the rotary valve body assembly 70 from the outlet passage 50 A is the at least one aligned portion 58 of the upstream enclosed space 54 and the downstream enclosed space 56 .
[0041] This embodiment operates as follows. Pressurized gas from the surge tank 24 is communicated via the tank conduit 38 to the rotary valve assembly housing assembly at least one inlet passage 48 and into rotary valve assembly housing assembly space 100 . When the rotary valve at least one axial opening 71 is disposed within the rotary valve assembly housing assembly substantially sealed portion 60 , there is no passage for fluid communication through the rotary valve assembly 40 . As the drive shaft 31 rotates, the rotary valve at least one axial opening 71 is brought into alignment with the rotary valve assembly housing assembly outlet passage 50 A, i.e., into alignment with the aligned portion 58 of the upstream enclosed space 54 and the downstream enclosed space 56 . When the rotary valve at least one axial opening 71 is brought into alignment with the rotary valve assembly housing assembly outlet passage 50 A gas may pass through the rotary valve assembly 40 . Thus, the gas is communicated to the at least one downstream pressure conduit 32 and then to the axial ram ejection conduit 18 whereby a cup 2 is ejected from the ram 12 . As the rotary valve at least one axial opening 71 is moved out of alignment with the rotary valve assembly housing assembly outlet passage 50 A, gas does not pass through the rotary valve assembly 40 . During this time, the ram 12 is actuated to form another cup.
[0042] It is noted that the configuration described above may be reversed, i.e., the rotary valve assembly housing assembly space 100 may be disposed on the downstream side of the rotary valve body assembly 70 .
[0043] Cupper 10 may include multiple rams 12 acting in cooperation, i.e., utilizing one drive mechanism. Either embodiment described above may be configured to operate with a manifold 90 , also described above. In an exemplary embodiment having four rams, the at least one downstream pressure conduit 32 may include a manifold 90 having four outlet conduits 94 , wherein each manifold outlet conduit 94 is in fluid communication with one of the four rams 12 . Thus, rather than ejecting a single cup 2 from a single ram 12 , four cups 2 are ejected from four rams 12 simultaneously. It is understood that in an embodiment having more than four rams 12 , the manifold 90 has more than four outlet conduits 94 , i.e., one outlet conduit 94 for each ram. Alternatively, there may be more than one manifold 90 as shown in FIG. 7 and discussed above.
[0044] The embodiment, shown in FIG. 8 , is also structured to eject four cups 2 from four rams 12 , but without using a manifold 90 . In this embodiment, the housing assembly at least one outlet passage 50 includes four housing assembly outlet passages 50 A, SOB, 50 C, 50 D. Each housing assembly outlet passage 50 A, 50 B, 50 C, 50 D is coupled to and in fluid communication with one of the four rams 12 . That is, there are also four downstream pressure conduits 32 A, 32 B, 32 C, 32 D, each coupled to and extending between each housing assembly outlet passage 50 A, SOB, 50 C, SOD and one of the four rams 12 . Moreover, each housing assembly outlet passage 50 A, 50 B, 50 C, SOD is separate from each other. There may also be housing assembly four inlet passages 48 (not shown), but as shown, there is one housing assembly four inlet passage 48 and a space 100 on one side of the upstream side of the rotary valve 44 . In this configuration, there are four aligned portions 58 A, 58 B, 58 C, 58 D of the upstream enclosed space 54 and the four aligned portions 59 A, 59 B, 59 C, 59 D downstream enclosed space 56 . Further, there are four each of the rotary valve body assembly at least one axial openings 71 A, 71 B, 71 C, 71 D. Each of the four rotary valve body assembly axial openings 71 A, 71 B, 71 C, 71 D is structured to provide selective fluid communication between the upstream enclosed space 54 and one of the four housing assembly outlet passage 50 A, SOB, 50 C, SOD. Although axial openings 71 A, 71 B, 71 C, 71 D are shown in the figures as having a similar width, the axial openings 71 A, 71 B, 71 C, 71 D would typically be thinner near the perimeter of rotary valve body assembly 70 and thicker near the center of rotary valve body assembly 70 . By selecting the thickness of the axial openings 71 A, 71 B, 71 C, 71 D, the volume of fluid passing through each axial opening 71 A, 71 B, 71 C, 71 D may be balanced.
[0045] In this configuration, pressurized gas from the surge tank 24 is communicated via the tank conduit 38 to the rotary valve assembly housing assembly at least one inlet passage 48 and into rotary valve assembly housing assembly space 100 . When each rotary valve at least one axial opening 71 A, 71 B, 71 C, 71 D is disposed within the rotary valve assembly housing assembly substantially sealed portion 60 , there is no passage for fluid communication through the rotary valve assembly 40 . As the drive shaft 31 rotates, each rotary valve at least one axial opening 71 A, 71 B, 71 C, 71 D is brought into alignment with one rotary valve assembly housing assembly outlet passage 50 A, 50 B, 50 C, SOD, i.e., into alignment with the aligned portion 58 of the upstream enclosed space 54 and the downstream enclosed space 56 . When the rotary valve at least one axial opening 71 is brought into alignment with the rotary valve assembly housing assembly outlet passage 50 A, SOB, 50 C, SOD, gas may pass through the rotary valve assembly 40 . Thus, the gas is communicated to the each downstream pressure conduits 32 A, 32 B, 32 C, 32 D and then to one of the four the axial ram ejection conduits 18 whereby a cup 2 is ejected from each ram 12 . As the rotary valve axial openings 71 A, 71 B, 71 C, 71 D are moved out of alignment with the rotary valve assembly housing assembly outlet passages 50 A, 50 B, 50 C, 50 D, gas does not pass through the rotary valve assembly 40 .
[0046] Further, this embodiment may be structured to allow for the ejection of the cups to be staggered. That is, the four rotary valve axial openings 71 A, 71 B, 71 C, 71 D may be disposed in a staggered configuration, i.e., disposed along different radial lines, as described above. In this configuration, and assuming the rotary valve assembly housing assembly outlet passages 50 A, 50 B, 50 C, 50 D are disposed along a single radial line, each rotary valve axial opening 71 A, 71 B, 71 C, 71 D enters the four aligned portions 58 A, 58 B, 58 C, 58 D of the upstream enclosed space 54 and the downstream enclosed space 56 at a slightly different time, thus providing for the gas to pass through the rotary valve 44 at slightly different times. This, in turn, causes the ejection of the cups 2 to be slightly staggered. Alternatively, the four rotary valve axial openings 71 A, 71 B, 71 C, 71 D may be disposed along the same radial line and the rotary valve assembly housing assembly outlet passages 50 A, 50 B, 50 C, SOD may be disposed along different radial lines. This means that the four aligned portions 58 A, 58 B, 58 C, 58 D of the upstream enclosed space 54 and the downstream enclosed space 56 are staggered and that the four rotary valve axial openings 71 A, 71 B, 71 C, 71 D will enter the four aligned portions 58 A, 58 B, 58 C, 58 D of the upstream enclosed space 54 and the downstream enclosed space 56 at slightly different times. The end result is the same; the gas passes through the rotary valve 44 at slightly different times and this, in turn, causes the ejection of the cups 2 to be slightly staggered.
[0047] In the examples above, it was assumed that there were four rams 12 operating on the cupper 10 . There may, however, be any number of rains 12 on the cupper 10 . Thus, in an embodiment without a manifold 90 as part of the at least one downstream pressure conduit 32 , there is at least one downstream pressure conduit 32 per ram 12 . That is, in such an embodiment the number of relevant components correspond to the number of rams 12 on the cupper 10 . Thus, the housing assembly at least one outlet passage 50 includes a plurality of housing assembly outlet passages 50 , the number of housing assembly outlet passages 50 correspond to the number of the downstream pressure conduits 32 . Further, each housing assembly outlet passage 50 is coupled to, and in fluid communication with, one of the downstream pressure conduits 32 . Further, the rotary valve body assembly at least one axial opening 71 includes a plurality of axial openings 71 , the number of axial openings also corresponding to the number of downstream pressure conduits 32 . Thus, each rotary valve body assembly axial opening 71 is structured to provide selective fluid communication between the upstream enclosed space 56 and one of the housing assembly outlet passages 50 .
[0048] While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of invention which is to be given the full breadth of the claims appended and any and all equivalents thereof. | The disclosed and claimed compressed gas system provides for the use of a rotary valve assembly in association with a cupper. A compressed gas system that utilizes a rotary valve assembly uses less gas than a constant flow compressed gas system and is quieter than a compressed gas system that uses valves. The rotary valve is a disk-like body having an opening therethrough. The rotary valve body is disposed within a housing assembly wherein gas may only flow through the housing when the rotary valve body is properly aligned with a space on one side of the rotary valve body. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. application Ser. No. 14/540,185, which was filed Nov. 13, 2014, now U.S. Pat. No. ______, which claims priority, under 35 U.S.C. §119(a), of European Application No. 13193375.6, which was filed Nov. 18, 2013, and each of which is hereby incorporated by reference herein.
BACKGROUND
[0002] The present disclosure relates to a person support apparatus, such as a bed and with a mechanism suitable for adjusting the height and orientation of a patient support frame forming part of that bed. It is more particularly suitable for a hospital or long-term care (LTC) bed.
[0003] Person support apparatus, such as hospital and long-term care beds, typically include a patient support deck and a support surface, such as a mattress, supported by the deck. The patient support deck may be controllably articulated so as to take up different support configurations.
[0004] The patient support deck is supported on a deck support or intermediate frame and the deck support frame is provided with a mechanism for adjusting the height of the deck and hence the height of the support surface above the floor on which the apparatus is located, and to control the orientation or inclination of the deck and hence the patient support surface relative to the floor. Adjustment of the height is helpful to allow care givers to access the patient, and to facilitate patient movement into and out of the bed. The inclination of the patient support surface is also desirable so as to make the patient more comfortable, or to, for example, take up the Trendelenburg position in which the body is laid flat on the back (supine position) with the feet higher than the head by 12-30 degrees, or the reverse Trendelenburg position, where the body is tilted in the opposite direction.
[0005] The deck support frame is supported on leg assemblies which are pivotally connected at their upper end to the deck support frame and which have linear actuators for pivoting the leg assemblies relative to the deck support frame and hence adjusting the height of the deck support frame. Separate and separately controllable head end and foot end leg assemblies are provided so that the height of the foot and head ends may be separately adjusted. The leg assemblies can be pivoted together by their respective actuators and thereby raise or lower the deck support frame whilst keeping it substantially parallel to the floor. Alternatively, one of the foot or head end assemblies can be pivoted to lower just one of the foot or head ends and thereby move the deck support frame into the Trendelenburg or reverse Trendelenburg positions.
[0006] Known arrangements for pivoting leg assemblies relative to a deck support frame to allow the raising and lowering of the deck support frame include a leg element pivotally connected at its upper end to a guide element which is coupled to and can slide along the outside of longitudinal elements arranged parallel to, or forming, the sides of the deck support frame. Those known arrangements comprise a U-shaped guide element arranged on its side (i.e. with its open side extending in a vertical direction) and arranged around the outside of longitudinal elements having a rectangular cross-section. Such arrangements suffer from a number of problems. These include: i) a risk of trapping fingers in the guide element which moves along the outside of the longitudinal elements: (ii) a need to overcome the frictional forces between the inner surface of the slideable guide element and the outer surface of the longitudinal element when pivoting the leg assembly and thereby sliding; and (iii) a propensity for dust and dirt to collect on the surface of the longitudinal element and hence interfere with the sliding operation.
[0007] US 2009/0094747 and US 2010/0050343 disclose alternative arrangements in which channels which correspond to U-shapes on their sides (i.e. with an open vertical side) are arranged on the sides of the intermediate or deck support frame and have follower or guide elements extending into the interior of the channels through the vertical open side. The follower or guide elements engage and run along an interior surface of the respective channels.
[0008] US 2006/0021143 discloses a further alternative arrangement in which guide tracks or channels are defined by slots extending through the vertical sides of longitudinal bed frame elements, and the upper end of the respective leg assemblies are provided with followers extending sideways out from the upper end of the leg assemblies to extend through or into the slots. The followers run along the guide tracks defined by the slots through the vertical sides of the bed frame elements.
[0009] A need exists for further contributions in this area of technology.
SUMMARY
[0010] An apparatus, system and/or method according to the present disclosure includes one or more of the features recited below or in the appended claims, and which alone, or in any combination, may define patentable subject matter:
[0011] The present disclosure, in a first aspect, provides a person support apparatus comprising: a person support frame for supporting a person support deck, the person support frame having two sides extending between a head end and a foot end; and a support assembly for supporting the person support frame and moving it relative to a floor surface, wherein the support assembly comprises at least one leg assembly pivotally coupled at a first upper end portion to the person support frame and coupled at its second lower end portion to floor engaging means, and an actuator element operable to move the leg assembly and thereby move the person support frame relative to the floor, wherein at least one of the sides of the person support frame comprises an inverted substantially U-shaped channel element having a substantially continuous upper surface, two substantially continuous side surfaces connected at their top edges to the upper surface, and a downward facing opening between the bottom edges of the two side surfaces, and the first upper end portion of the leg assembly includes a guide or follower element arranged to contact and run along an inner surface of the channel element.
[0012] This arrangement results in a deck support frame which is robust and stable and can accommodate the changes in geometry necessary for movement or adjustment between the horizontal, Trendelenburg and reverse Trendelenburg positions.
[0013] Some embodiments of the channel and roller mechanism change the height of a patient support deck by pivoting one or more leg assemblies relative to the under surface of the patient support frame.
[0014] Features of some illustrative embodiments include the following:
[0015] Some illustrative embodiments have a lower part count than known systems and are therefore likely to be both cheaper and more robust. More parts cost more to make and assemble and provide more elements capable of failure.
[0016] The opening of the channel carrying the guide elements or rollers faces the floor. This means that dirt is less likely to enter it and interfere with the mechanism. Furthermore, any dirt that enters will not be visible in normal use.
[0017] The leg assembly works vertically within the channel edges and a reduced force is therefore necessary to lift the patient support frame especially from the low position where the leg assemblies suspend a narrow angle relative to the underside of the patient support frame. The use of rollers in an optional embodiment rather than surfaces sliding relative to each other also reduces the frictional forces which must be overcome when moving the guide element. The use of a roller than a sliding element means that there is no need to overcome the friction between the sliding element and the frame element relative to which it slides thus reducing the force necessary to raise the deck support frame and makes the mechanism less likely to fail.
[0018] The use of a mechanism which includes a guide element inside a channel element means that the outside surface of the longitudinal channel element can be used as a fixing area for accessories or other elements.
[0019] Having the channel openly facing downwards and the guide element inside the channel make it harder for a patient or care-giver to trap their fingers or other body parts.
[0020] Features described in relation to one aspect and/or embodiment of the present disclosure may equally be applied to other embodiments and/or aspects of the present disclosure.
[0021] Additional features, which alone or in combination with any other feature(s), such as those listed above and/or those listed in the claims, may comprise patentable subject matter and will become apparent to those skilled in the art upon consideration of the following detailed description of various embodiments exemplifying the best mode of carrying out the embodiments as presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Illustrative embodiments will now be described in detail, by way of example only, with reference to the accompanying drawings, in which:
[0023] FIGS. 1 a and 1 b are isometric and perspective views from, respectively, the foot and head ends of a patient support apparatus including a deck support frame according to one embodiment of the present disclosure;
[0024] FIG. 2 is side view of the patient support apparatus of FIG. 1 with the patient support deck in a lowered position;
[0025] FIG. 3 is a view similar to that of FIG. 2 but with the patient support deck in a lowered position;
[0026] FIG. 4 is a detailed view of a section through the top of one of leg assemblies of the apparatus in FIG. 1 ;
[0027] FIG. 5 is an end view of an alternative embodiment according to the present disclosure having a braking mechanism, in which the deck support frame is at its lowermost position and the brake engaged;
[0028] FIG. 6 is a detailed view of portion VI of FIG. 5 ;
[0029] FIG. 7 is a perspective view corresponding to the view of FIG. 6 ;
[0030] FIGS. 8 a and 8 b are diagrams setting out roller dimensions (in mm) for an embodiment according to the present disclosure;
[0031] FIG. 9 is a diagram setting out dimensions (in mm) for a channel element suitable for use with the roller of FIGS. 8 a and 8 b; and
[0032] FIG. 10 is a diagram setting out dimensions (in mm) for a suitable brake lever and channel element.
DETAILED DESCRIPTION
[0033] Hospital beds typically include a deck supporting a mattress or other patient support element (not shown in the Figs.). The deck may be divided into articulated sections so as to create various seating and lying down configurations. Articulated beds with a controllable articulation system for the patient support surface are known and are not a novel and inventive part of embodiments of the subject disclosure so will not be described in detail. An example of such an articulated patient support surface is shown in EP 2 181 685 and WO 2004/021952 to which reference should now be made and whose contents are hereby expressly incorporated herein by reference.
[0034] Referring to FIGS. 1 to 3 , a hospital bed support assembly according to one embodiment of the present disclosure includes a deck support frame 3 to which a headboard and a footboard may be mounted at, respectively, its head 4 and foot 5 ends. The head board is mountable on head board plates 33 and the foot board on foot board plates 34 . The deck support frame has two leg or support structures 6 pivotally mounted to its under surface. Each of the leg structures or assemblies 6 includes a pair of legs 7 each coupled to the deck support frame 3 by a moveable upper pivot or guide element 8 at their deck or upper end 9 . The moveable upper guide elements can move parallel to the longitudinal axis of the deck frame. For example, the moveable upper guide element 8 of the left-hand leg in FIGS. 2 and 3 can move in the directions shown by arrows D1 and D2.
[0035] The lower portions of the legs 7 of each pair of legs are connected together by a lower bracing cross-element 10 at the bottom 12 of the legs. The lower cross-elements 10 are each in turn connected to a lower longitudinal or side element and able to rotate about their longitudinal axis. In the embodiment shown in FIGS. 1 to 3 , each end of the foot end leg assembly lower cross-element is pivotally connected to a lower portion of a respective length extension element and the upper portion of each length extension element is pivotally connected to the lower longitudinal side element. The foot and head ends of the lower side elements 35 each have a castor or castor device 14 so that the support assembly can move over a floor or surface on which it is placed.
[0036] A pair of stabilizer elements 16 is connected to each pair of legs. A stabilizer element is connected to and links each leg to the underside of the deck support frame. The stabilizer elements 16 , which are each coupled to a leg 7 , are pivotally connected at their first upper ends 17 to the underside of the deck support frame 3 . The upper ends 17 of each stabilizer are connected to a fixed upper pivot 18 displaced from the leg upper moveable pivot 8 of the respective leg, and are pivotally connected at their second lower ends 19 to the respective pair of legs at a pair of respective lower stabilizer pivots 20 .
[0037] A stabilizer cross-element 37 is pivotally connected between the pair of stabilizers 16 for each leg assembly. The respective stabilizer cross-element is connected to each respective stabilizer at a point 36 between its upper 17 and lower 19 ends.
[0038] An actuator-stabilizer yoke 21 is connected to each stabilizer cross-element at a point substantially mid-way along the stabilizer cross-element so that it is in the middle of the bed. The actuator-stabilizer yoke 21 is pivotally coupled to an end of an actuator 22 (which may be a hydraulic actuator, or a linear actuator such as model No LA27 actuators supplied by Linak U.S. Inc. located at 2200 Stanley Gault Parkway, Louisville Ky. 40223) which controllably extends and retracts an actuator rod 23 connected to the actuator-stabilizer yoke 21 . Extension and retraction of the actuator rod 23 causes the respective stabilizer cross-element 37 and hence the pair of stabilizers 16 connected to that stabilizer cross-element 37 to move and thence the pair of legs 7 connected to that stabilizer 16 to rotate relative to the deck support frame 3 and thence raises or lowers the deck support frame 3 and the patient support surface arranged on that deck support frame. The actuators 22 may be controlled by either the patient or a care-giver. Control mechanisms for such actuators are well known and may be either a foot operated pedal, control panel on the side of the bed, remote control or other control mechanism. Suitable actuators are well known and are therefore not described in detail in this application. They may be hydraulic, electric or pneumatic. An example of hydraulic actuators controlling the height of a deck is described in EP 2 181 685 and WO 2004/021952.
[0039] Referring to FIG. 1 , the deck support frame 3 is formed by three sides of a rectangle and comprises parallel side elements 24 connected at their head ends by a head frame element 25 . In the described embodiment there is no foot frame element closing the rectangle other than the foot board (not shown) when that is attached to the foot board plates 34 (not shown) but one could be provided if appropriate. One of the known patient support deck arrangements such as that described in EP 2 181 685 and WO 2004/021952 may be secured to the patient support frame.
[0040] As shown in, for example, FIG. 4 , the side rail elements each comprise a hollow channel element open, along at least a portion of its length, on its lower side 27 . The channel element is a modified inverted U-shaped channel in which a portion of the bottom edges 28 are lipped such that the sides of the channel extend partially across the bottom of the inverted U-shaped channel.
[0041] The upper end of each leg is connected to two rollers 29 . The rollers 29 are supported on axles 30 running through the leg 7 and can rotate relative to the leg 7 . The upper end 31 of each leg passes through the gap or space 32 in the bottom of the channel elements 24 defining the sides of the deck support frame. The rollers 29 each engage the inner surface of the channel element.
[0042] Referring to FIGS. 2 and 3 , when the actuators 22 extend their respective rods 23 together to move the deck support frame 3 from a lowered position (see FIG. 3 ) to a raised position (see FIG. 2 ), the stabilizer element moves in direction E and pivots about its upper pivot. At the same time, the leg element pivots in direction F with its respective guide element moving in direction D1. As the guide element moves in direction D1 while the deck support surface is being raised, the respective set of rollers 29 roll relative to the respective channel element 24 .
[0043] When the actuators 22 retract their respective rods 23 together to move the deck support surface from a raised position ( FIG. 2 ) to a lowered position ( FIG. 3 ), the stabilizer element moves in direction G and pivots about its upper pivot. At the same time, the leg element pivots in direction H with its respective guide element moving in direction D2. As the guide element moves in direction D2 while the deck support surface is being raised, the rollers roll relative to the channel element.
[0044] Movement of the legs 7 and associated rollers 29 brought about by extension of the actuator rod to raise the deck support frame, pushes the rollers against the inner surface of the top of the respective channel element 24 so the roller rolls against that inner top surface of the channel. When the deck support frame is lowered by retraction of the actuator rod, the weight of the deck support frame and the patient support surface and patient supported thereon presses the inner top surface of the channel 24 against the respective rollers so that again the rollers roll along that top inner surface.
[0045] The channel 24 is provided along a substantial part of its length with a lip portion 28 welded or otherwise attached to each of the bottom edges of the two sides of the channel element. This helps hold the rollers in place and, if the patient support deck is lifted manually or otherwise than using the actuators, pushes up against the bottom of the rollers such that they roll against the lipped bottom edges 28 .
[0046] Moving the deck support frame into the Trendelenburg position or reverse Trendelenburg position is not illustrated in the Figs. However, it is achieved by having one of the leg assemblies in the raised position and the other in the lowered position and is otherwise the same as for lowering or raising the whole height of a substantially horizontal deck support frame. For the Trendelenburg position the foot end is raised to be about 15-30 degrees above the head end, whereas in the reverse Trendelenburg the head end is raised to be above the foot end.
[0047] In a one embodiment of the patient support apparatus according to the present disclosure, at least one of the castors and/or castor devices at each of the foot and head ends of the apparatus are provided with a brake assembly with a brake lever as described in, for example, U.S. Pat. No. 7,703,157 and arranged to be contacted and pressed down by the lower surface of the channel element to lock or brake the respective castor or castor device when the respective portion of the deck support frame is lowered.
[0048] Each of the castors includes a braking mechanism. FIGS. 5 to 7 show how a braking mechanism of the type used in castors of the type supplied by Tente as parts reference 5944 USC125 R36 may be incorporated in an embodiment according to the present disclosure. In such castors, the castor wheels 38 are braked when a pliable braking element 39 is squeezed down by a braking surface 40 so that the sides of the braking element contact and push against the sides of the castor wheels. An alternative braking element is shown in U.S. Pat. No. 7,703,157 in which braking is by means of a floor engaging element which is pushed into contact with the floor when the braking surface is ousted downwards. Any castor with an actuator mechanism operable by being pressed down or contacted may be used.
[0049] The braking surface 40 at the foot ends of the bed is pushed downward by the action of a braking lever 41 which may be actuated by, for example, the foot of a care giver on, as is shown in FIGS. 5 to 7 , by contact with the underside of the channel element 24 as the bed is lowered to the lowermost position. The use of a guide element 8 which moves inside a channel 24 allows one to position the longitudinal channel 24 closer to the edges of the bed than is possible with the previous arrangements with a guide element on the outside of a channel. This means that the channel or longitudinal rod 24 can be positioned so it moves in a place sufficiently close to the wheels to itself directly engage the brake lever 41 .
[0050] The brake surfaces (not shown) of the head end castors are connected to a respective foot end braking levers 41 by a rod element running inside each of the lower rail elements 35 . Movement of the braking lever 41 causes the rod to rotate and hence push the braking surfaces associated with the head end castors to move and hence brake or release the head end castors.
[0051] Although certain illustrative embodiments have been described in detail above, variations and modifications exist within the scope and spirit of this disclosure as described and as defined in the following claims. | A patient support apparatus includes a frame having a first portion that is movable between a raised position and a lowered position to change an elevation at which a person is supported above a floor. Castors are coupled to the frame and are configured to rest upon the floor. An actuator is movable between a brake position in which at least one castor of the castors is braked and a release position in which the at least one castor is released. As the first portion of the frame is moved to the lowered position, the first portion automatically engages the actuator and moves the actuator to the brake position thereby to automatically brake the at least one castor. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to U.S. patent application Ser. No. 11/937,133, filed on Nov. 8, 2007, entitled “Blood Content Detecting Capsule.”
FIELD OF THE INVENTION
[0002] The present invention relates generally to the utilization of light scattering and absorption techniques to detect possible abnormal living tissue. More specifically, the invention relates to an apparatus and method for utilizing multiple blood content sensors to guide a probe or endoscope to more advantageously detect abnormal tissue within a living body.
BACKGROUND OF THE INVENTION
[0003] Scientists have discovered that a detectible increase in the blood content of superficial mucous membrane occurs proximate cancerous and precancerous lesions in the colon relative to the blood content of healthy tissue as described in, for example, R K Wali, H K Roy, Y L Kim, Y Liu, J L Koetsier, D P Kunte, M J Goldberg, V Turzhitsky and V Backman, Increased Microvascular Blood Content is an Early Event in Colon Carcinogenesis , Gut Vol. 54, pp 654-660 (2005), which is incorporated by reference herein. This phenomenon is referred to as early increase in blood supply (EIBS).
[0004] Relying on this phenomenon, it has been discovered that it is possible to predict an area of potential abnormality based on early increase in blood supply (EIBS) in the area of abnormality. Further, it has been discovered, that by using a probe applying collimated light to an area of interest, and detecting the amount of absorbed and reflected light it is possible to provide information to a clinician to guide an endoscope to detect a possible abnormality in vivo without an invasive procedure. Such techniques have been described for example in U.S. patent application Ser. No. 11/937,133 filed on Nov. 8, 2007, entitled “Blood Content Detecting Capsule”, assigned to the assignee of the present invention, which is incorporated by reference herein.
[0005] However, particular types of optical blood content sensors require contact between the detection sensors and the mucosa of the underlying tissue for accurate detection of blood content. When a gap is present between these detection sensor types and the tissue of interest, a reduced amplitude of light interacted with the illuminated tissue will be received by the sensor and may be of little value in detecting abnormalities. Accordingly, in order to improve the likelihood that an abnormal area of tissue will be detected, it is important to ensure that the measurement sensor remains in contact with the tissue under investigation. Prior contemplated configurations have not addressed this issue. As a result, areas of abnormality may be missed or not detected with such systems.
SUMMARY OF THE INVENTION
[0006] The present invention advantageously increases data accuracy from detection sensors based on systems and methods that increase the desired sensor contact and/or identify collected data during the instances when such contact with the tissue under investigation occurs. This increase is accomplished in the present invention by employing, for example, contact detectors associated with the blood content detectors as part of a probe for insertion into a cavity of a living body, such as an endoscope or endoscopic sheath, and/or employing multiple blood content detectors for beneficially providing data to better guide an endoscope, colonoscope, or other probe, to locate abnormal tissue, tumors, or tissues that precede the development of such lesions or tumors.
[0007] In one aspect of the invention, contact detectors are employed with optical blood content detectors that provide more accurate blood content data when such sensors are in direct contact with the subject tissue. The contact detectors beneficially indicate when such sensors are in contact with tissue and correspondingly indicate that the generated blood content information signals at that instance are more likely to have improved accuracy than during instances when such sensors are not in contact with tissue. Further, the contact sensors may generate signals or power to the blood content sensors such that the illuminators and collectors within the blood content sensors are energized or powered on only during periods when the contact sensors are in contact with the tissue mucosa.
[0008] In another aspect of the invention, improved blood content detection is achieved by the use of multiple blood content sensors advantageously positioned in or on the surface of the probe or endoscope. The detection and locating of abnormal tissue is enhanced based on the blood detection data from the multiple sensors. It is particularly advantageous to use substantially simultaneously generated data from such sensors which can be statistically processed or otherwise to better and more accurately provide information for use in guiding the probe or endoscope.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a better understanding of the present invention, reference is made to the following description and accompanying drawings, while the scope of the invention is set forth in the appended claims:
[0010] FIG. 1 illustrates a block diagram of an exemplary system in accordance with one aspect of the invention utilizing multiple blood content detector sensors;
[0011] FIG. 2 illustrates an exemplary diagram of a system in accordance with the invention utilizing at least three optical blood content detectors;
[0012] FIG. 3 illustrates an exemplary embodiment of an optical blood content sensor useable with the present invention;
[0013] FIG. 4 illustrates an alternative exemplary embodiment of the optical blood content sensor useable with the present invention;
[0014] FIG. 5 illustrates an exemplary embodiment of a polarizer useable with the present invention;
[0015] FIG. 6 illustrates a representative block diagram of a exemplary processor useable with the present invention;
[0016] FIG. 7 illustrates an exemplary embodiment of a first endoscope configuration utilizing the present invention;
[0017] FIG. 8 illustrates an exemplary embodiment of a second endoscope configuration utilizing the present invention;
[0018] FIG. 9 illustrates an exemplary embodiment of a third endoscope configuration utilizing the present invention;
[0019] FIG. 10 illustrates an exemplary embodiment of a fourth endoscope configuration utilizing the present invention;
[0020] FIG. 11 illustrates an embodiment of an exemplary portion of an endoscope utilizing the present invention;
[0021] FIG. 12 illustrates an exemplary endoscope and sheath configuration utilizing the present invention;
[0022] FIG. 13 illustrates a second exemplary endoscope and sheath configuration utilizing the present invention; and
[0023] FIG. 14 illustrates an exemplary light fiber bundle useable with the present invention.
DETAILED DESCRIPTION
[0024] The present invention relates generally to improvements in blood flow detection due to the improved contact and possibility of improved contact between the various detection sensors and the living tissue mucosa under investigation.
[0025] Referring to the drawings, like numbers indicate like parts throughout the views as used in the description herein, the meaning of “a” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes both “in” and “on” unless the context clearly dictates otherwise. Also, as used in the description herein, the meanings of “and” and “or” include both the conjunctive and disjunctive and may be used interchangeably unless the context clearly dictates otherwise.
[0026] FIG. 1 depicts a schematic diagram of blood detection system 100 containing three detection sensors.
[0027] However, as will be appreciated by those skilled in the art, the number of detection sensors or windows is not limited to three. Light source 1 is in contact with single fiber rod 2 . The light emanating from light source 1 is focused on the end face of single fiber rod 2 . Due to the internal configuration of single fiber rod 2 , the beams of light are repeatedly reflected off the inner walls of the single fiber's core resulting in a light source of uniform intensity, i.e., collimated light.
[0028] Single fiber rod 2 is further in contact with fiber bundle 3 . Fiber bundle 3 is made up of the independent illumination fibers 3 a , 3 b , 3 c , . . . 3 n . The transmitted light is communicated on the respective illumination fibers 3 a to 3 n to measurement units 12 a to 12 n. In each measurement unit 12 a to 12 n , the transmitted light passes through a series of polarizers, lenses and prisms before exiting. The exiting light illuminates the areas of living tissue under examination. Interacted light from the illuminated tissue mucosa is correspondingly detected by the measuring units 12 a to 12 n . In each measurement unit 12 a to 12 n , received interacted light passes through the measurement unit prism, lens, and polarizer as seen in FIG. 3 and is transmitted via collectors 7 a and 7 b back to spectroscope 9 for analysis.
[0029] FIG. 2 depicts a block diagram of an exemplary configuration of the system 100 of FIG. 1 . Referring to FIG. 2 , the exemplary system seen in FIG. 2 contains light source 1 for generating light of sufficient intensity and frequency to illuminate the tissue under investigation so as to ascertain the blood content within the illuminated tissue mucosa. Single fiber rod 2 may be, for example, a fiber optic conductor containing a optical core or similarly designed to equalize and collimate the light emitted from light source 1 to ensure uniform intensity and frequency of the light entering the illumination fibers. Illuminator fibers 3 a - 3 n are individual optical transmission lines that convey the light from single fiber rod 2 to the measurement units 12 a - 12 n . Light source 1 may be, for example, a xenon lamp, a halogen, lamp, an LED, or any other light source capable of providing a light of adequate intensity and frequency.
[0030] In addition to light source 1 , measurement units 12 a - 12 n further includes polarizer 4 , lens 5 , prism 6 and measurement window 15 . Polarizer 4 is a linear polarizer designed to ensue that the transmitted light waves are aligned in a linear fashion, i.e., horizontally or vertically. Lens 5 is an optical lens that conveys light waves in a parallel orientation. Light waves exit lens 5 in a generally parallel direction and strike the surface of prism 6 . Prism 6 is a optical prism with a coated reflective surface. Light waves striking the surface of prism 6 are orthogonally reflected through measurement window 15 into the underlying living tissue. Measurement window 15 is an optical window typically, glass or other transmissive material in the detection wavelength range, that does not adversely interact with or attenuate transmitted or reflected light waves.
[0031] Light that interacts with or is reflected off of the underlying tissue is conveyed through window 15 back through prism 6 , lens 5 and polarizer 4 onto collectors 7 a and 7 b . Optical fibers 7 a and 7 b each convey the reflected light back to spectroscope processing unit (spectroscope) 9 . It should be noted that as a result of the placement of optical collectors 7 a and 7 b with respect to polarizer 4 , optical fibers 7 a and 7 b convey either horizontally or vertically polarized light waves back to spectroscope 9 . Fibers 7 a and 7 b enter spectroscope 9 at slot 8 and convey there respective blood content data to the data receiver located in spectroscope 9 .
[0032] An exemplary detailed operation of the system 100 is now described with respect to a single measurement unit 12 a with regard to FIGS. 1 and 2 . However, it shall be understood that this operation may be carried out simultaneously or otherwise by the measurement units 12 a - 12 n depicted in FIG. 1 . Referring to FIG. 2 , light emitted from light source 1 passes through single fiber rod 2 to reach the individual optical fibers 3 . As light emanating from light source 1 passes through single fiber rod 2 , the rod 2 equalizes and collimates the intensity and wavelength of the light emitted from light source 1 and guides the equalized and collimated light into the individual illuminator fibers 3 a to 3 n.
[0033] Once the collimated light enters a single fiber 3 a to 3 n it is communicated to the individual measurement units 12 a to 12 n . Each measurement unit 12 a to 12 n is comprised of a illuminator fiber, a polarizer unit 4 , a lens 5 , a prism 6 , and window 15 . The transmitted light exits the measurement unit 12 a via window 15 and illuminates a region of tissue within the living body.
[0034] Certain light interacted with the illuminated tissue is reflected back and collected by the corresponding measurement unit 12 a to 12 n through its corresponding window 15 and passes back through prism 6 , lens 5 , and polarizer unit 4 to the collector fibers 7 a and 7 b.
[0035] Each measurement unit 12 a to 12 n has two optical receiving or collector fibers 7 a and 7 b that direct the received or collected interacted light to pass-through slit 8 in spectroscope 9 for analysis. As an alternative to the receiving fibers 7 a and 7 b of measurement units 12 a to 12 n , directly entering spectroscope processing unit 9 via a slit 8 , a lens may be provided between receiving fibers 7 a and 7 b and the slit 8 for an improved and more efficient light transmission. An exemplary configuration for such a lens is cylindrical. However, alternative shapes or other configurations may be employed in accordance with the invention.
[0036] As depicted in and later described with respect to FIG. 14 , individual fibers 3 a to 3 n may have a diameter as small as, for example, 100 μm, resulting in a fiber bundle 3 in FIG. 1 as small as 1 mm. In this example, the diameter of a single fiber should likewise be of sufficient size to receive light emitted from light source 1 to produce light emitted from the various windows of a desired intensity. In order to maintain each fiber bundle 3 a - 3 n of sufficiently small size, each individual fiber end may have a tapered shape and the area of the core at the end face close to the light source is greater than that of the other end face close to the respective single measurement unit 12 a - 12 n.
[0037] FIG. 3 depicts an exemplary configuration of measurement unit 12 a. Other measurement units 12 b to 12 n may contain similar optical configurations. Referring to FIG. 3 , Measurement unit 12 a contains illumination fibers, and collector fibers, linear polarizer 41 and 42 , lens 5 , prism 6 , and measurement window 15 .
[0038] In operation of the measurement unit of FIG. 3 , light emitted from light source 1 (shown in FIGS. 1 and 2 ) travels through illumination fiber 3 and passes through linear polarizer 4 . Polarizer 4 is comprised of two linear polarizers 41 and 42 . Linear polarizer 41 may be oriented for polarization in a horizontal direction and linear polarizer 42 may be oriented for polarization in a perpendicular direction relative to the linear polarization produced by polarizer 41 . The transmitted linear polarized light beams 301 pass through linear polarizer 41 and enter lens 5 . Due to the shape of lens 5 , the light beams 301 exit the lens parallel to each other before being refracted by prism 6 . The light is reflected off prism surface 21 and is conveyed through window 15 and illuminates the target tissue mucosa 17 . Prism surface 21 may contain, for example, a vapor-deposited coating of silver, aluminum, or other material in order to produce the preferred reflectivity.
[0039] In the instance when window 15 is in contact with the target tissue mucosa 17 , the transmitted light is interacted with by the tissue mucosa 17 . Portions of the interacted light 302 and 303 reenter prism 6 and again refracted off of the prism surface 21 and back through lens 5 . The interacted light 302 and 303 passes through lens 5 and into polarizer unit 4 , passing through either linear polarizer 41 or linear polarizer 42 . After passing through the respective polarizer 41 or 42 , the light 302 and 303 enters the respective collector fibers 7 a or 7 b depending on which linear polarizer 41 or 42 , the light has passed through.
[0040] Because of this lens, prism, and polarizer unit configuration, only light that interacts with tissue mucosa 17 at specific angles enters the collectors or receiving fibers 7 a and 7 b . More specifically, light entering collector or receiving fiber 7 a is oriented at the same polarization direction as the transmitted light, since both transmitted and reflected light are passing though linear polarizer 41 . In contrast, the light entering collector or receiving fiber 7 b is always perpendicular to the transmitted light since it passes through linear polarizer 42 which is oriented in a perpendicular direction relative to that of liner polarizer 41 .
[0041] FIG. 4 depicts an alternative embodiment of the polarizer, lens, prism combination of measurement unit 12 of FIG. 3 . In FIG. 4 , the lens 5 and the prism 6 of FIG. 3 are integrated into a single lens prism unit 19 . The integration of the two components decreases the number of sides the individual lens and prism combination has, thereby reducing the amount of stray light generated by reflection on the sides and accordingly, the stray light that reaches the light receiving fibers. A further advantage of utilizing a single lens prism combination may be realized due to the reduced number of optical components required, the reduced cost in manufacturing and assembly. In another embodiment, the flat reflection surface 21 of the prism may be spherical or ellipsoidal so as to achieve the same effect as the lens itself, thereby further reducing the number of components and manufacturing costs.
[0042] In operation, the measurement unit of FIG. 4 operates in a similar manner to that described with respect to FIG. 3 . Light emitted from light source 1 travels through illuminator fiber 3 and passes through linear polarizer 41 . Linear polarizer 41 may be oriented for polarization in a horizontal direction and linear polarizer 42 may be oriented for polarization in a perpendicular direction relative to the linear polarization produced by polarizer 41 . The transmitted linear polarized light beams 301 pass through linear polarizer 41 and enter lens prism unit 19 . Due to the shape of the lens portion of lens prism unit 19 , light beams 301 are oriented parallel to each other before being refracted by surface 21 of lens prism unit 19 . The light is reflected off surface 21 and is conveyed through window 15 and illuminates the target tissue mucosa 17 . Prism surface 21 may contain, for example, a vapor-deposited coating of silver, aluminum, or other material in order to produce the preferred reflectivity.
[0043] In the instance when window 15 is in contact with the target tissue mucosa 17 , the transmitted light interacts with the tissue mucosa 17 . Portions of the interacted light 302 and 303 reenter lens prism unit 19 and are again refracted off of surface 21 and back through the lens portion of lens prism unit 19 . The light 302 and 303 pass through lens prism unit 19 and into either linear polarizer 41 or linear polarizer 42 . After passing through the respective polarizer 41 or 42 , the light enters the respective collectors or receiving fibers 7 a or 7 b , accordingly.
[0044] Because of the configuration of lens prism unit 19 and polarizer units 41 and 42 only light that interacts with tissue mucosa 17 at specific angles enters the collectors or receiving fibers 7 a and 7 b . More specifically, light entering receiving fiber 7 a is oriented at the same polarization direction as the transmitted light, since both transmitted and reflected light are passing though linear polarizer 41 . In contrast, the light entering receiving fiber 7 b is always perpendicular to the transmitted light since it passes through linear polarizer 42 which is oriented in a perpendicular direction relative to that of liner polarizer 41 .
[0045] FIG. 5 depicts an exemplary configuration of the linear polarizer unit 4 of FIGS. 2-4 . FIG. 5 illustrates that the linear polarizers 41 and 42 of FIGS. 2 through 4 may be composed of a glass substrate 51 with a polymer material 52 bonded to a first side and an aluminum wire vapor-deposited on an opposite, second side 53 . The polarizing surfaces i.e., polymer side or aluminum-wire side, may preferably be bonded on the surface of the light receiving fibers. Due to the thermostability of the polarizing surface, the surface is preferably formed from an aluminum wire, such as, for example, the aluminum-wire grid polarizing filter manufactured by Edmunds Optics Inc. of Barnington, N.J.
[0046] In the present invention, calculations are computed based on the detection of interacted light received by each individual measurement unit. FIG. 6 shows a schematic diagram of an exemplary spectroscope 9 . In FIG. 6 , the spectroscope 9 includes a data receiver 620 , a data preprocessor 621 , a blood content estimator 622 (or blood content calculator), a data validator 623 , a power supply 624 , an optional display or indicator 625 and a data comparator 626 . Data receiver 620 receives information from the receiving fibers 7 a and 7 b.
[0047] In operation, the data received by the data receiver 620 of the spectroscope 9 in FIG. 6 is provided to a data preprocessor 621 . The data preprocessor 621 executes, for example, a data correction algorithm, such as white correction represented in the following equation (1).
[0000]
Δ
Ic
(
λ
)
=
Δ
I
(
λ
)
Δ
Iw
(
λ
)
=
I
Π
(
λ
)
-
I
⊥
(
λ
)
Iw
Π
(
λ
)
+
I
⊥
(
λ
)
(
1
)
[0048] Where the symbols Π and ⊥ used in the numerator and denominator of equation (1) represent the spectrum of horizontally polarized light and the spectrum of vertically polarized light, respectively. In equation (1), Λ represents wavelength, ΔI(λ) indicates the measured difference polarization spectrum, ΔIw(λ) is the spectrum measured using a standard white plate and is calculated by summing the white horizontal polarization spectrum Iw Π (λ) and the white perpendicular polarization spectrum Iw ⊥ (λ), as shown in the denominator of equation (1). In the numerator of equation (1), the difference between the horizontal polarization spectrum I Π (λ) and the perpendicular polarization spectrum I ⊥ (λ) is calculated and a signal indicative of ΔI(λ).
[0049] Based on the generated results of the data processor 621 , the blood content estimator 622 calculates the blood content by using equation (2) below, which is shown in, for example, M. P. Siegel et al. Assessment of blood supply in superficial tissue by polarization - gated elastic light - scattering spectroscopy, Applied Optics, Vol. 45, Issue 2, pp. 335-342 (2006), which is incorporated by reference herein.
[0000] Δ I (λ)=Δ I scattering (λ)exp[−α A PG (λ)] (2)
[0050] The blood content estimator 622 calculates the blood quantity by using a model equation, such as equation (2), and may provide a corresponding blood content value to optional display 625 . Alternatively, the blood content estimator 622 may also provide the blood content value to data validator 623 as a check on the integrity of the collected data. Further, blood content estimator 622 may provide the results from the various detection units to comparator unit 626 to determine the validity of a measurement and to improve the accuracy of detection based on the numerous measurement units.
[0051] Various configurations of exemplary endoscopes with multiple measurement units in accordance with the invention are depicted in FIGS. 7 to 13 . More specifically, FIG. 7 depicts an endoscope tip 71 with multiple measurement units. Endoscope tip 71 is generally concave in shape with the multiple measuring units 72 deployed along the concave surface of the tip. In operation, by pressing an endoscope tip 71 into living tissue, the tissue is drawn into, or aspirated into contact with the multiple measuring units 72 . The placement of numerous measurement units on the concave surface ensures contact by one or more of the measurement units. Contact with multiple measurement units would tend to provide a more accurate reading than a probe with a single measurement unit. In additional, greater accuracy in blood content detection is achievable by comparing the data obtained from the multiple measuring units 72 .
[0052] In the configuration of FIG. 8 multiple measurement units 84 are employed with a traditional flexible endoscope 8 . Endoscope 8 contains a rigid tip 81 , a connecting portion 82 , angled portion 83 , and measurement units 84 in accordance with the invention. By placing the measurement units 84 on the outer circumference of the insertion portion of the flexible endoscope, the detection windows are advantageously more likely to contact the tissue mucosa upon insertion and removal of the device.
[0053] FIG. 9 depicts a variation of the configuration of the invention shown in FIG. 8 . A second ring of detection units 184 is longitudinally located on the circumference of the connecting portion 82 . By utilizing a second ring of measurement units 184 on the circumference of the flexible endoscope, a user is able to obtain measurement results at two different locations along the longitudinal access of the endoscope. By analyzing the data from the two different regions on the living tissue, an operator can more accurately determine the proximity of the abnormal lesion by utilizing the differences between the two areas of measurement.
[0054] FIG. 10 depicts an alternative embodiment to those disclosed in FIGS. 8 and 9 . As seen in FIG. 10 , the measurement units 184 may be arranged in a substantially helical arrangement about the circumference of the insertion portion of a flexible endoscope. Such an arrangement significantly increases the coverage area of the multiple detection windows.
[0055] FIG. 11 depicts an embodiment of the present invention wherein the connecting portion of the endoscope has a thread-like or helical protruded portion 112 . In this embodiment, the multiple measurement units 111 are placed in the outer circumference of the helical protrusion 112 . In operation of this configuration, the multiple measurement units 111 tend to serially come into contact with the same areas of tissue mucosa as the insertion portion is rotated upon insertion or extraction.
[0056] FIG. 12 depicts an endoscope 122 covered by a sheath 121 with measurement units 123 disposed therein. Sheath 121 is essentially a tube into which, for example, an endoscope 122 , such as a conventional endoscope is inserted. Multiple measurement units 123 are arranged along the circumference of sheath 121 and contact living tissue mucosa 124 . This type of sheath configuration allows the user to employ a conventional endoscope while at the same time advantageously utilizing blood content detection methods for guiding the endoscope to abnormal tissue. It will be appreciated by one skilled in the art that sheath 121 may also be configured with the thread-like protrusions 112 and the multiple measurement units 123 may likewise be configured in a spiral configuration along the circumference of the thread-like shape.
[0057] FIG. 13 depicts an embodiment with sheath 131 , endoscope 132 , and balloon 133 having multiple measurement units 134 disposed therein. Sheath 131 is typically a hollow tube through which, for example, a endoscope 132 will be inserted. Balloon 133 is attached to or formed integral with the sheath 131 and is inflated by either air or water pressure. Upon placement of sheath 131 , balloon 133 is inflated to contact the target tissue mucosa 135 . The inflation of balloon 133 ensures contact between the multiple measurement units 134 and tissue mucosa 135 . Further, a sensor 136 may be employed to start the blood detection process based on inflation of balloon 133 . As will be appreciated by those skilled in the art, sensor 136 may be located internally or externally to the sheath 131 or balloon 133 . For example a sensor could be located on the surface of balloon 136 or within sheath 131 and may sense the back pressure exerted by the balloon 133 when it inflates and contacts living tissue 135 .
[0058] In an alternative embodiment, two or more balloons may be utilized, each with its own set of measurement units 134 . By utilizing multiple balloons 133 , the multiple measurement units 134 can be spread out along sheath 131 . In the manner, the blood content detection data can be analyzed to determine which of the balloons 133 is closest to an area of interest. Such information will aid in isolating and detecting potential areas of interest.
[0059] In another exemplary embodiment of the present invention, blood data collection is triggered upon the sensing of contact between balloon 133 and tissue mucosa 135 . Such sensing of contact may be the result of back pressure sensed in the balloon inflation mechanism or as a result of surface sensors 136 located in balloon 133 .
[0060] While the foregoing description and drawings represent the preferred embodiments of the present invention, it will be understood that various changes and modifications may be made without departing from the spirit and scope of the present invention. For example, although the improved method and apparatus described herein as part of or in conjunction with an endoscope, it is also possible to use the invention with a stand alone probe or other medical device. | Light scattering and absorption techniques for the detection of possible abnormal living tissue. Apparatus and methods for utilizing multiple blood content detection sensors and/or contact sensors for beneficially providing data to better guide an endoscope or colonoscope to locate abnormal tissue, tumors, or tissues that precede the development of such lesions or tumors. | 0 |
FIELD OF THE INVENTION
The present invention relates to incoming call indication in a mobile telecommunication system.
Especially the present invention relates to incoming call indication in a call initialization process in a mobile telecommunication, whereby a user (caller) having a calling mobile phone makes a call to another user (recipient) having a called mobile phone.
In the call initialization process the calling user dials or selects the called user's telephone number, the calling mobile phone contacts the called mobile phone according to the mobile telecommunication system protocol and alarms (alerts) the called mobile phone. The calling user's ID, preferably the phone number, is transmitted to the called mobile phone.
Naturally instead a mobile phone any other mobile telecommunication terminal device operable in that mobile telecommunication system may be used.
BACKGROUND OF THE INVENTION
A ringtone is an electric telephony signal that conventionally causes a mobile phone to alert the user to an incoming call.
It has been showed that people would wait until the phone stopped ringing before picking it up. Breaks were thus introduced into the signal to avoid this problem, resulting in the common ring-pause-ring cadence pattern used today. Caller ID signals identifying the caller are sent during the silent interval between the first and second bursts of the ringing signals.
Mobile phones allow the users to associate different ringtones for different phone book entries. Websites let users make ringtones from the music they already own (MP3, CD etc.) and upload directly to their mobile phone. In addition to the cost benefits, a key feature is the music editor that lets the user easily pick the part of the song they wish to set as a ringtone. Such services automatically detect the phone settings to ensure the best file type and format.
An alternative to a ring tone for mobile phones is a vibrating alert. It may be useful in noisy environments, in places where ring tone noise would be disturbing and for those with a hearing loss.
US2007192067 discloses an apparatus for automatically selecting alert option of a communication device is provided. The apparatus includes a noise detection unit for collecting a current ambient noise, and generating a quantified value of the current ambient noise according to the current ambient noise collected; and a central processing unit (CPU), including a detecting module for detecting the communication signal from the receiver, enabling the noise detection unit to perform the corresponding function, and determining a volume level of the current ambient noise according to the quantified value of the current ambient noise from the noise detection unit; and a controlling module for selecting a current alert option of the communication device according to the volume level of the current ambient noise, and controlling the ringing unit and the vibrating unit of the communication device to perform corresponding functions according to the alert option selected.
Typical for the prior art incoming call indication systems are that incoming call indication type is defined only by the recipient, naturally within the limits of the user's mobile phone capabilities.
SUMMARY OF THE INVENTION
The object of the present invention is to overcome the problems and limitations with the existing incoming call indication methods and systems.
The present invention is based on an idea that instead of the called user the caller (calling user) specifies how the incoming call is indicated in the recipient's phone and what kind of media is steered to and displayed in the recipient's mobile phone during the call initialization process.
This is implemented so that the caller by using a mobile phone incoming call media application, so called MadTag application, steers a desired media, such as a tag, e.g. from his MadTag www-site, to the recipient's mobile phone so that when this specific caller calls the recipient a caller specific tag is steered to the recipient's mobile phone and displayed therein.
In a preferred embodiment the application starts immediately and automatically after the connection is created. e.g. within some seconds from the time when the call connection is ready.
The present invention is in detail defined in the enclosed claims, especially in the independent method and system claims.
By means of the present invention it is possible that, on the contrary to the conventional systems, the caller defines which indication the recipient gets of an incoming call. This gives a totally new way of communication and especially dialing indication possibilities.
Many kind of mobile telecommunication systems and terminal devices, such as communicators etc, having 3G, GPRS or corresponding properties may be used in the present invention.
BRIEF DESCRIPTION OF THE FIGURES
In the following, preferred embodiments of the present invention will be described in detail by reference to the enclosed drawings, wherein
FIG. 1 presents a schematical view of a 3G mobile telecommunication system.
FIG. 2 presents a block diagram of the operation of incoming call indication according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 presents of a 3G mobile telecommunication system operating with a 3G protocol and comprising users having 3G mobile phones, here for simplification only two, USER 1 with MOBILE 1 and USER 2 with MOBILE 2 who are in communication with each other via the 3G network having base stations, here for simplification only one BS 1 . All users in a 3G network having a 3G mobile phone have access to Internet and may use the Internet and its services provided for 3G networks.
Each phone is a 3G mobile phone provided with corresponding processor and memory capacity and further provided in this embodiment with an Symbian Operative System which is a proprietary operating system, designed for mobile devices, with associated libraries, user interface frameworks and reference implementations of common tools, produced by Symbian Ltd. It runs exclusively on ARM processors.
A calling user USER 1 makes a telephone call CALL 1 to another client USER 2 with his mobile phone MOBILE 1 by dialing the recipient's telephone number NUMBER 2 or selecting it from the telephone book. The called (receiving) mobile phone MOBILE 2 alerts for incoming call with a ringtone and a tag ALERT 2 which may be text, images, video clips and their combinations, based on the caller's telephone number NUMBER 1 which is transmitted to the recipient according to the present invention as in detail described later.
Each phone utilizing the present invention is provided with a MadTag application MadTag 1 , MadTag 2 operating as a client software application the operation and structure of which is described in the following in further detail.
The called user gets the tag alerting of an incoming call by using the incoming call media application, so called MadTag application MadTag 2 , which steers a desired tag ALERT 2 from the caller's MadTag www-site stored in Internet in the www-server SERVER 1 to the recipient's mobile phone so that when this specific user USER 1 calls the recipient USER 2 the desired incoming call tag is steered to this specific recipient's mobile phone and displayed therein. Thus the request from MOBILE 2 is steered via the base station BS 1 and Internet to the MadTag server SERVER 1 and the tag is then steered from SERVER 1 via Internet and base station BS 1 to the recipient's mobile phone MOBILE 2 . The total time for sending the request until the tag is displayed is typically 2 to 3 s. The provision for the operation is that both users are member of a same MadTag user group (community).
MadTag is a Symbian software application operating in the 3G layer embedded in the dialing procedure which starts automatically in the calling phone MOBILE 1 when the caller calls a user within this MadTag application community, and in the called phone when the user receives a call from a user within this MadTag application community.
MadTag application tag is typically displayed in the recipient's phone only during the call initialization process and thus stops when the recipient answers to the call.
Madtag—Principal Operation
1. Client www Registration
upon registration the user gets a link that he writes/dials into the mobile phone http link is stored in the phone the Madtag application is fetched from the server a downloading software is installed in the phone the software inquires if the application shall be downloaded if yes then the Madtag application may be used in that mobile phone
2. Adding Madtag Users to the Profile
the user gets a Madtag folder from the server where the client stores contents (tags) which is addressed according to a name and mobile phone number to include friends in the client's Madtag community if the client wants these friends to his community he sends to them an email from a site having the www site link.
3. Madtag Process (see Block Diagram in FIG. 2 )
the user (USER 1 ) chooses another user (USER 2 ) from the phonebook (A), the user (USER 1 ) calls the other user (USER 2 ) so that the mobile phone dials the other user's number (B), in the receiving other user having also the Madtag application in his phone the called phone gets an alert (e.g. a ringtone) and starts the MadTag application immediately (in some ms) after the first ringtone or other alert for incoming call (C), the called phone contacts the server (SERVER 1 ) and SERVER 1 checks that both users are members in the same community and informs that USER 1 has a Madtag tag for USER 2 and sends it to USER 2 (D) (see also FIG. 1 ), when USER 2 looks at his mobile phone he notices that he has got a tag ALERT 2 from USER 1 displayed in the display of his called phone (E), typically in some seconds from the first alert (see also FIG. 1 ).
Application Modules
1—Server Data Base
The server data base will be MySql 5.x data base that will hold and maintain and manage all data used by the system. It will provide security level DB to the contained data.
2—Back Ground Symbian Application (3 rd Symbian SDKs)
The back ground Symbian application will be installed with the interface application on the same setup file. After installation the background application will be disabled until registration is done. After that it is enabled and running all the time until the end-user disables it from the settings in the interface application. If the mobile is restarted the application will start with it. The application will do the following tasks.
a) Monitoring for any incoming call.
b) If call comes, the application catches the calling mobile number and queries the server about it.
c) When the response arrives, it save it to a log database or file and show the result on the screen. The name of the caller and image are the only shown info while call is received, the rest of the data (example phone numbers) can be viewed using the interface application.
3—Interface Symbian Application (3 rd Symbian SDKs)
This is the application that the user sees on his mobile. It enables him to control the work of the other application and view recent calls and to edit his own data. The application will be installed on the user mobile and after installation it will appear as an Icon and a Name in the installed applications place in the phone menu. When the user selects the application to run the following screens may appear.
a) Splash Screen
It will be shown in the beginning of the program only for 2→3 seconds. It personalizes the program and to give a chance for initialization data to be loaded without appearing delay.
b) Main Screen
The screen is the first screen to show after the splash disappears. The screen also will have menu options (Options—Exit). The options part of the menu will have the following submenu.
i—Register: This will be shown only at first until the user performs registration. When executed it will ask the user for registration code and contacts the server with entered code and mobile IMEI to perform the registration. If the process succeeded, an info message will tell the user that the registration success and the item will not appear again. ii—Settings: to enable user to edit the settings from the settings screen. iii—Help: For viewing the help part of this screen. iv—Exit: to exit the interface program
c) User Info (WWW)
The Symbian application will not provide an interface for adding numbers, this will be done via the WWW pages, which allows the user to easily manage many contacts. The program should include a search function to search by name from the MadTag list name or names matching the search query. The text part of the selected name can then be edited and saved.
d) Settings Screen
This screen will enable the user to control the working of the background and interface application. The screen will display a list with the various settings and the user selects what he wants to change. The menu of this screen will be in the form of (options—Back). The menu will contain the following submenu
i—Change: to change the current setting value.
a. Options like activate/deactivate background service
ii—Help: to view help file for this screen. iii—Exit: to exit interface application.
Operation of Madtag in More Detail
The application operates as follows.
The application in hand is a Symbian application aims to do the following
1—To be installed on mobile phones that support 3G, GPRS & compatible with e.g. Symbian 3 rd edition. The owner of the mobile that the application is installed on is referred to as the end-user.
2—After installation the end-user should register his/her version of the application to be able to use it. Registration is free and done by entering a given code acquired from a web site. The code entered can't be used again with any other registration because it is attached to mobile IMEI.
3—The end-user will have settings in the installed application that enable him to control the behavior of the installed application.
4—The application starts automatically in the back-ground to catch an incoming call. This feature can be cancelled by enable/disable setting in the settings screen.
5—When the application is installed and enabled, and a call is received, the application queries the server (through 3G or GPRS) for the owner of the caller mobile number, and if found it displays his/her information to the end-user, the information may be both text and a small image (if available). After the call ends a customized advertisement or a graphical business card supplied by MadTag is shown to the recipient's device (if available). If the caller number is not found then no indication is made. The caller also has the ability to control if the data to be shown at call received or not by another setting (Show caller info immediately Yes/No).
6—The end-user can update his own information on the server using the application (Text only) from his mobile phone that has access to internet (see the dashed line in FIG. 1 ) or a laptop or alike by using an updating software and its user interface. And he can edit his image and Customized add from a dedicated web site.
Task for Admin www-Site Interface
The admin will be able to add sponsors of competitions. And by default the first sponsor will be the Madtag portal itself otherwise administrator will be able to mange sponsors.
There will be a calendar, (with start and end dates), which is categorized by day and by time, that regulates the duration of each advert.
On the web user inter face there will be advertising spots, banners, links and click counter, and the admin will have full control over them.
Also a wild card search will be available.
It is obvious to the person skilled in the art that the embodiments of the invention are not restricted to the example presented above, but that they can be varied within the scope of the following claims. The tag can be stored in addition to a www site in a www server also in the caller's mobile phone (intern memory) or in TV or elsewhere in an appropriate external memory device. Steering of media from the memory to the user's mobile phone can be implemented either by pulling or pushing. The Madtag application can also be controlled with a timer so that it operates a certain time, typically some seconds, also after the initialization process.
The mobile telecommunication system may be a 3G network i.e. third generation of mobile phone standards and technology providing wide area cellular telephone networks which evolved to incorporate Internet access and video telephony, or a General Packet Radio Service (GPRS) network providing Mobile Data Service available to users of Global System for Mobile Communications (GSM) and IS-136 mobile phones or any other mobile telecommunication system having high rate data transmission e.g. capable of having access to Internet. | Incoming call indication method and system in a call initialization process in a mobile telecommunication system, whereby a user (caller, USER 1 ) having a calling mobile telecommunication terminal device (MOBILE 1 ) makes a call to another user (recipient, USER 2 )) having a called mobile telecommunication terminal device (MOBILE 2 ), in which the call initialization process the calling user dials or selects the called user's telephone number and the calling mobile phone contacts the called mobile phone according to the mobile telecommunication system protocol and preferably alarms (alerts) the called mobile phone for an incoming call, and wherein the calling user's ID, preferably the phone number, is transmitted to the called mobile phone, and wherein media, such as a tag, specified by the calling user (USER 1 ) is steered to and displayed and/or otherwise processed in the called mobile telecommunication terminal device at least during the call initialization process. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation application, under 35 U.S.C. §120, of copending international application No. PCT/DE2009/000374, filed Mar. 18, 2009, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German patent application No. DE 20 2008 004 809.5, filed Apr. 8, 2008; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention relates to a height-adjustable equipment stand, for a notebook or for a monitor with keyboard in particular, which can be placed on a table and which, when lowered, is flat so that a keyboard situated on the stand can be operated without difficulty, and the support surface of which can be lifted quickly and holds the equipment situated on it in a horizontal or defined oblique position at each height.
[0003] When working with personal computers or other equipment for a long time it is desirable and healthy to change one's body position from time to time, e.g. by alternating between sitting and standing positions. Known height-adjustable equipment for this purpose is manufactured mainly in the now described variants.
[0004] In a first variant, the entire top plate of a desk is height-adjustable. This construction is usually very expensive and replaces an already existing desk.
[0005] Further known variants with swivel arms can be mounted on an existing desktop, normally at the rear or side edge of the desktop, by a clamp. These variants have the disadvantages that they block the space behind the monitor and the keyboard, that even in the lowered position they are optically incommoding, and that because of the supporting arm, which needs to be long and stable, it is not possible to lower the keyboard to a few millimetres above the desktop, so that the user cannot keep arms and hands in their normal position. Moreover, with these variants it is difficult to achieve sufficient stability when working with a keyboard or a mouse.
[0006] Other variants, which can be placed on an existing desktop, have one or more of the abovementioned disadvantages or their adjustment to different heights is laborious.
[0007] Many construction principles are known for height-adjustable devices. The well-known scissor-type constructions have the disadvantage that they become more unstable with increasing height variation. Also the ends of their scissor arms often glide noisily in a rail and get stuck easily when tilted, and these constructions are normally not very flat.
[0008] German utility model DE 8631449.1 indicates a solution for a lifting platform in which the support surface is being held horizontally by two pairs of toggle links which are oriented parallel on the base surface in such a way that their middle flexible connections are simultaneously and evenly pulled inwards by two cable pulls. But this construction requires both links to be folded outwards in the lowered position.
[0009] This construction would be disadvantageous for the task of the present invention, because it would unnecessarily take up space on the desktop. The wellknown foldable plastic shopping boxes present a similar solution. The base surface and the upper frame are connected by foldable side panels, but base surface and upper frame are not guided in a parallel manner.
[0010] Japanese patent JP 10099171 shows a support surface, which is connected to its base surface by two foldable brackets that are attached to the base and support surfaces by hinges at a 90° angle and thus form a parallel guidance of the support surface.
[0011] In this construction, the height of each of the halves of the brackets equals half the distance between base and support surface in a completely lifted position. At least one of the brackets (e.g. the rear left in FIG. 3 of the Japanese patent) can therefore only be as narrow as the difference between the depth of the support surface and half its distance to the base surface in the lifted position. If the support surface measures, for example, 30 cm×45 cm and is lifted to a maximum height of 40 cm, this bracket can thus have a maximum width of 10 cm. With a hinge length this short, the bracket would have to sustain the support surface and maintain its position against an inclination. This requires high material thickness resulting in high weight, and conflicts with the object of low height in a lowered position. This patent does not provide a mechanism for locking quickly at different heights.
SUMMARY OF THE INVENTION
[0012] It is accordingly an object of the invention to provide a height-adjustable equipment stand which overcome the above-mentioned disadvantages of the prior art devices of this general type, which is transportable, and which in the lowered position does not incommode in terms of appearance and space requirement, which in this position also allows a user to operate it with his normal arm position and which, at the same time, always holds the equipment on the support surface in a nearly horizontal or defined oblique position during and after height-adjustment, so that they do not slide down.
[0013] With the foregoing and other objects in view there is provided, in accordance with the invention a height-adjustable equipment stand for a notebook or a monitor with a keyboard. The height-adjustable equipment stand contains a base surface, at least two collapsible brackets having edges and bracket parts, and a support surface, which can be raised or lowered to a flat position, and guided by the at least two collapsible brackets. The edges of the collapsible brackets are fastened non-parallel to each other to the support surface and the base surface in an articulating manner, and thus at each height cause a defined position of the support surface relative to the base surface. The support surface can be locked in at least one height to prevent accidental lowering. The collapsible brackets are guided towards a centre of the base surface and the support surface when the support surface is lowered. The bracket parts of at least one of the collapsible brackets has cut-outs formed therein into which the bracket parts of at least another of the two collapsible brackets project in at least one height of the support surface. The collapsible brackets do not interfere with each other during lifting and lowering processes of the support surface and do not project beyond an outline of the base surface and the support surface at any height of the support surface.
[0014] The task is achieved in that a support surface is guided by at least two foldable brackets which cause a parallel guidance of the support surface relative to the base surface, in that the edges thereof are attached non-parallel to each other to the support surface and the base surface in an articulating manner, and that at least one of the brackets has cutouts into which at least one other bracket part projects in at least one height, wherein the support surface can be locked in at least one height to prevent lowering.
[0015] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0016] Although the invention is illustrated and described herein as embodied in a height-adjustable equipment stand, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0017] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0018] FIG. 1 is a diagrammatic, perspective view for illustrating a basic principle according to the invention;
[0019] FIG. 2 is a diagrammatic, perspective view of a solid bracket;
[0020] FIG. 3 is a diagrammatic, perspective view of an auxiliary bracket at one of the brackets;
[0021] FIG. 4 is a diagrammatic, perspective view of an auxiliary bracket at the support surface;
[0022] FIG. 5 is a diagrammatic, perspective view of auxiliary brackets with a handle; and
[0023] FIGS. 6A and 6B are diagrammatic side views showing brackets made up of several parts.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a base surface 1 and a support surface 2 connected by at least two brackets, in FIG. 1 e.g. by three brackets. The brackets in FIGS. 1 to 5 each are formed of two bracket parts 3 and 4 , 5 and 6 or 7 and 8 , called bracket halves in the following text, while in FIGS. 6A and 6B e.g. they consist of four bracket parts ( 18 to 21 ). The lower half of each bracket is flexibly connected, e.g. by hinges, with the upper half of the bracket. The lower halves 3 , 5 and 7 of each bracket are articulated at the base surface 1 . The upper halves 4 , 6 and 8 of each bracket are also articulated at the support surface 2 , with their bracket edges 4 a , 6 a and 8 a.
[0025] In the solution according to the invention, parallelism of the base surface and support surface is achieved by the fact that the bracket edge 4 a (drawn with dotted lines in FIG. 1 ) of the bracket 3 , 4 is not parallel to at least one of the bracket edges 6 a or 8 a (drawn with dotted lines) of the other brackets 5 , 6 or 7 , 8 , in the plane of the support surface 2 , but that they are arranged at an angle 2 a.
[0026] Given ideal stiffness of the bracket and surface material and zero clearance of all flexible connections, the parallelism of the support surface 2 to the base surface 1 would be forced in each height. With real material, the angle 2 a between two of the bracket edges should advantageously be 90 degrees, for example, as shown in FIG. 1 , if both base surface and support surface are rectangular.
[0027] For lifting and lowering, the equipment stand can be handled e.g. at the support surface 2 . When the support surface 2 is lowered further from the position shown in FIG. 1 , the bracket halves 4 , 6 and 8 come to lie flat on the corresponding bracket halves 3 , 5 and 7 . At the lowest position, the support surface 2 , with e.g. a keyboard on it, is situated only four times the material thickness of the surfaces 1 , 2 , 3 and 4 above the desktop on which the equipment stand is placed. If appropriate material is used, this distance need only be a few millimetres.
[0028] In another embodiment, the total height of the equipment stand in the lowered position can be further reduced, if the bracket halves 3 to 8 disappear in recesses 3 a , 5 a , 7 a of the base surface 1 and/or the support surface 2 , so that the upper surface of the support surface 2 is situated above the desktop surface at a height of only the material thickness of the base surface plus that of the support surface.
[0029] In another embodiment, there are not only two but three or more brackets to achieve a higher stability, the material of all parts not being ideal.
[0030] In all embodiments, when the stand is lowered, the middle hinges of all brackets move towards the centre of the base surface 1 and the support surface 2 . For this purpose the brackets are shaped in such a way, or have such cut-outs, that they do not interfere with each other during lifting and lowering processes.
[0031] Furthermore, as shown in FIG. 1 , the arrangement and shape of the brackets can be such that they do not project over the edges of the base surface or support surface at any height, thus taking up minimal space on the desktop, and that, given the same overall dimensions of the equipment stand, the total length of the bracket edges 4 a plus 6 a plus 8 a and the torsional moment of the brackets 5 , 6 and 7 , 8 is significantly higher than it would be with brackets without cutouts.
[0032] In another embodiment, as shown exemplarily for the bracket 30 , 31 in FIG. 2 , one bracket half 31 disappears in recesses of its corresponding bracket half 30 , when the support surface 2 is lowered. This way, the total height of all brackets can be reduced to one material thickness.
[0033] In another embodiment, the bracket halves are shaped in such a way, that their upper and lower edges are not parallel to each other. This way, an inclination of the support surface, e.g. towards the user, can be achieved, which increases when the equipment stand is lifted, while the perpendicular direction of the support surface 2 remains horizontal, because the bracket halves 3 and 4 are rectangular. This embodiment can be used, for example, as a portable lectern.
[0034] In another embodiment, at least two of the brackets, e.g. 5 , 6 and 7 , 8 , have a different height, consequently also forcing an inclination when lifting the stand, if in this case, for example, the bracket halves 3 and 4 are shaped as rhomboids.
[0035] Both embodiments described above can be combined, so that two different inclinations in two different planes are forced when lifting the support surface.
[0036] The mechanism for locking the structure at its maximum height and/or at intermediate heights must be such, that the support surface 2 is then in a defined stable condition. For aesthetic reasons, the components of the locking mechanism should advantageously be located between the base surface 1 and the support surface 2 in the lowered position. They should also increase as little as possible the height of the device in the lowered position.
[0037] In a further embodiment ( FIG. 2 ) the shape of one bracket half is such, that it is articulated with the support surface 2 at its upper edge 30 a and that it contains two bracket arms 34 , 35 , which in the lifted position are supported on the base surface 1 . In FIG. 2 , for example, the final position in the lifted position is clearly defined by the articulated connections 32 and 33 with the other bracket half 31 , and by the bracket 3 , 4 . In order to lower the support surface 2 , it is lifted up slightly until the bracket half 30 is aligned with the bracket half 31 , and then the bracket half 30 is folded further inwards, either manually or, for example, by use of springs, until in the lowered position it is parallel to the base surface and the support surface.
[0038] In a further embodiment, locking is achieved by using auxiliary brackets, which like the brackets disappear between the base surface and the support surface when the stand is folded. FIG. 3 shows, by way of example, an auxiliary bracket 14 , which is prevented from sliding by one or more notches 15 in the base surface 1 , and which supports the bracket half 3 . This way, given ideal material, the entire structure can be locked at one or more heights.
[0039] FIG. 4 shows, by way of example, one of four auxiliary brackets 16 in another embodiment, which support the corners of the support surface 2 , and which can engage in one or more notches 17 in the base surface 1 . This arrangement is stable even if the material of the brackets is relatively elastic.
[0040] In further embodiments, locking can be done by constructional elements which are subjected to tension, such as tie rods, cables or chains, instead of auxiliary brackets. For example, the position of the bracket 30 in FIG. 2 can be achieved without the bracket arms 34 and 35 , if a tensioned cable between the articulation 33 and the corresponding articulation of a symmetrically opposed bracket, not shown in FIG. 2 , prevents both brackets from moving apart and thus locks the support plate 2 .
[0041] FIG. 5 shows a further embodiment, in which, by way of example, the auxiliary bracket 9 is articulated at the upper bracket half 8 and is supported on the lower bracket half 7 by a notch 12 . The same applies analogously for the other three auxiliary brackets, which are not shown. As the lower end of the auxiliary bracket 9 is still at a distance to the base surface 1 in a lifted position of the equipment stand, the auxiliary bracket 9 can be locked in lower positions of the equipment stand by additional notches 13 . Moreover, such dimensions can be chosen for the brackets and auxiliary brackets, that the auxiliary brackets are vertical at each locked height.
[0042] In a further embodiment, the auxiliary brackets 9 and 10 are connected at the top by a handle surface 11 , the same applies analogously, for the other side of the equipment stand in FIG. 4 . Thus, when the user manually lifts the support surface 2 , he or she can press the two auxiliary brackets inwards, respectively with the left and right hand, thereby release the lock and lower the support surface 2 again.
[0043] With real material, the most stable position of an equipment stand without auxiliary brackets is achieved when the two halves of each bracket are aligned, because the brackets then only have to absorb compressive forces in their longitudinal direction, and no bending forces. However, this is only the case at the maximum working height of the equipment stand.
[0044] In order to still achieve different working heights for the equipment stand, each in the most stable position, in a further embodiment the brackets not only consist of two, but of more parts. FIGS. 6A and 6B are side views of a bracket, which by way of example is formed of four parts 18 - 21 , which are articulated. Here, the bracket as a whole consists of the lower bracket half with the bracket parts 18 and 19 and the upper bracket half, the overall height of which is the same, with the bracket parts 20 and 21 .
[0045] In this example, the PC stand can thus be adjusted to four different working heights, e.g. for users of different body heights. It is adjusted to the lowest working height by fixing the bracket part 18 parallel to the base surface 1 and the bracket part 21 parallel to the support surface 2 , wherein the fixation is permanent but can be released again for another user. In FIG. 6A the articulation between the bracket parts 19 and 20 is moved to the right and to the left in order to adjust the height, while the bracket parts 18 and 21 remain fixed. At the maximum working height, the two bracket parts 19 and 20 can then be connected with a suitable locking connection to form a continuous bracket, which is slightly tilted, but which can absorb a large pressure load and which ensures maximum stability of the position of the support surface 2 .
[0046] A somewhat larger maximum working height is achieved, as shown in FIG. 6B , by permanently connecting the bracket parts 20 and 21 to form a continuous bracket half. An even greater working height is achieved, if instead the bracket parts 18 and 19 are permanently connected to form a bracket half, since the bracket part 18 is longer than the bracket part 21 . The highest of the four possible working heights is achieved if both measures are applied jointly.
[0047] In a further embodiment, the support surface 2 is brought to a permanent inclination by additional surfaces, which are articulated with the brackets, but rigidly connected to the support surface 2 . If the support surface extends beyond the base surface 1 , its front edge is lowered a little further, which improves the arm position of the user. This also facilitates mounting a motor drive 36 , 37 for height adjustment underneath the rear part of the support surface, which is slightly elevated.
[0048] In a further embodiment, the equipment stand is incorporated in a tabletop. Due to the low height of the equipment stand, this can be done by working a recess for the equipment stand into the table top from above, with the bottom of the tabletop board remaining intact. Thus, the base of the recess can also function as the base surface 1 . In the lowered position, the support surface 2 can then form a common plane with the tabletop surface, and be raised if necessary.
[0049] Because of its low height, the equipment stand can be incorporated in the device the working height of which is to be changed, such as a notebook, wherein the base surface 1 can then be a part of the bottom of this device. | A fast height-adjustable equipment stand, particularly for a notebook or for a monitor with a keyboard, which can be placed on a table and a support surface of which can be raised or lowered so low that a keyboard situated on the support surface can be operated without difficulty while sitting. To this end, at any height the equipment present thereon is held in a horizontal or defined oblique position such that the support surface is guided by at least two folding brackets, which cause a parallel guidance of the support surface relative to the base surface in that the edges thereof are fastened non-parallel to each other to the support surface in an articulating manner, and that the support surface can be locked in one or more heights to prevent accidental lowering. | 5 |
RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/622,580, filed Oct. 27, 2004, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed to novel pyridine imidazoles and aza-indole derivatives, the pharmaceutical compositions containing them and their use in the treatment or prevention of disorders and diseases mediated by agonists and antagonists of the progesterone receptor. The clinical usage of these compounds are related to hormonal contraception, the treatment and/or prevention of secondary dysmenorrhea, amenorrhea, dysfunctional uterine bleeding, uterine leiomyomata, endometriosis; polycystic ovary syndrome, carcinomas and adenocarcinomas of the endometrium, ovary, breast, colon, prostate, or minication of side effects of cyclic menstrual bleeding. Additional uses of the invention include stimulation of food intake.
BACKGROUND OF THE INVENTION
[0003] Intracellular receptors are a class of structurally related proteins involved in the regulation of gene proteins. Steroid receptors are a subset of these receptors, including the progesterone receptors (PR), androgen receptors (AR), estrogen receptors (ER), glucocorticoid receptors (GR) and mineralocorticoid receptors (MR). Regulation of a gene by such factors requires the intracellular receptor and a corresponding ligand which has the ability to selectively bind to the receptor in a way that affects gene transcription.
[0004] Progesterone receptor modulators (progestagens) are known to play an important role in mammalian development and homeostasis. Progesterone is known to be required for mammary gland development, ovulation and the maintenance of pregnancy. Currently, steroidal progestin agonists and antagonists are clinically approved for contraception, hormone replacement therapy (HRT) and therapeutic abortion. Moreover, there is good preclinical and clinical evidence for the value of progestin antagonists in treating endometriosis, uterine leiomyomata (fibroids), dysfunctional uterine bleeding and breast cancer.
[0005] The current steroidal progestagens have been proven to be quite safe and are well tolerated. Sometimes, however, side effects (e.g. breast tenderness, headaches, depression and weight gain) have been reported that are attributed to these steroidal progestagens, either alone or in combination with estrogenic compounds.
[0006] Steroidal ligands for one receptor often show cross-reactivity with other steroidal receptors. As an example, many progestagens also bind to glucocorticoid receptor. Non-steroidal progestagens have no molecular similarity with steroids and therefore one might also expect differences in physicochemical properities, pharmacokinetic (PK) parameters, tissue distribution (e.g. CNS versus peripheral) and, more importantly, non-steroidal progestagens may show no/less cross-reactivity to other steroid receptors. Therefore, non-steroidal progestagens will likely emerge as major players in reproductive pharmacology in the foreseeable future.
[0007] It was known that progesterone receptor existed as two isoforms, full-length progesterone receptor isoform (PR-B) and its shorter counterpart (PR-A). Recently, extensive studies have been implemented on the progesterone receptor knockout mouse (PRKO, lacking both the A- and B-forms of the receptors), the mouse knockoutting specifically for the PR-A isoform (PRAKO) and the PR-B isoform (PRBKO). Different phenotypes were discovered for PRKO, PRAKO and PRBKO in physiology studies in terms of fertility, ovulation uterine receptivity, uterine proliferation, proliferation of mammary gland, sexual receptivity in female mice, sexual activity in male mice and infanticide tendencies in male mice. These findings provided great challenge for synthetic chemists to construct not only selective progesterone receptor modulator (SPRM), but also PR-A or PR-B selective progesterone receptor modulator.
SUMMARY OF THE INVENTION
[0008] The present invention provides novel pyridine imidazoles and aza-indole derivatives of the formula (I) or (II):
[0009] wherein
[0010] R 1 and R 2 are independently selected from the group consisting of hydrogen, alkyl, cycloalkyl, aralkyl or heteroaryl-alkyl; wherein the cycloalkyl, aralkyl or heteroaryl-alkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, —SH, —S(alkyl), SO 2 (alkyl), NO 2 , CN, CO 2 H, —OR C , —SO 2 —NR D R E , —NR D R E , NR D —SO 2 —R F , -(alkyl) 0-4 -C(O)NR D R E , (alkyl) 0-4 -NR D —C(O)—R F , -(alkyl) 0-4 -(Q) 0-1 -(alkyl) 0-4 -NR D R E ;
[0011] wherein R C is selected from the group consisting of alkyl, cycloalkyl, cycloalkyl-alkyl, aryl, aralkyl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl and heterocycloalkyl-alkyl; wherein the cycloalkyl, cycloalkyl-alkyl, aryl, aralkyl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl or heterocycloalkyl-alkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, —SH, —S(alkyl), SO 2 (alkyl), NO 2 , CN, CO 2 H, R C , —SO 2 —NR D R E , NR D R E , NR D —SO 2 —R F , -(alkyl) 0-4 -C(O)—NR D R E , -(alkyl) 0-4 -NR D —C(O)—R F , -(alkyl) 0-4 -(Q) 0-1 -(alkyl) 0-4 -NR D R E ,
[0012] wherein Q is selected from the group consisting of O, S, NH, N(alkyl) and —CH═CH—;
[0013] wherein R D and R E are each independently selected from the group consisting of hydrogen and alkyl; alternatively R D and R E are taken together with the nitrogen atom to which they are bound to form a 4 to 8 membered ring selected from the group consisting of heteroaryl or heterocycloalkyl; wherein the heteroaryl or heterocycloalkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, carboxy, amino, alkylamino, dialkylamino, nitro or cyano;
[0014] wherein R F is selected from the group consisting of hydrogen, alkyl, cycloalkyl, cycloalkyl-alkyl, aryl, aralkyl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl and heterocycloalkyl-alkyl; wherein the cycloalkyl, aryl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl or heterocycloalkyl-alkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, carboxy, amino, alkylamino, dialkylamino, nitro or cyano;
[0015] R 3 is selected from the group consisting of halogen, CF 3 , hydroxy, R C , nitro, cyano, SO 2 (alkyl), —C(O)R G , —C(O)OR G , —OC(O)R G , —OC(O)OR G , —OC(O)N(R G ) 2 , —N(R G )C(O)R G , —OSi(R G ) 3 —OR G , —SO 2 N(R G ) 2 , —O-(alkyl) 1-4 -C(O)R G , —O-(alkyl) 1-4 -C(O)OR G , aryl and heteroaryl, wherein aryl or heteroaryl is optionally substituted with one or more substituents independently selected from alkyl, halogenated alkyl, alkoxy, halogen, hydroxy, nitro, cyano, —OC(O)-alkyl or —C(O)O-alkyl;
[0016] wherein each R G is independently selected from hydrogen, alkyl, aryl, aralkyl; wherein the alkyl, aryl or aralkyl group is optionally substituted with one or more substituents independently selected from alkyl, halogenated alkyl, alkoxy, halogen, hydroxy, nitro, cyano, —OC(O)-alkyl or —C(O)O-alkyl;
[0017] alternatively two R G groups are taken together with the nitrogen atom to which they are bound to form a heterocycloalkyl group; wherein the heterocycloalkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, carboxy, amino, alkylamino, dialkylamino, nitro or cyano;
[0018] R 4 is selected from the group consisting of hydrogen, acetyl, SO 2 (alkyl), alkyl, cycloalkyl, aralkyl or heteroaryl-alkyl; wherein the cycloalkyl, aralkyl or heteroaryl-alkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, —SH, —S(alkyl), SO 2 (alkyl), NO 2 , CN, CO 2 H, —OR C , —SO 2 —NR D R E , NR D R E , NR D —SO 2 —R F , -(alkyl) 0-4 -C(O)NR D R E , (alkyl) 0-4 -NR D —C(O)—R F , -(alkyl) 0-4 -(Q) 0-1 -(alkyl) 0-4 -NR D R E ,
[0019] wherein R C is selected from the group consisting of alkyl, cycloalkyl, cycloalkyl-alkyl, aryl, aralkyl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl and heterocycloalkyl-alkyl; wherein the cycloalkyl, cycloalkyl-alkyl, aryl, aralkyl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl or heterocycloalkyl-alkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, —SH, —S(alkyl), SO 2 (alkyl), NO 2 , CN, CO 2 H, R C , —SO 2 —NR D R E , NR D R E , NR D —SO 2 —R F , -(alkyl) 0-4 -C(O)—NR D R E , -(alkyl) 0-4 -NR D —C(O)—R F , -(alkyl) 0-4 -(Q) 0-1 -(alkyl) 0-4 -NR D R E ,
[0020] wherein Q is selected from the group consisting of O, S, NH, N(alkyl) and —CH═CH—;
[0021] wherein R D and R E are each independently selected from the group consisting of hydrogen and alkyl; alternatively R D and R E are taken together with the nitrogen atom to which they are bound to form a 4 to 8 membered ring selected from the group consisting of heteroaryl or heterocycloalkyl; wherein the heteroaryl or heterocycloalkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, carboxy, amino, alkylamino, dialkylamino, nitro or cyano;
[0022] wherein R F is selected from the group consisting of hydrogen, alkyl, cycloalkyl, cycloalkyl-alkyl, aryl, aralkyl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl and heterocycloalkyl-alkyl; wherein the cycloalkyl, aryl, heteroaryl, heteroaryl-alkyl, heterocycloalkyl or heterocycloalkyl-alkyl group is optionally substituted with one or more substituents independently selected from halogen, hydroxy, alkyl, alkoxy, carboxy, amino, alkylamino, dialkylamino, nitro or cyano;
[0023] or a pharmaceutically acceptable salt thereof.
[0024] The compounds of this invention may contain an asymmetric carbon atom and some of the compounds of this invention may contain one or more asymmetric centers and may thus give rise to optical isomers and diastereomers. While shown without respect to stereochemistry in Formula 1 and 2, the present invention includes such optical isomers and diastereomersl as well as the racemic and resolved, enantiomerically pure S and R stereoisomersa dn pharmaceutically acceptable salts thereof.
[0025] Illustrative of the invention is a pharmaceutical composition comprising a pharmaceutically acceptable carrier and any of the compounds described above. An illustration of the invention is a pharmaceutical composition made by mixing any of the compounds described above and a pharmaceutically acceptable carrier. Illustrating the invention is a process for making a pharmaceutical composition comprising mixing any of the compounds described above and a pharmaceutically acceptable carrier.
[0026] Exemplifying the invention are methods of treating a disorder mediated by one or more progesterone receptors in a subject in need thereof comprising administering to the subject a therapeutically effective amount of any of the compounds or pharmaceutical compositions described above.
[0027] Illustrating the invention is a method of contraception comprising administering to a subject in need thereof co-therapy with a therapeutically effective amount of a compound of formula (I) with an estrogen or estrogen antagonist.
[0028] Another example of the invention is the use of any of the compounds described herein in the preparation of a medicament for treating: (a) dysfunctional bleeding, (b) endometriosis, (c) uterine leiomyomata, (d) secondary amenorrhea, (e) polycystic ovary syndrome, (f) carcinomas and adenocarcinomas of the endometrium, ovary, breast, colon, prostate, (g) minication of side effects of cyclid menstrual bleeding and for (h) contraception and i) stimulation of food intake in a subject in need thereof.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The present invention is further directed to a compound of formula (I) or (II):
[0030] wherein R 1 , R 2 , R 3 and R 4 are as herein defined, useful for the treatment of disorders mediated by an progesterone receptor. More particularly, the compounds of the present invention are useful for the treatment and prevention of disorders mediated by the progesterone-A and progesterone-B receptors. More preferably, the compounds of the present invention are tissue selective progesterone receptor modulators.
[0031] The compounds of the present invention are useful in the treatment of disorders associated with the depletion of progesterone, hormone sensitive cancers and hyperplasia, endometriosis, uterine fibroids, osteoarthritis and as contraceptive agents, alone or in combination with a estrogen or a partial estrogen antagonist.
[0032] The compounds of the present invention are useful in the treatment of disorders associated with the depletion of progesterone, secondary amenorrhea, dysfunctional bleeding, uterine leiomyomata, endometriosis; polycystic ovary syndrome, carcinomas and adenocarcinomas of the endometrium, ovary, breast, colon, prostate, or minication of side effects of cyclid menstrual bleeding, and as contraceptive agents, alone or in combination with a estrogen or restrogen antagonist.
[0033] In an embodiment of the present invention R 1 , R 2 are both methyl groups. In another embodiment of the present invention R 1 , R 2 are connected by —(CH 2 ) 4 — to form a 5-membered spiro ring. In another embodiment of the present invention R 1 , R 2 are connected by —(CH 2 ) 5 — to form a 6-membered spiro ring.
[0034] In an embodiment of the present invention R 3 is selected from halogen, CN, CF 3 , NO 2 or SO 2 (alkyl) group. In another embodiment of the present invention R 3 is selected from aryl, heteroaryl groups, wherein aryl or heteroaryl groups are mono-, di-, or tri-substituted by halogen, NO 2 , CF 3 , CN, O(alkyl).
[0035] In an embodiment of the present invention R 4 is selected from hydrogen, acetyl or SO 2 (alkyl), lower alkyl, aralkyl, heteroarylalkyl.
[0036] For use in medicine, the salts of the compounds of this invention refer to non-toxic “pharmaceutically acceptable salts.” Other salts may, however, be useful in the preparation of compounds according to this invention or of their pharmaceutically acceptable salts. Suitable pharmaceutically acceptable salts of the compounds include acid addition salts which may, for example, be formed by mixing a solution of the compound with a solution of a pharmaceutically acceptable acid such as hydrochloric acid, sulfuric acid, fumaric acid, maleic acid, succinic acid, acetic acid, benzoic acid, citric acid, tartaric acid, carbonic acid or phosphoric acid. Furthermore, where the compounds of the invention carry an acidic moiety, suitable pharmaceutically acceptable salts thereof may include alkali metal salts, e.g., sodium or potassium salts; alkaline earth metal salts, e.g., calcium or magnesium salts; and salts formed with suitable organic ligands, e.g., quaternary ammonium salts. Thus, representative pharmaceutically acceptable salts include the following:
[0037] acetate, benzenesulfonate, benzoate, bicarbonate, bisulfate, bitartrate, borate, bromide, calcium edetate, camsylate, carbonate, chloride, clavulanate, citrate, dihydrochloride, acetate, edisylate, estolate, esylate, fumarate, gluceptate, gluconate, glutamate, glycollylarsanilate, hexylresorcinate, hydrabamine, hydrobromide, hydrochloride, hydroxynaphthoate, iodide, isothionate, lactate, lactobionate, laurate, malate, maleate, mandelate, mesylate, methylbromide, methylnitrate, methylsulfate, mucate, napsylate, nitrate, N-methylglucamine ammonium salt, oleate, pamoate (embonate), palmitate, pantothenate, phosphate/diphosphate, polygalacturonate, salicylate, stearate, sulfate, subacetate, succinate, tannate, tartrate, teoclate, tosylate, triethiodide and valerate.
[0038] The present invention includes within its scope prodrugs of the compounds of this invention. In general, such prodrugs will be functional derivatives of the compounds which are readily convertible in vivo into the required compound. Thus, in the methods of treatment of the present invention, the term “administering” shall encompass the treatment of the various disorders described with the compound specifically disclosed or with a compound which may not be specifically disclosed, but which converts to the specified compound in vivo after administration to the patient. Conventional procedures for the selection and preparation of suitable prodrug derivatives are described, for example, in “Design of Prodrugs”, ed. H. Bundgaard, Elsevier, 1985.
[0039] As used herein, the term “progestogen antagonist” shall include mifepristone, J-867 (Jenapharm/TAP Pharmaceuticals), J-956 (Jenapharm/TAP Pharmaceuticals), ORG-31710 (Organon), ORG-32638 (Organon), ORG-31806 (Organon), onapristone and PRA248 (Wyeth).
[0040] As used herein, unless otherwise noted, “halogen” shall mean chlorine, bromine, fluorine and iodine.
[0041] As used herein, unless otherwise noted, the term “alkyl” whether used alone or as part of a substituent group, include straight and branched chain compositions of one to eight carbon atoms. For example, alkyl radicals include methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, t-butyl, pentyl and the like. Unless otherwise noted, “lower” when used with alkyl means a carbon chain composition of 1-4 carbon atoms. Similarly, the group “-(alkyl) 0-4 -”, whether alone or as part of a large substituent group, shall me the absence of an alkyl group or the presence of an alkyl group comprising one to four carbon atoms. Suitable examples include, but are not limited to —CH 2 —, —CH 2 CH 2 —, CH 2 —CH(CH 3 )—, CH 2 CH 2 CH 2 —, —CH 2 CH(CH 3 )CH 2 —, CH 2 CH 2 CH 2 CH 2 —, and the like.
[0042] As used herein, unless otherwise noted, “alkoxy” shall denote an oxygen ether radical of the above described straight or branched chain alkyl groups. For example, methoxy, ethoxy, n-propoxy, sec-butoxy, t-butoxy, n-hexyloxy and the like.
[0043] As used herein, unless otherwise noted, “aryl” shall refer to unsubstituted carbocyclic aromatic groups such as phenyl, naphthyl, and the like.
[0044] As used herein, unless otherwise noted, “aralkyl” shall mean any lower alkyl group substituted with an aryl group such as phenyl, naphthyl and the like. Suitable examples include benzyl, phenylethyl, phenylpropyl, naphthylmethyl, and the like.
[0045] As used herein, unless otherwise noted, the term “cycloalkyl” shall mean any stable 3-8 membered monocyclic, saturated ring system, for example cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl and cyclooctyl.
[0046] As used herein, unless otherwise noted, the term “cycloalkyl-alkyl” shall mean any lower alkyl group substituted with a cycloalkyl group. Suitable examples include, but are not limited to cyclohexyl-methyl, cyclopentyl-methyl, cyclohexyl-ethyl, and the like.
[0047] As used herein, unless otherwise noted, the terms “acyloxy” shall mean a radical group of the formula —O—C(O)—R where R is alkyl, aryl or aralkyl, wherein the alkyl, aryl or aralkyl is optionally substituted. As used herein, the term “carboxylate” shall mean a radical group of the formula —C(O)O—R where R is alkyl, aryl or aralkyl, wherein the alkyl, aryl or aralkyl is optionally substituted.
[0048] As used herein, unless otherwise noted, “heteroaryl” shall denote any five or six membered monocyclic aromatic ring structure containing at least one heteroatom selected from the group consisting of O, N and S, optionally containing one to three additional heteroatoms independently selected from the group consisting of O, N and S; or a nine or ten membered bicyclic aromatic ring structure containing at least one heteroatom selected from the group consisting of O, N and S, optionally containing one to four additional heteroatoms independently selected from the group consisting of O, N and S. The heteroaryl group may be attached at any heteroatom or carbon atom of the ring such that the result is a stable structure.
[0049] Examples of suitable heteroaryl groups include, but are not limited to, pyrrolyl, furyl, thienyl, oxazolyl, imidazolyl, purazolyl, isoxazolyl, isothiazolyl, triazolyl, thiadiazolyl, pyridyl, pyridazinyl, pyrimidinyl, pyrazinyl, pyranyl, furazanyl, indolizinyl, indolyl, isoindolinyl, indazolyl, benzofuryl, benzothienyl, benzimidazolyl, benzthiazolyl, purinyl, quinolizinyl, quinolinyl, isoquinolinyl, isothiazolyl, cinnolinyl, phthalazinyl, quinazolinyl, quinoxalinyl, naphthyridinyl, pteridinyl, and the like.
[0050] As used herein, unless otherwise noted, the term “heteroaryl-alkyl” shall mean any lower alkyl group substituted with a heteroaryl group. Suitable examples include, but are not limited to pyridyl-methyl, isoquinolinyl-methyl, thiazolyl-ethyl, furyl-ethyl, and the like.
[0051] As used herein, the term “heterocycloalkyl” shall denote any five to seven membered monocyclic, saturated or partially unsaturated ring structure containing at least one heteroatom selected from the group consisting of O, N and S, optionally containing one to three additional heteroatoms independently selected from the group consisting of O, N and S; or a nine to ten membered saturated, partially unsaturated or partially aromatic bicyclic ring system containing at least one heteroatom selected from the group consisting of O, N and S, optionally containing one to four additional heteroatoms independently selected from the group consisting of O, N and S. The heterocycloalkyl group may be attached at any heteroatom or carbon atom of the ring such that the result is a stable structure.
[0052] Examples of suitable heteroaryl groups include, but are not limited to, pyrrolinyl, pyrrolidinyl, dioxalanyl, imidazolinyl, imidazolidinyl, pyrazolinyl, pyrazolidinyl, piperidinyl, dioxanyl, morpholinyl, dithianyl, thiomorpholinyl, piperazinyl, trithianyl, indolinyl, chromenyl, 3,4-methylenedioxyphenyl, 2,3-dihydrobenzofuryl, and the like.
[0053] As used herein, unless otherwise noted, the term “heterocycloalkyl-alkyl” shall mean any lower alkyl group substituted with a heterocycloalkyl group. Suitable examples include, but are not limited to piperidinyl-methyl, piperazinyl-methyl, piperazinyl-ethyl, morpholinyl-methyl, and the like.
[0054] When a particular group is “substituted” (e.g., cycloalkyl, aryl, heteroaryl, heterocycloalkyl), that group may have one or more substituents, preferably from one to five substituents, more preferably from one to three substituents, most preferably from one to two substituents, independently selected from the list of substituents. Additionally when aralkyl, heteroaryl-alkyl, heterocycloalkyl-alkyl or cycloalkyl-alkyl group is substituted, the substituent(s) may be on any portion of the group (i.e. the substituent(s) may be on the aryl, heteroaryl, heterocycloalkyl, cycloalkyl or the alkyl portion of the group.)
[0055] With reference to substituents, the term “independently” means that when more than one of such substituents is possible, such substituents may be the same or different from each other.
[0056] Under standard nomenclature used throughout this disclosure, the terminal portion of the designated side chain is described first, followed by the adjacent functionality toward the point of attachment. Thus, for example, a “phenylC 1 -C 6 alkylaminocarbonylC 1 -C 6 alkyl” substituent refers to a group of the formula
[0057] Abbreviations used in the specification, particularly the Schemes and Examples, are as follows
Ac Acetyl group (—C(O)—CH 3 ) DCM Dichloromethane DMF Dimethyl formamide ERT Estrogen replacement therapy Et ethyl (i.e. —CH 2 CH 3 ) EtOAc Ethyl acetate FBS Fetal bovine serum HPLC High pressure liquid chromatography HRT Hormone replacement therapy MeOH Methanol Ph Phenyl TEA or Et 3 N Triethylamine THF Tetrahydrofuran TsOH Toluene sulfonic acid
[0058] The term “subject” as used herein, refers to an animal, preferably a mammal, most preferably a human, who has been the object of treatment, observation or experiment.
[0059] The term “therapeutically effective amount” as used herein, means that amount of active compound or pharmaceutical agent that elicits the biological or medicinal response in a tissue system, animal or human that is being sought by a researcher, veterinarian, medical doctor or other clinician, which includes alleviation of the symptoms of the disease or disorder being treated. Wherein the present invention directed to co-therapy comprising administration of one or more compound(s) of formula I and a progestogen or progestogen antagonist, “therapeutically effective amount” shall mean that amount of the combination of agents taken together so that the combined effect elicits the desired biological or medicinal response. For example, the therapeutically effective amount of co-therapy comprising administration of a compound of formula I and progestogen would be the amount of the compound of formula I and the amount of the progestogen that when taken together or sequentially have a combined effect that is therapeutically effective. Further, it will be recognized by one skilled in the art that in the case of co-therapy with a therapeutically effective amount, as in the example above, the amount of the compound of formula I and/or the amount of the progestogen or progestogen antagonist individually may or may not be therapeutically effective.
[0060] As used herein, the term “co-therapy” shall mean treatment of a subject in need thereof by administering one or more compounds of formula I with a progestogen or progestogen antagonist, wherein the compound(s) of formula I and progestogen or progestogen antagonist are administered by any suitable means, simultaneously, sequentially, separately or in a single pharmaceutical formulation. Where the compound(s) of formula I and the progestogen or progestogen antagonist are administered in separate dosage forms, the number of dosages administered per day for each compound may be the same or different. The compound(s) of formula I and the progestogen or progestogen antagonist may be administered via the same or different routes of administration. Examples of suitable methods of administration include, but are not limited to, oral, intravenous (iv), intramuscular (im), subcutaneous (sc), transdermal, and rectal. Compounds may also be administered directly to the nervous system including, but not limited to, intracerebral, intraventricular, intracerebroventricular, intrathecal, intracisternal, intraspinal and/or peri-spinal routes of administration by delivery via intracranial or intravertebral needles and/or catheters with or without pump devices. The compound(s) of formula I and the progestogen or progestogen antagonist may be administered according to simultaneous or alternating regimens, at the same or different times during the course of the therapy, concurrently in divided or single forms.
[0061] As used herein, the term “composition” is intended to encompass a product comprising the specified ingredients in the specified amounts, as well as any product which results, directly or indirectly, from combinations of the specified ingredients in the specified amounts.
[0062] One skilled in the art will recognize that it may be necessary and/or desirable to protect one or more of the R 3 and/or R 4 groups at any of the steps within the process described above. This may be accomplished using known protecting groups and know protection and de-protection reagents and conditions, for example such as those described in Protective Groups in Organic Chemistry , ed. J. F. W. McOmie, Plenum Press, 1973; and T. W. Greene & P. G. M. Wuts, Protective Groups in Organic Synthesis , John Wiley & Sons, 1991.
[0063] Compounds of formula (I) may be prepared according to the process outlined in Scheme (I).
[0064] More particularly, a suitably substituted compound of formula (II), wherein X is halogen, CN, CF 3 , NO 2 , or SO 2 (alkyl), a known compound or compound prepared by known methods, is reacted with a compound of formula (III), a known compound, in an organic solvent such as acetone, THF, 1,4-dioxane, ethyl ether and the like, at a temperature in the range of about 0° C. to about 30° C., to yield the corresponding compound of formula (IV). The cyclization of compound IV and alkyl iodide (V) or alkyl diiodide (VI) can be affected under the organic base such as NaOMe, NaOEt, KOtBu, NaOtBu and the like or inorganic base, such as NaOH, KOH, Na 2 CO 3 , NaHCO 3 , K 2 CO 3 , Cs 2 CO 3 , KF and the like; in the presence of organic solvent, such as MeOH, EtOH, iPrOH, tBuOH at a temperature in the range of about 0° C. to 100° C., to yield the corresponding compound of formula (VII).
[0065] Preferably, compound of formula (VII), wherein X is Br or I, a compound made from Scheme I, can react further with aryl or heteroaryl boronic acid of formula R 3 B(OH) 2 , a known compound or a compound prepared from known methods, under the palladium (0) or palladium (+2) catalysts, such as Pd(PPh 3 ) 4 , Pd(OAc) 2 with PPh 3 , PdCl 2 (PPh 3 ) 2 , or PdCl 2 (dppf) 2 and the like, in the presence of inorganic base, such as K 2 CO 3 , Na 2 CO 3 , KOAc, K 3 PO 4 , NaOAc, Cs 2 CO 3 , and the like, in the organic solvent such as 1,4-dioxane, THF, toluene, with small amount of water; at a temperature in the range of 0 to 125° C., to yield the corresponding compound of formula (VIII).
[0066] Preferably, compound of formula (X), a known compound prepared according to the procedure described in WO2003/082868, was deprotonated under an organic base, such as nBuLi, LDA, NaHMDS and the like, in the aprotice solvent such as THF, ether, or hexane at a temperature in the range of −78° C. to −40° C.; the anion was then reacted with iodide of formula R 1 I or R 2 I or diiodide of formula I—(R 1 -R 2 )—I to generate the compound of formula (XI).
TABLE 1 ex. # R 1 , R 2 R 3 MF 1-C3 Spirocyclohexane Br C 12 H 13 BrN 2 O 3 Spirocyclohexane 3-Cl-phenyl C 18 H 17 ClN 2 O 1-C1 Dimethyl Br C 9 H 9 BrN 2 O 2 Dimethyl 3-Cl-phenyl C 15 H 13 ClN 2 0 4 Dimethyl 3-CN-phenyl C 16 H 13 N3O 5 Dimethyl Cl C9H9ClN2O 6 Spirocyclohexyl Cl C12H13ClN2O 7 Dimethyl 3,5-di-F-phenyl C15H12F2N2O 8 Dimethyl 3-N0 2 -phenyl C15H13N3O3 9 Dimethyl 3-CF 3 -phenyl C16H13F3N2O 10 Dimethyl 2,4-di-F-phenyl C15H12F2N2O 11 Dimethyl 3,5-di-CF 3 -phenyl C17H12F6N2O 12 Dimethyl 3-MeO-phenyl C16H16N2O2 13 Dimethyl 3-F-phenyl C15H13FN2O 14 Dimethyl 2-Cl-phenyl C15H13ClN2O 1-C2 spirocyclopentane Br C11H11BrN2O 15 spirocyclohexane 3-F-phenyl C18H17FN2O 16 spirocyclohexane 3-MeO-phenyl C19H20N2O2 17 spirocyclohexane 3,5-di-CF 3 -phenyl C2OH16F6N2O 18 spirocyclohexane 3-NO2-phenyl C18H17N3O3 19 spirocyclohexane 3-CF 3 -phenyl C19H17F3N2O 20 spirocyclohexane 3-CN-phenyl C19H17N3O 21 spirocyclohexane 3,5-di-F-phenyl C18H16F2N2O 22 spirocyclohexane 3,4-di-Cl-phenyl C18H16Cl2N2O 23 spirocyclohexane 2,4-di-F-phenyl C18H16F2N2O 24 spirocyclopentane 3-Cl-phenyl C17H15ClN2O 25 spirocyclopentane 3-CN-phenyl C18H15N3O 26 spirocyclopentane 3-F-phenyl C17H15FN2O 27 spirocyclopentane 3-NO 2 -phenyl C17H15N3O3 28 spirocyclopentane 3,4-di-Cl-phenyl C17H14Cl2N2O 29 spirocyclopentane 3,5-di-CF 3 -phenyl C19H14F6N2O 30 spirocyclopentane 3-Cl-4-F-phenyl C17H14ClFN2O
[0067]
TABLE 2
Ex. #
R 1 , R 2
R 3
MF
31
Spirocyclohexane
3-F-phenyl
C 23 H 21 FN 2 O 3 S
32
Dimethyl
3-F-phenyl
C 23 H 21 ClN 2 O 3 S
[0068] It is intended that the definition of any substituent or variable at a particular location in a molecule be independent of its definitions elsewhere in that molecule. It is understood that substituents and substitution patterns on the compounds of this invention can be selected by one of ordinary skill in the art to provide compounds that are chemically stable and that can be readily synthesized by techniques known in the art as well as those methods set forth herein. It is further intended that when m is >1, the corresponding R 4 substituents may be the same or different.
[0069] The compounds of the present invention can be used in the form of salts derived from pharmaceutically or physiologically acceptable acids or bases. These salts include, but are not limited to, the following salts with inorganic acids such as hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid and as the case may be, such organic acids as acetic acid, oxalic acid, succinic acid, and maleic acid. Other salts include salts with alkali metals or alkaline earth metals, such as sodium, potassium, calcium or magnesium in the form of esters, carbamates and other conventional “pro-drug” forms, which, when administered in such form, convert to the active moiety in vivo.
[0070] This invention includes pharmaceutical compositions comprising one or more compounds of this invention, preferably in combination with one or more pharmaceutically acceptable carriers and/or excipients. The invention also includes methods of contraception and methods of treating or preventing maladies associated with the progesterone receptor, the methods comprising administering to a mammal in need thereof a pharmaceutically effective amount of one or more compounds as described above wherein R is alkyl, aryl, heteroary or alkylaryl groupI.
[0071] The progesterone receptor antagonists of this invention, used alone or in combination, can be utilized in methods of contraception and the treatment and/or prevention of benign and malignant neoplastic disease. Specific uses of the compounds and pharmaceutical compositions of invention include the treatment and/or prevention of uterine myometrial fibroids, endometriosis, genign prostatic hypertrophy; carcinomas and adenocarcinomas of the endometrium, ovary, breast, colon, prostate, pituitary, meningioma and other hormone-depent tumors. Additional uses of the present progesterone receptor antagonists include the synchronization of the estrus in livestock.
[0072] When used in contraception the progesterone receptor antagonists of the durrent invention may be used either alone in a continuous administration of between 0.1 and 500 mg per day, or alternatively used in a different regimen which would entail 2-4 days of treatment with the progesterone receptor antagonist after 21 days of a progestin. In this regimen between 0.1 and 500 mg daily doses of the progestin (e.g. levonorgestrel, trimegestone, gestodene, norethistrone acetate, norgestimate or cyproterone acetate) would be followed by between 0.1 and 500 mg daily doses of the progesterone receptor antagonists of the current invention.
[0073] The progesterone receptor agonists of this invention, used alone or in combination, can also be utilized in methods of contraception and the treatment and/or prevention of dysfunctional bleeding, uterine leiomyomata, endometriosis; polycystic ovary syncrome, carcinomas and adenocarcimomas of the endometrium, ovary, breast, colon, prostate. Additional uses of the invention include stimulation of food intake.
[0074] When used in contraception the progesterone receptor agonists of the durrent invention are preferably used in combination or sequentially with an estrogen agonist (e.g. ethinyl estradiao). The preferred dose of the progesterone receptor agonist is 0.01 mg and 500 mg per day.
[0075] This invention also includes pharmaceutical compositions comprising one or more compounds described herein, preferably in combination with one or more pharmaceutically acceptable carriers or excipients. When the compounds are employed for the above utilities, they may be combined with one or more pharmaceutically acceptable carriers, or excipients, for example, solvents, diluents and the like and may be administered orally in such forms as tablets, caplules, dispersible powders, granules, or suspensions containing, for example, from about 0.05 to 5% of suspending agent, syrups containing, for example, from about 10 to 50% of sugan, and elixirs containing, for example, from 20 to 50% ethanol, and the like, or parenterally in the form of sterile injectale solutions or suspensions containing from about 0.05 to 5% suspending agent in an isotonic medium. Such pharmaceutical preparations may contain, for example, from about 25 to about 90% of the active ingredient in combination with the carrier, more usually between about 5% and 60% by weight.
[0076] The effective dosage of active ingredient employed may vary depending on the particular compound employed, the mode of administration and the severity of the condition being treated. However, in general, satisfactory results are obtained when the compounds of the invention are administered at a daily dosage of from about 0.5 to about 500 mg/kg of animal body weight, preferably given in dibided doses two to four times a day, or in a sustained release from. For most large mammals, the total daily dosage is from about 1 to 100 mg, preferably from about 2 to 80 mg Dosage froms suitable for internal use comprise from about 0.5 to 500 mg of the active compound in intimate admixture with a solid or liquid pharmaceutically acceptable carrier. This dosage regimen may be adjusted to provide the optimal therapeutic respose. For example, several divided doses may be administered daily or the dose may be proportionally reduced as indicated by the exigencies of the therapeutic situation.
[0077] These active compounds may be administered orally as well as by intervenous, imtramuscular, or subcutaneous routes. Solid carriers include starch, lactose, dicalcium phosphate, microcrystalline cellulose, sucrose and kaolin, while liquid carriers include sterile water, polyethylene glycols, non-ionic surfactants and edible oils such as corn, peanut and sesame oil, as are appropriate to the nature of the active ingredient and the particular form of administration desired. Adjuvants customarily employed in the preparation of pharmaceutical compositions may be advantageously included, such as flavoring agents, coloring agents, preserving agents, and antioxidants, for example, vitamin E, ascorbic acid, BHT and BHA.
[0078] The preferred pharmaceutical compositions from the standpoint of ease of preparation and administration are solid compositions, particularly tablets and hardfilled or liquid-filled capsules. Oral administration of the compounds is preferred.
[0079] These active compounds may also be administered parenterally or intraperitoneally. Solutions or suspensions of these active compounds as a free base or pharmacologically acceptable salt can be prepared in water suitably mixed with a surfactant such as hydroxylpropylcellulose. Dispersions can also be prepared in glycerol, liquid, polyethylene glycols and mixtures thereof in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
[0080] The pharmaceutical forms suitable for injectable use include sterile aqueous solutions or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions of dispersions. In all cases, the form must be sterile and must be fluid to the extent that easy syring ability exits. It must be stable under conditions of manufacture and storage and must be preserved against the contaminating action of microorganisms such as bacterial and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol (e.g., glycerol, propylene glycol and liquid polyethylene glycol), suitable mixtures thereof, and vegetable oil.
[0081] The following non-limiting examples illustrate preparation and use of the compounds of the invention.
EXAMPLE 1
A. 2-Amino-5-bromo-1-ethoxycarbonylmethyl-pyridinium; bromide
[0082]
[0083] 2-Amino-5-bromopyridine (10.88 g, 62.9 mmol) was dissolved in acetone (65 mL). To this solution was added ethyl bromoacetate (7.7 mL, 69.2 mmol). The solution was heated to reflux overnight under nitrogen. The reaction mixture was cooled and an off-white solid was filtered off. The solid was washed with acetone and dried to provide title compound as an off-white solid (13.74 g, 64%). 1 H NMR (DMSO-d 6 ) δ 8.91 (s, 2H), 8.42 (d, J=2.2 Hz, 1H), 8.09 (dd, J=2.2 and 9.5 Hz, 1H), 7.10 (d, J=9.5 Hz, 1H), 5.11 (s, 2H), 4.21 (q, J=7.1 and 14.2, 2H), 1.26 (t, J=7.1, 3H); MS (m/e): 259 (MH + ).
B. 6-Bromo-imidazo[1,2-a]pyridin-2-one
[0084]
[0085] To a solution of 2-Amino-5-bromo-1-ethoxycarbonylmethyl-pyridinium; bromide (2.86 g, 8.4 mmol) in methanol (30 mL) was added sodium methoxide (25 wt %, 2.5 mL, 10.1 mmol). The reaction mixture was stirred at room temperature overnight under argon. The reaction mixture was diluted with water and then extracted three times with ethyl acetate. The organic extracts were washed with brine, dried over magnesium sulfate, filtered, evaporated to yield a tan solid. The crude material was purified by column chromatography eluting with 3, 5, and 10% methanol/dichloromethane. The product was obtained as a brown solid (56 mg, 3%). 1 H NMR (CDCl 3 ) δ 7.85 (s, 1H), 7.67 (dd, J=1.6, 9.5 Hz, 1H), 7.07 (d, J=9.5 Hz, 1H), 4.52 (s, 2H); MS (m/e): 215 (MH + ); HRMS: calc'd MH + for C 7 H 5 BrN 2 O 212.9672; found 212.9664.
C1. 6-Bromo-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one
[0086]
[0087] A solution of 2-Amino-5-bromo-1-ethoxycarbonylmethyl-pyridinium; bromide (6.11 g, 17.97 mmol) in 100 mL of ethanol was prepared followed by sodium ethoxide (21 wt %, 20.5 mL, 54.9 mmol). After one hour, iodomethane was added (2.3 mL, 37.7 mmol) and the reaction was stirred at room temperature overnight. The solvent was evaporated and the residue was taken up in dichloromethane. The mixture was filtered and the filtrate was purified by column chromatography eluting with 5% methanol/dichloromethane. The product was obtained as a tan solid (1.07 g, 25%). 1 H NMR (CDCl 3 ) δ 7.73 (s, 1H), 7.67 (dd, J=1.8 and 9.4 Hz, 1H), 7.13 (d, J=9.4 Hz, 1H), 1.59 (s, 6H); MS (m/e): 241 (MH + ).
C2. 6-Bromo-3,3-spiro[cyclopentane]-imidazo[1,2-a]pyridin-2-one
[0088]
[0089] 6-Bromo-imidazo[1,2-a]pyridin-2-one (0.211 g 1 mmol), NaOMe (25% in MeOH, 0.26 g, 1.2 mmole), was stirred in MeOH (5.0 mL). 1,4-Diiodobutane (0.310 g, 1.0 mmol) was added slowly. This was stirred at ambient temperature for 16 hours. The reaction mixture was diluted with water and then extracted three times with ethyl acetate. The organic extracts were washed with brine, dried over magnesium sulfate, filtered, evaporated to yield a tan solid. The crude material was purified by column chromatography eluting with 5% methanol/dichloromethane. The product was obtained as a white solid (20 mg, 20%). Several runs with different scale was carried out and the best yield is 50%. 1 H NMR (CDCl 3 ) δ 7.68 (s, 1H), 7.62 (d, 1H, J=12 Hz), 7.04 (d, 1H, J=12 Hz), 2.52-1.83 (m, 8H); MS (m/e): 267(MH + ).
C3. 6-Bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
[0090]
[0091] A solution of 2-Amino-5-bromo-1-ethoxycarbonylmethyl-pyridinium; bromide (4.66 g, 13.70 mmol) in 80 mL of ethanol was prepared followed by sodium ethoxide (21 wt %, 15.4 mL, 41.11 mmol). After one hour, 1,5-diiodopentane was added (2.2 mL, 15.07 mmol) and the reaction allowed to proceed overnight. The reaction mixture was diluted with water and then extracted three times with ethyl acetate. The organic extracts were washed with brine, dried over magnesium sulfate, filtered, evaporated to yield a tan solid. The crude material was purified by column chromatography eluting with 5% methanol/dichloromethane. The product was obtained as an orange solid (1.15 g, 30%). 1 H NMR (CDCl 3 ) δ 7.73 (d, J=1.8 Hz, 1H), 7.63 (dd, J=2.2 and 9.4 Hz, 1H), 7.07 (d, J=9.0 Hz, 1H), 2.35-2.24 (m, 2H), 2.01-1.96 (m, 2H), 1.88-1.81 (m, 1H), 1.75-1.64 (m, 4H), 1.46-1.37 (s, 1H); MS (m/e): 282(MH + ).
EXAMPLE 2
6-(3-Chloro-phenyl)-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one
[0092]
[0093] To a round-bottom flask was added 6-bromo-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one (60 mg, 0.25 mmol), 3-chlorophenylboronic acid (39 mg, 0.25 mmol), potassium carbonate (69 mg, 0.25 mmol), Pd(PPh 3 ) 4 (29 mg, 0.025 mmol), dioxane (5 mL) and water (1 mL). The mixture was heated at reflux until the starting material was consumed monitored by HPLC-MS. The solution was cooled and water was added. The reaction mixture was extracted twice with ethyl acetate and the combined organic layers were dried, filtered and concentrated. The residue was purified by column chromatography eluting with 5% methanol/dichloromethane to provide the desired product as an off-white solid (43 mg, 63%). 1 H NMR (CDCl 3 ) δ 7.84 (dd, J=1.8 and 9.1 Hz, 1H), 7.74 (s, 1H), 7.46-7.27 (m, 5H), 1.64 (s, 6H); MS (m/e): 273 (MH + ); HRMS: calc'd MH + for C 15 H 13 ClN 2 O 273.0794; found 273.0800.
EXAMPLE 3
6-(3-chloro-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
[0094]
[0095] The title compound was prepared in 71% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohepane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.81 (dd, J=2.1 and 9.2 Hz, 1H), 7.76 (d, J=1.4, 1H), 7.45-7.33 (m, 3H), 7.25-7.23 (m, 2H), 2.40-2.30 (m, 2H), 2.05-2.00 (m, 2H), 1.91-1.86 (m, 1H), 1.78-1.71 (m, 4H), 1.49-1.42 (m, 1H); MS (m/e): 313 (MH + ).
EXAMPLE 4
3-(3,3-Dimethyl-2-oxo-2,3-dihydro-imidazo[1,2-a]pyridin-6-yl)-benzonitrile (JNJ-27385696)
[0096]
[0097] The title product was prepared in 12% yield as a yellow solid according to the procedure described in Example 2 using 3-cyanophenylboronic acid as starting material. 1 H NMR (CDCl 3 ) δ 7.82 (dd, J=2.1 and 9.2 Hz, 1H), 7.76-7.69 (m, 4H), 7.61 (m, 1H), 7.31 (d, J=9.3 Hz, 1H), 1.65 (s, 6H); MS (m/e): 264(MH + ); HRMS: calc'd MH + for C 16 H 13 N 3 O 264.1137; found 264.1130.
EXAMPLE 5
6-Chloro-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one
[0098]
[0099] The title compound was prepared in 44% yield according to the procedure described in Example 1-C1, starting from 5-chloro-pyridin-2-ylamine. 1 H NMR (CDCl 3 ) δ 7.62 (d, J=2.2 Hz, 1H), 7.57 (dd, J=2.3 and 9.5 Hz, 1H), 7.16 (d, J=9.5 Hz, 1H), 1.59 (s, 6H); MS (m/e): 197 (MH + ).
EXAMPLE 6
6-Chloro-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
[0100]
[0101] The title compound was prepared in 14% yield according to the procedure described in Example 1-C3, starting from 5-chloro-pyridin-2-ylamine. 1 H NMR (CDCl 3 ) δ 7.63 (t, J=1.8 and 0.4 Hz, 1H), 7.53 (dd, J=2.3 and 9.4 Hz, 1H), 7.11 (dd, J=0.4, 9.4 Hz, 1H), 2.36-2.25 (m, 2H), 2.00-1.96 (m, 2H), 1.88-1.81 (m, 1H), 1.75-1.63 (m, 4H), 1.46-1.36 (m, 1H); MS (m/e): 237 (MH + ).
EXAMPLE 7
6-(3,5-Difluoro-phenyl)-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one (JNJ-27446913)
[0102]
[0103] The title product was prepared in 73% yield as a yellow solid according to the procedure described in Example 2 using 3,5-difluorophenylboronic acid as starting material. 1 H NMR (CDCl 3 ) δ 7.81 (dd, J=2.1 and 9.2 Hz, 1H), 7.77 (d, J=1.4 Hz, 1H), 7.29 (d, J=0.6 Hz, 1H), 7.02-6.98 (m, 2H), 6.90-6.84 (m, 1H), 1.64 (s, 6H); MS (m/e): 275(MH + ); HRMS: calc'd MH + for C 15 H 12 FN 2 O 275.0996; found 275.1009.
EXAMPLE 8
3,3-Dimethyl-6-(3-nitro-phenyl)-imidazo[1,2-a]pyridin-2-one (JNJ-27504646)
[0104]
[0105] The title product was prepared in 37% yield as a yellow solid according to the procedure described in Example 2, using 3-nitrophenylboronic acid as starting material. 1 H NMR (400 MHz, CDCl 3 ) δ 8.35 (t, J=2.0 Hz, 1H), 8.30-8.27 (m, 1H), 7.89 (dd, J=2.1 and 9.2 Hz, 1H), 7.83-7.80 (m, 2H), 7.70 (t, J=8.0 Hz, 1H), 7.33 (d, J=9.3 Hz, 1H), 1.66 (s, 6H); MS (m/e): 284 (MH + ); HRMS calc'd MH + for C 15 H 13 N 3 O 3 284.1035; found 284.1028.
EXAMPLE 9
3,3-Dimethyl-6-(3-trifluoromethyl-phenyl)-imidazo[1,2-a]pyridin-2-one (JNJ-27512277)
[0106]
[0107] The title product was prepared in 73% yield as an off-white solid according to the procedure described in Example 2, using 3-trifluoromethylphenylboronic acid as starting material. 1 H NMR (CDCl 3 ) δ 7.86 (dd, J=2.1 and 9.2 Hz, 1H), 7.76 (s, J=1.5 Hz, 1H), 7.70-7.61 (m, 4H), 7.30 (d, J=9.2, 1H), 1.65 (s, 6H); MS (m/e): 307 (MH + ); HRMS: calc'd MH + for C 16 H 13 F 3 N 2 O 307.1058; found 307.1052.
EXAMPLE 10
6-(2,4-Difluoro-phenyl)-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one (JNJ-27518738)
[0108]
[0109] The title product was prepared in 65% yield as a white solid according to the procedure described in Example 2 using 2,4-di-fluorophenylboronic acid as starting material. 1 H NMR (CDCl 3 ) δ 7.78-7.74 (m, 2H), 7.37 (m, 1H), 7.28-7.26 (m, 1H), 7.05-6.95 (m, 2H), 1.62 (s, 6H); MS (m/e): 275 (MH + ); HRMS: calc'd MH + for C 15 H 12 FN 2 O 275.0996; found 275.1008.
EXAMPLE 11
6-(3,5-Bis-trifluoromethyl-phenyl)-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one (27518803)
[0110]
[0111] The title compound was prepared in 75% yield according to the procedure described in Example 2, starting from 3,5-di-trifluoromethylphenyl boronic acid. 1 H NMR (CDCl 3 ) δ 7.93-7.91 (m, 3H), 7.88-7.86 (m, 2H), 7.33 (dd, J=1.8 and 8.4 Hz, 1H), 1.67 (s, 6H); MS (m/e): 375 (MH + ).
EXAMPLE 12
6-(3-Methoxy-phenyl)-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one
[0112]
[0113] The title compound was prepared in 54% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one and 3-methoxyphenyl boronic acid. 1 H NMR (CDCl 3 ) δ7.86 (dd, J=2.1 and 9.2 Hz, 1H), 7.73 (d, J=1.5 Hz, 1H), 7.43-7.39 (m, 1H), 7.28-7.25 (m, 1H), 7.05 (m, 1H), 6.97-6.94 (m, 2H), 3.88 (s, 3H), 1.63 (s, 6H); MS (m/e): 269 (MH + ).
EXAMPLE 13
6-(3-Fluoro-phenyl)-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one
[0114]
[0115] The title compound was prepared in 72% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.84 (dd, J=2.1 and 9.2 Hz, 1H), 7.75 (d, J=1.6 Hz, 1H), 7.49-7.43 (m, 1H), 7.29-7.24 (m, 2H), 7.19-7.10 (m, 2H), 1.64 (m, 6H); MS (m/e): 257 (MH + ).
EXAMPLE 14
6-(2-Chloro-phenyl)-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one
[0116]
[0117] The title compound was prepared in 46% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-dimethyl-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.77-7.73 (m, 2H), 7.55-7.51 (m, 1H), 7.40-7.32 (m, 3H), 7.28-7.23 (m, 1H), 1.62 (s, 6H); MS (m/e): 273 (MH + ).
EXAMPLE 15
6-(3-Fluro-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
[0118]
[0119] The title compound was prepared in 39% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.81 (dd, J=2.1 and 9.2 Hz, 1H), 7.77 (d, J=1.4, 1H), 7.50-7.40 (m, 1H), 7.25-7.23 (m, 2H), 7.18-7.10 (m, 2H), 2.40-2.30 (m, 2H), 2.05-2.00 (m, 2H), 1.91-1.81 (m, 1H), 1.77-1.71 (m, 4H), 1.50-1.38 (m, 1H); MS (m/e): 297 (MH + ).
EXAMPLE 16
6-(3-Methoxy-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
[0120]
[0121] The title compound was prepared in 67% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.83 (dd, J=2.1 and 9.2 Hz, 1H), 7.77 (d, J=1.4 Hz, 1H), 7.40-7.38 (m, 1H), 7.24-7.22 (m, 1H), 7.04-7.02 (m, 1H), 6.97-6.95 (m, 2H), 3.88 (s, 3H), 2.40-2.30 (m, 2H), 2.05-2.00 (m, 2H), 1.92-1.80 (s, 1H), 1.77-1.68 (m, 4H), 1.50-1.38 (m, 1H); MS (m/e): 309 (MH + ).
EXAMPLE 17
6-(3,5-Bis-trifluoromethyl-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
[0122]
[0123] The title compound was prepared in 35% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.93-7.79 (m, 5H), 7.30-7.28 (m, 1H), 2.40-2.36 (m, 2H), 2.06-2.01 (m, 2H), 1.92-1.88 (m, 1H), 1.82-1.72 (m, 4H), 1.50-1.38 (m, 1H); MS (m/e): 415 (MH + ).
EXAMPLE 18
6-(3-nitro-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
[0124]
[0125] The title compound was prepared in 8% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 8.34 (t, J=1.9 Hz, 1H), 8.29-8.26 (m, 1H), 7.88-7.79 (m, 3H), 7.69 (t, J=7.9, 1H), 7.31-7.26 (m, 1H), 2.45-2.30 (m, 2H), 2.10-2.00 (m, 2H), 1.93-1.83 (m, 1H), 1.81-1.70 (m, 4H), 1.50-1.40 (m, 1H); MS (m/e): 324 (MH + ).
EXAMPLE 19
6-(3-trifluoromethyl-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
[0126]
[0127] The title compound was prepared in 65% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.84 (dd, J=2.2 and 9.2 Hz, 1H), 7.78 (d, J=1.4 Hz, 1H), 7.69-7.62 (m, 4H), 7.28-7.25 (m, 1H), 2.39-2.32 (m, 2H), 2.05-2.00 (m, 2H), 1.91-1.86 (m, 1H), 1.80-1.71 (m, 4H), 1.47-1.43 (m, 1H); MS (m/e): 347 (MH + ).
EXAMPLE 20
6-(3-cyano-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
[0128]
[0129] The title compound was prepared in 47% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.82-7.79 (m, 2H), 7.77-7.70 (m, 3H), 7.28-7.26 (m, 1H), 7.28-7.26 (m, 1H), 2.38-2.30 (m, 2H), 2.05-2.01 (m, 2H), 1.91-1.87 (m, 1H), 1.80-1.71 (m, 4H), 1.49-1.43 (m, 1H); MS (m/e): 304 (MH + ).
EXAMPLE 21
6-(3,5-Difluoro-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
[0130]
[0131] The title compound was prepared in 36% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.78-7.75 (m, 2H), 7.23 (s, 1H), 7.00-6.97 (m, 2H), 6.90-6.84 (m, 1H), 2.40-2.23 (m, 2H), 2.05-1.95 (m, 2H), 1.91-1.81 (m, 1H), 1.77-1.65 (m, 4H), 1.50-1.37 (m, 1H); MS (m/e): 315 (MH + ).
EXAMPLE 22
6-(3,5-Dichloro-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
[0132]
[0133] The title compound was prepared in 48% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.79-7.76 (m, 1H), 7.69-7.64 (m, 1H), 7.58-7.53 (m, 1H), 7.49-7.45 (m, 1H), 7.31-7.23 (m, 2H), 2.38-2.30 (m, 2H), 2.04-2.00 (m, 2H), 1.90-1.85 (m, 1H), 1.79-1.65 (m, 4H), 1.50-1.38 (m, 1H); MS (m/e): 347 (MH + ).
EXAMPLE 23
6-(2,4-Difluoro-phenyl)-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one
[0134]
[0135] The title compound was prepared in 48% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclohexane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.81 (s, 1H), 7.75-7.72 (m, 1H), 7.40-7.33 (m, 1H), 7.25-7.22 (m, 1H), 7.08-6.95 (m, 2H), 2.37-2.28 (m, 2H), 2.05-2.02 (m, 2H), 1.87-1.84 (m, 1H), 1.75-1.71 (m, 4H), 1.45-1.39 (m, 1H); MS (m/e): 315 (MH + ).
EXAMPLE 24
6-(3-chloro-phenyl)-3,3-spiro[pentane]-imidazo[1,2-a]pyridin-2-one
[0136]
[0137] The title compound was prepared in 60% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclopenane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.80 (dd, J=2.1 and 9.2 Hz, 1H), 7.73 (d, J=1.6 Hz, 1H), 7.45-7.39 (m, 3H), 7.34-7.31 (m, 1H), 7.25-7.23 (m, 1H), 2.53-2.48 (m, 2H), 2.20-2.16 (m, 2H), 2.05-1.94 (m, 4H); MS (m/e): 299 (MH + ).
EXAMPLE 25
6-(3-cyano-phenyl)-3,3-spiro[pentane]-imidazo[1,2-a]pyridin-2-one
[0138]
[0139] The title compound was prepared in 31% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclopenane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.80 (dd, J=2.2 and 9.2 Hz, 1H), 7.75-7.68 (m, 4H), 7.62 (t, J=7.7 Hz, 1H), 7.28 (s, 1H), 2.55-2.48 (m, 2H), 2.22-2.18 (m, 2H), 2.06-1.95 (m, 4H); MS (m/e): 290 (MH + ).
EXAMPLE 26
6-(3-Fluoro-phenyl)-3,3-spiro[pentane]-imidazo[1,2-a]pyridin-2-one
[0140]
[0141] The title compound was prepared in 58% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclopenane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.81 (dd, J=2.0 and 9.1 Hz, 1H), 7.74 (d, J=1.8 Hz, 1H), 7.49-7.43 (m, 1H), 7.27-7.22 (m, 2H), 7.17-7.10 (m, 2H), 2.54-2.48 (m, 2H), 2.21-2.14 (m, 2H), 2.08-1.94 (m, 4H); MS (m/e): 283 (MH + ).
EXAMPLE 27
6-(3-nitro-phenyl)-3,3-spiro[pentane]-imidazo[1,2-a]pyridin-2-one
[0142]
[0143] The title compound was prepared in 48% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclopenane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 8.33 (t, J=2.0 Hz, 1H), 8.29-8.27 (m, 1H), 7.87 (dd, J=2.1 and 9.2 Hz, 1H), 7.83-7.68 (m, 2H), 7.70 (t, J=8.0 Hz, 1H), 7.30 (d, J=9.2 Hz, 1H), 2.54-2.49 (m, 2H), 2.22-2.18 (m, 2H), 2.07-1.97 (m, 4H); MS (m/e): 310 (MH + ).
EXAMPLE 28
6-(3,4-Dichloro-phenyl)-3,3-spiro[pentane]-imidazo[1,2-a]pyridin-2-one
[0144]
[0145] The title compound was prepared in 58% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclopenane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.77 (dd, J=2.1 and 9.2 Hz, 1H), 7.72 (m, 1H), 7.57-7.53 (m, 2H), 7.30-7.23 (m, 2H), 2.53-2.47 (m, 2H), 2.21-2.14 (m, 2H), 2.08-1.94 (m, 4H); MS (m/e): 331 (MH − ).
EXAMPLE 29
6-(3,5-Bis-trifluoromethyl-phenyl)-3,3-spiro[pentane]-imidazo[1,2-a]pyridin-2-one
[0146]
[0147] The title compound was prepared in 80% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclopenane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.93 (s, 1H), 7.88 (s, 2H), 7.84-7.79 (m, 2H), 7.30-7.28 (m, 1H), 2.54-2.48 (m, 2H), 2.23-2.16 (m, 2H), 2.09-1.97 (m, 4H); MS (m/e): 401 (MH + ).
EXAMPLE 30
6-(3-Chloro-4-fluoro-phenyl)-3,3-spiro[pentane]-imidazo[1,2-a]pyridin-2-one
[0148]
[0149] The title compound was prepared in 44% yield according to the procedure described in Example 2, starting from 6-bromo-3,3-spiro[cyclopenane]-imidazo[1,2-a]pyridin-2-one and the corresponding boronic acid. 1 H NMR (CDCl 3 ) δ 7.76 (dd, J=2.1 and 9.2 Hz, 1H), 7.70 (d, J=1.4 Hz, 1H), 7.49 (dd, J=2.3 and 6.7 Hz, 1H), 7.34-7.22 (m, 3H), 2.53-2.47 (m, 2H), 2.22-2.12 (m, 2H), 2.07-1.94 (m, 4H); MS (m/e): 317 (MH + ).
EXAMPLE 31
A. 5-(3-Fluoro-phenyl)-1,3-dihydro-pyrrolo[2,3-b]pyridin-2-one
[0150]
[0151] The title compound was prepared in 32% yield according to the procedure described in Example 2, starting from 5-bromo-1,3-dihydro-pyrrolo[2,3-b]pyridin-2-one (prepared according to the procedure described in WO2003082868, Page 33) and 3-fluoro-phenyl boronic acid. 1 H NMR is the same as the one reported in WO2003082868, page 34.
B. 5-(3-Fluoro-phenyl)-3,3-dimethyl-1,3-dihydro-pyrrolo[2,3-b]pyridin-2-one
[0152]
[0153] A solution of 5-(3-Fluoro-phenyl)-1,3-dihydro-pyrrolo[2,3-b]pyridin-2-one (91 mg, 0.40 mmol) in THF (8 mL) was cooled to between −10 and −30° C. under argon. To this solution was added n-butyllithium (0.34 mL, 0.84 mmol) followed by N,N,N′,N′-tetramethylenediamine (0.13 mL, 0.84 mmol). The solution was stirred at −10° C. for 0.5 hours. Iodomethane was added (0.05 mL, 0.84 mmol) and the solution was allowed to warm to room temperature overnight. The reaction mixture was diluted with water and then extracted three times with ethyl acetate. The organic extracts were washed with brine, dried over magnesium sulfate, filtered, evaporated to yield a tan solid. The crude material was purified by column chromatography eluting with 40% ethyl acetate/hexanes. The product was obtained as off-white solid (23 mg, 22%). 1 H NMR (CDCl 3 ) δ 8.74 (s, 1H), 8.36 (d, J=1.9 Hz, 1H), 7.62 (d, J=2.0 Hz, 1H), 7.46-7.41 (m, 1H), 7.33 (d, J=7.8 Hz, 1H), 7.24-7.23 (m, 1H), 7.11-7.06 (m, 1H), 1.48 (s, 6H); MS (m/e): 257 (MH + ).
EXAMPLE 32
5-(3-Fluoro-phenyl)-3,3-spiro[cyclohxane]-1,3-dihydro-pyrrolo[2,3-b]pyridin-2-one
[0154]
[0155] The title compound was prepared in 24% yield according to the procedure described in Example 30B, starting from 5-(3-Fluoro-phenyl)-1,3-dihydro-pyrrolo[2,3-b]pyridin-2-one and 1,5-diiodopentane. 1 H NMR (CDCl 3 ) δ 9.40 (s, 1H), 8.37 (s, 1H), 7.87 (d, J=1.9 Hz, 1H), 7.47-7.38 (m, 1H), 7.33 (d, J=7.8 Hz, 1H), 7.24-7.23 (m, 1H), 7.11-7.06 (m, 1H), 1.99-1.67 (m, 10H); MS (m/e): 297 (MH + ).
EXAMPLE 33
In Vitro Test
[0156] T47D human breast cancer cells are grown in RPMI medium without phenol red (Invitrogen) containing 10% (v/v) heat-inactivated fetal bovine serum (FBS; Hyclone), 1% (v/v) penicillin-streptomycin (Invitrogen), 1% (w/v) glutamine (Invitrogen), and 10 mg/mL insulin (Sigma). Incubation conditions are 37 □C in a humidified 5% (v/v) carbon dioxide environment. For assay, the cells are plated in 96-well tissue culture plates at 10,000 cells per well in assay medium [RPMI medium without phenol red (Invitrogen) containing 5% (v/v) charcoal-treated FBS (Hyclone) and 1% (v/v) penicillin-streptomycin (Invitrogen)]. Two days later, the medium is decanted and the compounds are added in a final concentration of 0.1% (v/v) dimethyl sulfoxide in fresh assay medium. Twenty-four hours later, an alkaline phosphatase assay is performed using a SEAP kit (BD Biosciences Clontech, Palo Alto, Calif.). Briefly, the medium is decanted and the cells are fixed for 30 minutes at room temperature with 5% (v/v) formalin (Sigma). The cells are washed once with room temperature Hank's buffered saline solution (Invitrogen). Equal volumes (0.05 mL) of 1× Dilution Buffer, Assay Buffer and 1:20 substrate/enhancer mixture are added. After 1-hour incubation at room temperature in the dark, the lysate is transferred to a white 96 well plate (Dynex) and luminescence is read using a LuminoSkan Ascent (Thermo Electron, Woburn, Mass.).
TABLE 3 Ex. # R 1 , R 2 R 4 % inh. 1-C3 Spirocyclohexane Br 3 Spirocyclohexyl 3-Cl-phenyl 104% 1-C1 Dimethyl Br 53% 2 Dimethyl 3-Cl-phenyl 15% 4 Dimethyl 3-CN-phenyl 19% 5 Dimethyl Cl 31% 6 Spirocyclohexyl Cl 42% 7 Dimethyl 3,5-di-F-phenyl 40% 8 Dimethyl 3-NO 2 -phenyl 33% 9 Dimethyl 3-CF 3 -phenyl 17% 10 Dimethyl 2,4-di-F-phenyl 29% 11 Dimethyl 3,5-di-CF 3 -phenyl 19% 12 Dimethyl 3-MeO-phenyl 3.1% 13 Dimethyl 3-F-phenyl 14% 14 Dimethyl 2-Cl-phenyl 0% 1-C2 spirocyclopentane Br 35% 15 spirocyclohexane 3-F-phenyl 0% 16 spirocyclohexane 3-MeO-phenyl 01% 17 spirocyclohexane 3,5-di-CF 3 -phenyl 04% 18 spirocyclohexane 3-NO 2 -phenyl 98% 19 spirocyclohexane 3-CF 3 -phenyl 97% 20 spirocyclohexane 3-CN-phenyl 96% 21 spirocyclohexane 3,5-di-F-phenyl 99% 22 spirocyclohexane 3,4-di-Cl-phenyl 88% 23 spirocyclohexane 2,4-di-F-phenyl 96% 24 spirocyclopentane 3-Cl-phenyl 1% 25 spirocyclopentane 3-CN-phenyl 2% 26 spirocyclopentane 3-F-phenyl 2% 27 spirocyclopentane 3-NO 2 -phenyl 86% *28 spirocyclopentane 3,4-di-Cl-phenyl 22% 29 spirocyclopentane 3,5-di-CF 3 -phenyl 25% 30 spirocyclopentane 3-Cl-4-F-phenyl 21% *% activation: 93.82% @ 3000 nM, EC50 = 1950 nM.
[0157]
TABLE 4
Ex. #
R 1 , R 2
R 3
% inh.
IC 50 (nM)
31
Spirocyclo
3-F-phenyl
92% @ 10 uM
4484
hexane
95% @ 3 uM
32
Dimethyl
3-F-phenyl
58% @ 10 uM
7027
58% @ 3 uM
EXAMPLE 34
[0158] While the foregoing specification teaches the principles of the present invention, with examples provided for the purpose of illustration, it will be understood that the practice of the invention encompasses all of the usual variations, adaptations and/or modifications as come within the scope of the following claims and their equivalents. | The present invention is directed to novel heteroatom containing tetracyclic derivatives, pharmaceutical compositions containing them and their use in the treatment of disorders mediated by one or more estrogen receptors. The compounds of the invention are useful in the treatment of disorders associated with the depletion of estrogen such as hot flashes, vaginal dryness, osteopenia and osteoporosis; hormone sensitive cancers and hyperplasia of the breast, endometrium, cervix and prostate; endometriosis, uterine fibroids, osteoarthritis and as contraceptive agents, alone or in combination with a progestogen or progestogen antagonist. | 2 |
BACKGROUND OF THE INVENTION
[0001] (a) Field of the Invention
[0002] The present invention relates to a hematopoietic stem cell expansion factor, and to a method for enhancing hematopoietic stem cell expansion by direct delivery of a protein in the cell.
[0003] (b) Description of Prior Art
[0004] Hematopoietic stem cells (HSCs) are rare cells that have been identified in fetal bone marrow, umbilical cord blood, adult bone marrow, and peripheral blood, which are capable of differentiating into each of the myeloerythroid (red blood cells, granulocytes, monocytes), megakaryocyte (platelets) and lymphoid (T-cells, B-cells, and natural killer cells lineages. In addition these cells are long-lived, and are capable of producing additional stem cells, a process termed self-renewal. Stem cells initially undergo commitment to lineage restricted progenitor cells, which can be assayed by their ability to form colonies in semisolid media. Progenitor cells are restricted in their ability to undergo multi-lineage differentiation and have lost their ability to self-renew. Progenitor cells eventually differentiate and mature into each of the functional elements of the blood.
[0005] The lifelong maintenance of mature blood cells results from the proliferative activity of a small number of totipotent HSCs that have a high, but perhaps limited, capacity for self-renewal.
[0006] The hematopoietic stem cell (HSC) can be operationally defined as a cell responsible for the long-term engraftment of all blood cell types following bone marrow transplantation. Its evaluation should therefore take into account this definition thus implying in vivo testing. There are several assays that have been described to measure the frequency of HSCs. The assay to evaluate stem cell numbers is called the CRU (competitive repopulation unit) assay. This assay combines principles of limiting dilution analysis and competitive repopulation to quantitate HSC frequencies in unknown test populations. In its original description, various numbers of test cells were co-injected with “compromised” helper cells into irradiated (myeloablated) recipients. The helper cells assured short-term hematopoietic reconstitution and are the to be compromised because they have lost most of their long-term repopulating ability as a result of serial transplantation (Mauch, P., Hellman, S. Blood. 74, 872-875, 1989). Because lympho-myeloid elements that originate from the test cell can be identified either by genetic marker or by cell surface antigen (Ly5.1/Ly5.2), it is possible to identify recipients in which a test cell has significantly contributed to long-term repopulation of both lymphoid and myeloid cells (both>1% contribution). The HSC operationally defined by this assay is termed a CRU and its frequency is established based on Poisson statistics from the proportion of mice that meet the repopulation criteria described above. More precisely, the frequency of CRU in the test population is [CRU frequency 1/(No. of bone marrow test cells that repopulated exactly 63% of the irradiated recipients)] . The growing therapeutic use of stem cell transplantation and potential applications of in vitro HSC expansion have focussed attention on defining regulators (both intrinsic and extrinsic) of self-renewal division of HSC.
[0007] A variety of in vitro culture conditions have been described that permit substantial expansion of primitive cells detected as long-term culture-initiating cells (LTC-IC) (>50-fold). However, the in vitro expansion of rigorously defined HSC has proven a greater challenge. With careful selection of growth factor combinations and culture conditions, maintenance and even modest but significant net expansion (<10 fold) have been reported for adult mouse bone marrow CRU 36 and human cord blood CRU, the latter detected using the NOD/SCID repopulation model. The growth factor requirements appear complex with positive regulators such as FL, SF, and Il-11 being critical, while conversely, certain cytokines such as IL-3 or Il-1 have potentially detrimental effects. CRU expansions so far documented are considerably lower than that observed during the regeneration of CRU following transplantation (in vivo). Additional or alternative stimulatory growth factors (Thrombopoietin (TPO), Steel or bone morphogenetic protein), timely addition of negative regulators to suppress cell cycle and/or novel stromal supports (Moore, K. A. et al., Blood. 89, 4337-4347, 1997) are several promising avenues for achieving increased expansion. Increased understanding of the underlying intrinsic molecular mechanisms regulating HSC growth properties also appears crucial to achieving greater HSC expansion both in vitro and in vitro.
[0008] Following bone marrow transplantation (BMT), there is rapid regeneration to normal pre-transplantation levels in the number of hematopoietic progenitors and mature end cells whereas hematopoietic stem cell (HSC) numbers recover to only 5-10% of normal levels. This suggests that HSC are significantly restricted in their self-renewal behavior and hence in their ability to repopulate the host stem cell compartment.
[0009] The Hox family of homeobox genes are defined by the presence of a conserved 180 nucleotide sequence called the homeobox. Hox homeobox genes are related by the presence of a conserved 60-amino acid sequence that specifies a helix-turn-helix DNA-binding domain. Increasing evidence points to Hox homeobox genes as playing important lineage-specific roles throughout life in a variety of tissues including the hematopoietic system.
[0010] Hematopoiesis is the process by which mature blood cells are continuously generated throughout adult life from a small number of totipotent hematopoietic stem cells (HSC). The HSCs have the key properties of being able to self-renew and to differentiate into mature cells of both lymphoid and myeloid lineages. Although the genetic mechanisms responsible for the control of self-renewal and differentiation outcomes of HSC divisions remain largely unknown, a number of studies have implicated a variety of transcription factors as key regulatory components of these processes.
[0011] Among such factors are the mammalian Hox homeobox gene family of transcription factors, consisting of 39 members arranged in 4 clusters (A, B, C and D), initially described as important regulators of pattern formation in a variety of embryonic tissues. These genes are structurally related by the presence of a 183-bp sequence, the homeobox, that encodes a helix-turn-helix DNA binding motif. Apparent stage- and lineage-specific expression of numerous HOXA, B, and C genes has now been demonstrated for both hematopoietic cell lines and primary hematopoietic cells. For example, we have shown that members of the HOXA and HOXB cluster genes are preferentially expressed in the CD34 + fraction of human bone marrow cells that contains most if not all of the hematopoietic progenitor cells. Further detailed analysis of Hox gene expression in functionally distinct subpopulations of CD34 + cells has shown that genes, primarily located at the 31 end of the clusters (HOXB3 and HOXB4), are preferentially expressed in the subpopulation containing the most primitive hematopoietic cells.
[0012] Major new insights into the mechanisms involved in HSC regulation has come from evidence that molecules normally involved in regulating embryonic development also control proliferation and differentiation of hematopoietic cells. Hox genes are part of this family of developmental regulators. Primitive human bone marrow cells express a large number of Hox genes and the expression of these genes decreases as the cells differentiate into more mature elements. Retroviral overexpression of several of these genes assessed in the murine model reveals effects that are specific for each Hox gene tested. For example, Hoxb4 specifically enhances the repopulation potential of HSCs without inducing leukemic transformation. On the other hand, Hoxb3 induces a complete block in the production of CD4 + CD8 + αβ thymocytes but significantly enhances the generation of γδ T-lymphocytes. Hoxa10 inhibits monocytic differentiation but dramatically enhances the generation of megakaryocytic progenitors. It thus appears that each Hox gene, when overexpressed, has the capacity to influence differentiation and proliferation of specific hematopoietic cells and suggest that they each regulate a specific set of target genes.
[0013] As most transcription factors, Hox are modular proteins with a DNA-binding domain and a transcriptional activator (or repressor) domain usually located in the N-terminal part of the protein. Most Hox proteins have the small 4-6 amino acid motif required for their interaction with another group of homeodomain-containing proteins called PBX. Hox/PBX cooperatively bind DNA on TGATNNAT sites.
[0014] It is known to transduce HSC with a retroviral vector comprising a Hoxb4 gene. For example, in U.S. Pat. No. 5,837,507, there is described a gene therapy approach based on the stable integration of a HOX gene in a stem cell, to enhance stem cell expansion. Hematopoietic stem cells (HSCs) genetically engineered to overexpress the Hoxb4 gene have a 20- to 55-fold repopulation advantage over untransduced cells. This capacity of the Hoxb4 gene to selectively enhance HSC regeneration appears to occur without blocking or skewing their differentiation or inducing leukemic transformation. This “Hoxb4 effect” occurs shortly (days) after retroviral transduction and primitive human bone marrow cells can also “respond” to retrovirally engineered Hox gene overexpression. In U.S. Pat. No. 5,837,507, a gene therapy based on the exogenous expression of a HOX gene for the enhanced ability of cells to proliferate to form expanded population of pluripotent stem cell.
[0015] Numerous studies have reported that proteins present in the cellular environment can be efficiently transduced into mammalian cells while preserving their functional activity. It was reported that the homeodomain (HD) of a Drosophila Hox gene (Antennapedia or Antp) is capable of translocating across the neuronal membranes and is conveyed to the nuclei. However, the mechanism responsible for this capture remains poorly defined. Interestingly, the Antp protein remains functional once captured by the cell. 98 It was later demonstrated that this capture of Antp was dependent on a 16-amino acid-long peptide present in the conserved third a-helix of the HD. Comparison between this region of Antp and that of Hoxb4 shows a complete conservation thus suggesting that the Hoxb4 protein could be directly incorporated into the cellular environment where it could be translocated into the nucleus, as observed with Antp.
[0016] Intracellular protein delivery was also reported with 2 viral-derived proteins, the HSV VP16 and the HIV TAT proteins. The 86 amino acid HIV TAT protein has been the focus of several studies. TAT is involved in the replication of HIV-1. Several studies have shown that TAT is able to translocate through the plasma membrane and to reach the nucleus where it transactivates the viral genome. It was recently shown that this “translocating activity” of TAT resides within residues 47 to 60 of the protein 103 and that this 13mer peptide accumulates in cells (nucleus) extremely rapidly (seconds to minutes) at concentrations as low as 100 nM. The internalization process used by the TAT peptide does not seem to involve an endocytic pathway since no inhibition of uptake was observed at 4° C.
[0017] In a recent study, Nagahara et al. have reported the ability of several TAT (11 mer) fusion proteins to be efficiently captured by several cell types (including primary hematopoietic cells). According to a recent communication by these authors, this approach has been used with success with at least 50 different proteins (Nagahara, H. et al., Nat Med. 4, 1449-1452, 1998). The authors have shown that denatured proteins transduce more efficiently than correctly folded proteins. The exact reason for this observation may relate to reduced structural constraints of denatured proteins. Once inside the cells, the denatured proteins are correctly folded by cellular chaperones. The incorporated proteins were shown to preserve functional activity.
[0018] In a more recent paper, Dowdy et al. have reported the in vivo (intra-peritoneal) delivery of large (120 kDa) TAT-fusion proteins with a remarkable efficiency of protein transfer to most tissues including “functional protein transfer” to 100% of hematopoietic blood cells in 20 minutes (Schwarze, S. R. et al., Science 285, 1569-1572. 1999). Moreover, the authors showed the absence of toxicity for mice receiving up to 1 mg i.p. of TAT-fusion proteins daily for 14 days.
[0019] Autologous and allogeneic transplantation of hematopoietic stem cells using bone marrow or peripheral blood stem cells is a well-established procedure for restoring normal hematopoiesis in patients undergoing ablative treatments for cancer. The major toxicity of allogeneic transplantation is graft vs. host disease caused by immunologic differences between donors and recipients. Current techniques for collecting autologous peripheral blood stem cells require the administration of potentially toxic cytokines and chemotherapeutic agents to the patient to mobilize stem cells from the bone marrow, and subjecting the patient to sometimes multiple leukopheresis procedures to collect a sufficient number of stem cells.
[0020] A major limitation in bone marrow transplantation is obtaining enough stem cells to restore blood formation. The overexpression of the Hox4 gene in bone marrow cells using a retroviral vector expands the cells up to 750 fold. However, gene transfer efficiency remains low, and long-term over-expression of the gene could predispose to leukemic transformation. A better approach (proposed here) would be to provide a gene product (e.g., HOXB4 protein fused to TAT peptide) which would avoid the risks associated gene transfer as suggested in U.S. Pat. No. 5,837,507.
[0021] It would therefore be highly desirable to be provided with a protein therapy as opposed to a gene therapy for enhancing hematopoietic stem cell expansion in vivo following bone marrow transplantation and/or in vitro prior to the transplantation. Stem cell expansion would permit collection of smaller blood samples, with less discomfort and risks to the patient. It would allow the use of alternative source of stem cells such as those derived from cord blood, for bone marrow transplantation procedures.
SUMMARY OF THE INVENTION
[0022] One aim of the present invention is to provide a protein therapy for enhancing hematopoietic stem cell expansion in vivo following bone marrow transplantation and/or in vitro prior to the transplantation. This cellular therapy would be possible by the use of HOXB4 or TAT-HOXB4 proteins as a “stem cell expanding factor”.
[0023] In accordance with a broad aspect of the present invention, there is provided a method for enhancing expansion of a hematopoietic stem cell (HSC) population. The method comprises directly delivering to a HSC population an amino acid sequence having the activity of a peptide encoded by a Hoxb4 nucleotide sequence. Once delivered, the amino acid sequence is functionally active in the hematopoietic stem cell population and enhances expansion thereof.
[0024] The amino acid sequence may consist of a Hoxb4 peptide such as the whole Hoxb4 protein or a part thereof.
[0025] The amino acid sequence may comprise an HIV-derived peptide able to cross the cell membrane, such as the NH 2 -terminal protein transduction domain (PTD)derived from the HIV TAT protein.
[0026] It was surprisingly discovered that HOXB4 protein delivery to hematopoietic stem cells in vitro resulted in enhanced expansion after 4 days.
[0027] Alternatively, the protein delivery may be placed under inducible control using a drug inducible system.
[0028] In accordance with another broad aspect of the present invention, there is provided a drug-inducible method for enhancing hematopoietic stem cell expansion. The method comprises delivering in a hematopoietic stem cell population a nucleotide sequence linked to a drug-binding protein and encoding one of a DNA-binding domain and a N-terminal domain of a peptide having the activity of a HOXB4 peptide, delivering in the hematopoietic stem cell population a nucleotide sequence encoding the remainder of the DNA-binding domain and N-terminal domains linked to a drug-binding protein, and exposing the hematopoietic stem cell to a dimerizing agent. A functionally active HOXB4 peptide is reconstituted in the hematopoietic stem cell in which are delivered the two nucleotide sequences, thereby enhancing expansion of the hematopoietic stem cell. The binding protein may consist of FKBP12 and the dimerizing agent may consist of FK1012 or an analog thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] [0029]FIG. 1 illustrates the primary structure of HOXB4. HOXB4 is a relatively small protein of 251 amino acids. Based on comparative analysis with paralogs and orthologs, the HOXB4 protein can be divided into 6 distinct domains. A: Foremost N-terminal domain: Conserved from Drosophila to human; B: Very little conservation; proline rich in human Hoxb4; c: Pbx-interacting hexapeptide; highly conserved from Drosophila to human; D: Region between hexapeptide and HD; highly conserved between vertebrate paralogs; E: homeodomain; highly conserved from Drosophila to human;
[0030] [0030]FIG. 2 illustrates results in producing (A), purifying (A and B) and incorporating FITC-labeled TAT-Hoxb4 into hematopoietic cells (C); A: purification of TAT-HOXB4 protein from bacterial lysage; Lane 1: bacterial lysate before purification on Nickel column; Lane 2 and 3: aliquot of TAT-HOXB4 protein after purification (2 different concentrations of Imidazole); B: Western blot analysis of the TAT-HOXB4 protein purified in A; C: FACS analysis of Ba/F3 cells exposed for 20 to 60 minutes to TAT-HOXB4 previously conjugated to FITC and separated from free-FITC by chromatography;
[0031] [0031]FIG. 3 illustrates increased Human myelopoiesis in NOD/SCID mice transplanted with human CB cells transduced with Hoxa10-GFP compared to GFP control. GFP+CD15+ human cells were measured in recipient mouse BM aspiratees 8 weeks post tx. Circles: individual mice; horizontal line: median number;
[0032] [0032]FIG. 4 illustrates (A) the primary structure of the HOXB4 protein divided in 6 different domains; (B) the capacity of mutant HOXB4 proteins to induce proliferative effects in Rat-1 cells or primary bone marrow cells as summarized; The point mutants in C (Try>Gly) and E (Asn>Ser) inhibit the capacity of Hoxb4 to interact with PBX and DNA respectively;
[0033] [0033]FIG. 5 illustrates a comparison of the domains A and B of the protein; and
[0034] [0034]FIG. 6 illustrates a Western blot analysis of nuclear extracts from Rat-1 (lane 1 and 2) and 3T3 cells (lane 3 and 4) transduced with a Hoxb4 (lane 2 and 4) or a neo control (lane 1 and 3) retrovirus.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The term “stem cell” is meant a pluripotent cell capable of self-regeneration when provided to a subject in vivo, and give rise to lineage restricted progenitors, which further differentiate and expand into specific lineages. As used herein, “stem cells” includes hematopoietic cells and may include stem cells of other cell types, such as skin and gut epithelial cells, hepatocytes, and neuronal cells. Stem cells include a population of hematopoietic cells having all of the long-term engrafting potential in vivo. Preferable, the term “stem cells” refers to mammalian hematopoietic stem cells; more preferably, the stem cells are human hematopoietic stem cells.
[0036] The term “CRU” means competititve repopulation unit representing long-lived and totipotent stem cells.
[0037] Expansion may occur in vitro (prior to transplantation) and/or in vivo (enhanced regeneration of stem cell pools after transplantation.
[0038] The expression “direct delivery” is intended to mean delivery of a gene product (i.e., protein) into the cell, as opposed to the insertion of the gene itself in the genome of the cell.
[0039] “Protein” is intended to mean any protein which can enhance stem cell expansion and is not limited to the HOXB4 peptide.
[0040] “Enhancement” is intended to correspond to substantial self-renewal compared to non-enhanced stem cell expansion.
[0041] The protein may be delivered to the hematopoietic stem cell by any means known in the art which results in functional activity of the protein in the cell.
[0042] The present invention will be more readily understood by referring to the following examples which are given to illustrate the invention rather than to limit its scope.
EXAMPLE I
Hoxb4-Induced Proliferative Effect on Mouse HSC Origin
[0043] This example defines the early kinetics, duration and magnitude of Hoxb4-induced enhancement of HSC expansion in the in vivo murine model, determines the requirement for myeloablative conditioning and identifies and optimizes in vitro conditions for achieving Hoxb4 effects on repopulating cells.
[0044] Hoxb4 overexpression can significantly increase the rate and level of CRU expansion in vivo, as evident by increased numbers as early as 2 weeks post-transplantation, and ultimate recoveries to normal numbers. Based on these observations, it was hypothesized that Hoxb4 could positively alter HSC self-renewal behavior and that this effect could require conditions existing in myeloablated recipients. It also appears that the “expanding effect” produced by Hoxb4 on the stem cell pool remains subject to mechanisms that normally limit HSC population size, suggesting that expansion potential of the Hoxb4-transduced HSC may be underestimated. These hypotheses were tested by evaluating the kinetics, magnitude and conditions associated with Hoxb4 enhanced mouse stem cell expansion. Proliferation-enhancing effects of Hoxb4 are also manifest in vitro as so far revealed by increased numbers of day 12 CFU-S and competitive growth of transduced cells in short-term liquid culture. Coupled with recent advances in conditions that support CRU self-renewal in vitro and the rapid effect of Hoxb4 seen in vivo, it is shown that Hoxb4 overexpression may potentiate HSC expansion in short-term in vitro culture. This possibility was tested, and in vitro conditions that permit maximal expansion of mouse HSC engineered to overexpress Hoxb4 were identified.
[0045] The MSCV-Hoxb4-IRES-GFP or MSCV-IRES-GFP retroviral vectors (henceforth termed Hoxb4-GFP or GFP respectively) were used. No evidence of “promoter shutdown” were seen with the MSCV vector even after repeated transplantations. Thus, GFP expression provides a rigorous indicator of origin from a transduced cell. Donor mice (C57Bl/6J:Pep3b which have the Ly5.1 antigen on the surface of their leukocytes) were injected with 5-Fluorouracil (5-FU, 150 mg/kg) 4 days prior to bone marrow (BM) harvest and infected using a 4 day protocol consisting of 2 days prestimulation in a combination of growth factors (6 ng/ml mIl-3; 100 ng/ml mSF; 10 ng/ml hI16) followed by exposure to virus-containing supernatants with continued growth factor stimulation on fibronectin-coated dishes for 2 more days with 1 change of media and virus at 24 hours. These infection conditions routinely yielded 40 to 60% gene transfer as monitored by GFP + cells 2 days following termination of the infection procedure.
[0046] Transplantation and Kinetics of CRU Regeneration in vivo
[0047] Donor (Ly5.1 + ) BM cells were recovered immediately after the termination of the infection period and transplanted without prior selection at a dose of 2×10 5 into multiple lethally irradiated recipient mice (C57BL/6J which are Ly5.2 + ). This represented ˜40 CRU (frequency of ˜1 in 5,000 in cells immediately after infection (Sauvageau, G. et al., Genes Dev. 9, 1753-1765, 1995) of which 40-60% were transduced (20 transduced CRU per mouse). Aliquots of these cells were maintained in liquid culture for an additional 2 days to assess gene transfer efficiency by FACS analysis for GFP + cells, and plated in methylcellulose culture to monitor the yield and proportion of GFP + colonies (visualized by fluorescence microscopy). Cohorts of recipient mice (3-4 mice per time point) were sacrificed starting at day 4 post-transplant and thereafter at days 8, 12, and 16 and then week 4, 6 and 8 to measure donor-derived contributions to bone marrow cellularity, clonogenic progenitors and CRU content. These time points were chosen in order to define the very early kinetics of CRU reconstitution not previously assessed, and to better define the earliest time at which plateau CRU levels are reached. CRU measurements were carried out by limiting dilution analysis of secondary transplant recipients. Four months following transplantation, blood samples were obtained from CRU assay (secondary) recipients and analyzed by FACS for evidence of significant (>1% lymphoid and 1% myeloid) contribution from transduced (GFP + Ly5.1 + ) or non-transduced (GFP − Ly5.1 + ) cells in the initial donor mouse. CRU frequencies in the original donor mice were then calculated.
[0048] Determinations were repeated at 6 months post-transplant to verify the long-term repopulating ability of the CRU measured. At this time, secondary assay recipients were sacrificed and donor contributions confirmed by FACS analysis of thymus and bone marrow (BM) and clonal assessment of provirally-marked CRU carried out by Southern blot analysis of proviral integration patterns. Using unsorted cells in the initial transplant allowed to assess contributions to reconstitution of the various hematopoietic compartments in primary and secondary (CRU assay) mice by monitoring for the presence (or absence) of GFP + expression and the donor-specific cell surface marker Ly5.1 thus providing an additional control for documenting Hoxb4 effects. In recipients of Hoxb4infected BM, there were essentially exclusive (>95%) reconstitution of primary mice with transduced cells (evident by high proportion of GFP + progenitors, BM cells, etc.) and of CRU (evident by the presence of GFP + donor-derived cells in CRU assay recipients even at limiting dilution). Together these experiments provide important new data relating to the kinetics and duration of Hoxb4 effects on CRU regeneration and help guide further studies to optimize and extend this effect.
[0049] Estimating the Maximal Expansion (Self-Renewal) Potential of Hoxb4-Transduced CRU by Serial Transplantation Analyses
[0050] In the absence of optimized in vitro conditions for maximal CRU expansion, the in vivo environment was relied upon in order to determine the maximal expansion of a given CRU (Hoxb4-transduced or not). Normal (or neo-transduced) BM CRU can expand by ˜20-fold in vivo following BMT into myeloablated mice. In sharp contrast, Hoxb4-transduced CRU expanded by ˜900-fold under the same conditions. These numbers are derived from mice reconstituted with 10 to 40 CRUs and therefore do not necessarily reflect the expansion per individual CRU, but rather for the whole population of CRU.
[0051] To measure the maximal in vivo expansion of individual Hoxb4-transduced CRU, numerous lethally irradiated recipients were reconstituted with limiting numbers of Hoxb4-transduced CRU. Six months after BMT (long-term reconstitution), recipients of 1 CRU (limit dilution) were sacrificed and CRU expansion measured as described above. CRU determination were performed on 10 different primary recipients of 1 Hoxb4-transduced CRU (expansion of 10 different Hoxb4-transduced CRU were measured). This experiment provides information on the possible heterogeneity of the Hoxb4 effect, if there is ˜equal expansion of each CRU or preferential expansion of a subgroup of cells. These experiments were repeated over the course of at least 3 serial transplantations. Together these studies reveal the self-renewal capacity of individual CRU (monitored by clonal analysis) and provide valuable information about the intriguing possibility that Hoxb4-transduced CRU have an unlimited self-renewal capacity.
[0052] To minimize “dilution effects” 28 as a trivial cause for a decline in CRU number, the transplant dose used for the first and subsequent serial transplants were adjusted to ensure the presence of at least 1 CRU in the bone marrow innoculum (measured by CRU assay) For example, each serial transplant resulting in at least a return to 10% of normal levels represents a net expansion in (Hoxb4-transduced) CRU numbers of 2000-fold (input=1; output=10%×20000 CRU per normal mouse or 2000 CRU).
[0053] Selected secondary (tertiary, etc . . . ) recipients transplanted with one Hoxb4-transduced CRU were followed for extended times post-transplant to verify the long-term repopulating nature of the CRU detected and to assess whether there is any decline in the “quality” of serially transplanted CRU as indicated by decreased levels of lymphoid and/or myeloid reconstitution in these recipients. For all of the experiments described, parallel experiments were also conducted with control-GFP transduced BM cells. In order to draw definitive conclusions on the “quality” of a given CRU, clonal analysis (persistence of proviral integration patterns) were also performed on secondary and tertiary recipients. 15 These experiments provide a unique opportunity to define the potential for (Hoxb4-transduced) HSC expansion and a benchmark for attempts to achieve similar in vitro expansion.
[0054] In vivo Conditioning Requirements for Hoxb4 Effects
[0055] In the setting of total myeloablation, CRU levels rapidly rise during the early transplant period but plateau at normal levels along with full hematopoietic recovery of the recipient. These findings suggest that conditions established during myeloablation may be a requisite for the observed Hoxb4 effects in vivo. To test this, hematopoietic contributions of Hoxb4-GFP were monitored versus normal (transduced and not) BM cells following transplant of untreated or minimally ablated recipients achieved by low dose irradiation. The experimental conditions were modeled after those described by Quesenberry et al. which have shown significant (up to 40%) contributions to hemopoiesis by donor cells transplanted at very high cell numbers (a total of 2×10 8 marrow cells over 5 consecutive days) into untreated recipients or at modest numbers (a single infusion of 10 7 ) into mice receiving low dose sub-lethal irradiation (100 cGy). Rapid cell cycle such as associated with 5-FU treated BM may significantly compromise hematopoietic contributions in non-ablative settings 78 . Moreover, relatively large numbers of cells are required. To circumvent both potential problems, BM was harvested from mice previously transplanted (with Hoxb4transduced cells) under standard ablative conditions 3-4 months earlier and when it was expected they had recovered to normal CRU levels. In initial experiments, 10 7 BM cells from such a Hoxb4 transplant recipient or an equivalent number from unmanipulated normal mice were transplanted into recipients that were untreated, had received minimal irradiation (50 or 100 cGY) or had total myeloablation (900 cGy), and donor engraftment was monitored by sampling peripheral blood for Hoxb4 transduced cells (GFP + ) or normal BM-derived (Ly5.1 + ) cells. Transgenic mice (n=2 lines, backrossed 9 times into C57Bl/6J background) that express Hoxb4 in hematopoietic cells were generated. Whether these mice express the transgene in Sca1 + lin − BM cells and whether the proliferative activity of Hoxb4 on CRU is present in these mice may be evaluated. If so, the Hoxb4 transgenic mice may be used as a source of donor cells.
[0056] Significant hematopoietic contributions by normal cells at these modest transplant cell doses is only expected with partial (100 cGy) or complete ablation. Hoxb4 BM transplantation may have several different outcomes each having interesting interpretations. Results equivalent to that seen for normal marrow argue that the Hoxb4 effect requires stimuli triggered by a degree of myeloablation and regenerative stress. This may be further examined by tests over a broader range of irradiation doses (350 cGy, 600 cGy) to see if increased Hoxb4 BM contributions can be achieved at non lethal irradiation doses. Greater contributions for Hoxb4-overexpressing cells compared to normal controls with minimal ablation (50 and/or 100 cGy) but not in the absence of conditioning would be consistent with a need for moderate stem cell ablation and possibly additional stimuli present with low dose irradiation. Significant Hoxb4 cell contributions in unconditioned host provides novel evidence of the competitive growth advantage of Hoxb4 transduced cells and argues that it can occur under “homeostatic” conditions.
[0057] It is conceivable that in the absence of myeloablation, it may take longer for Hoxb4-transduced cells to “outcompete” or that some additional stress needs to be imposed. This may be explored by prolonged observation and treatment of mice with cytotoxic drugs such as 5-FU. To further test the possibility that growth factors triggered during hematopoietic regeneration play a role in the Hoxb4 effect, the effect of growth factor administration during the early transplant period (first 2 weeks) was tested under all transplant conditions (untreated, low dose and lethal irradiation). Initial candidates included SF and IL-11, based on results from Iscove 28 suggesting that these could enhance regeneration of normal BM and evidence of their potent effects on hematopoietic expansion in vitro. Depending on the lack or presence of effects, additional growth factors were tested e.g., IL-3, FL and TPO. For additional clues to the possible factors involved, mice set up for the kinetic analyses of regeneration were used to monitor, by ELISA assay, serum levels of these candidate growth factors in the early post transplant period. These studies provide important insights into critical determinants of Hoxb4 effects on HSC growth.
[0058] In vitro Expansion of Hoxb4-Overexpressing CRU
[0059] In a pilot study, CRU numbers were measured at >10-fold above input values in cultures initiated with Hoxb4-transduced cells and maintained for 4 days in vitro after viral transduction using conditions described above. This initial data suggests that Hoxb4 has the capacity to induce significant CRU expansion in vitro (if cells are maintained in culture for at least 4 days post-transduction). One major goal of these studies was to determine optimal conditions for Hoxb4enhanced CRU expansion in vitro. Day 4-5-FU BM from C57Bl/6J:Pep3b (Ly5.1 + ) donors were infected with Hoxb4-GFP or GFP retrovirus as mentioned above. Immediately after the infection period GFP + BM cells were isolated by FACS and assayed for clonogenic progenitors, day 12 CFU-S and CRU content. Aliquots were then placed in replicate liquid culture under various conditions and changes in total cellularity, progenitor (CFC and day 12 CFU-S) and CRU content determined at 2 day intervals initially up to a total duration of 14 days. To determine whether accessory cells (macrophages, etc.) are required, parallel experiments were performed with purified GFP + Sca1 + lin − BM cells.
[0060] Experiments were initially conducted with non-sorted cells (mixture of transduced and untransduced cells). The growth of Hoxb4-transduced cells including CRU was compared to the nontransduced cells in the same culture and to the control cultures established with mixtures of GFP and non-transduced cells. Initial conditions chosen were modeled after those shown to support at least modest increases in CRU numbers for normal BM (FL, SF and IL-11 in serum free medium). Additional growth factors were also tested alone and in combination using a factorial design method for optimizing conditions for in vitro expansion of primitive murine and human hematopoietic stem cells. Interesting additional candidate factors tested include thrombopoietin (TPO) based on studies indicating its potential to enhance stem cell recovery in vitro. Confirmation of CRU expansion suggested by net increases in CRU number over input was sought by analysis of proviral marking to detect common patterns in multiple recipients of cells from the same culture to document CRU self-renewal in stromal LTC. If significant CRU expansions was apparent, this effect was further assessed by establishment of replica cultures initiated with individual GFP + Sca1 + lin − BM cells which were then individually monitored for cell division and CRU output at a clonal level.
EXAMPLE II
[0061] These studies were extended for the first time to both in vitro and in vivo models of human hemopoiesis, to evaluate in human hematopoietic cells, the effect of Hoxb4 overexpression on the in vitro and in vivo expansion of primitive long-term repopulating cells assayed in the immuno-deficient (NOD/SCID) mouse model.
[0062] Given the long established methods for efficient genetic manipulation and rigorous quantitative measures of murine HSC, functional studies of Hoxb4 have so far concentrated on murine BM cells. The recent development of assays for primitive human repopulating cells based on the immuno-deficient mouse model and improved conditions for gene transfer to NOD/SCID CRU now present an opportune time to extend investigations directly to human cells. Studies of Hoxa10 overexpression on growth of transduced human cord blood cells both in vitro and in vivo were recently carried out. Key findings include marked increases in “replating” ability of Hoxa10-transduced CFC, increased nucleated cell expansion (with a skew to blast cell production) in serum-free liquid culture and, most strikingly, greatly enhanced myelopoiesis in NOD/SCID mice.
[0063] These findings are remarkably similar to the effects of Hoxa10 overexpression in the murine model and support the hypothesis that Hox gene overexpression could impact on human hematopoietic cell growth, and encourage a direct test of the ability of Hoxb4 to influence primitive human hematopoietic cell growth potential.
[0064] The experiments were modeled from murine studies. High titer viral producers (>5×10 5 ) were generated for the control GFP vector in the PG13 packaging line generated PG13 producers for Hoxb4-GFP virus. Infections of cord blood (CB) cells enriched for CD34 + cells by lineage depletion (using StemSep columns) were carried out using optimized conditions that were established to achieve in excess of 40% gene transfer with the GFP virus to human LTC-IC and at least 10-20% to NOD/SCID CRU. Equivalent gene transfer to CRU from adult BM is possible. Lenti-based vectors were also evaluated and may be employed if their early promise of affording high gene transfer and increased stem cell recovery without prolonged in vitro culture are realized. Possible effects of Hoxb4 overexpression may first be assessed with relatively straightforward in vitro methods. To minimize the scale of experiments involving costly serum free reagents and growth factors, transduced primitive cells may be pre-enriched by FACS isolation of CD34 + CD38 − GFP + cells 1 to 2 days after termination of the infection procedure. Starting clonogenic progenitor content may be assessed using methylcellulose assay and the “replating” capacity of these resulting colonies compared for Hoxb4- and GFP-control transduced cells. The initial LTC-IC content may be assessed by limiting dilution assay and the progenitor output per LTC-IC determined after 6 weeks in culture as another possible measure of a Hoxb4 effect on primitive cell growth.
[0065] Serum-free liquid cultures with selected growth factors may also be established and yield of phenotypically defined subsets (CD34 + CD38 − , total CD34 + , total nucleated cells) monitored over 1 to 2 weeks, as well as output of clonogenic progenitors and LTC-IC. Initial culture conditions chosen may be those previously documented to support significant expansion of both LTC-IC and CRU (FL, SF, IL-3, IL-6 and G-CSF). Additional factors (TPO, etc.) may be tested using factorial design experiments. If positive effects of Hoxb4 are detected with any or all of the above assays, they may be tested directly on expansion of CRU using the limiting dilution assay in NOD/SCID. The low starting frequency of CRU in cord blood (˜6 per 10 5 CD34 + cells, or some 100 fold lower than LTC-IC) dictates considerably larger scale experiments and thus cultures may be initiated with cells recovered after infection of CD34 + lin − CB cells without further enrichment to avoid excessive sorting times. The presence of the GFP marker may enable direct tracking of transduced CRU versus non transduced CRU repopulation in recipient mice. Current optimized conditions support ˜5-10-fold expansion of normal CB NOD/SCID CRU in 1 week serum-free liquid culture conditions. If increases in this are seen following Hoxb4 transduction, the potential duration of expansion and effects of other growth factor combinations and levels may be explored in a manner similar to that outlined for the murine studies.
[0066] The human CRU assay has reached a state of refinement in which it has been possible to additionally demonstrate CRU regeneration in primary NOD/SCID recipients by carrying out a CRU assay in secondary recipients in a manner identical to that employed in the murine system (Sauvageau, G. et al., Genes Dev. 9, 1753-1765, 1995; Thorsteinsdottir, U. et al., Blood. 94(8), 2605-2612, 1999). Accordingly, cord blood transduced with the Hoxb4-GFP retrovirus (or Lentiviral vector when available) may be transplanted into NOD/SCID recipients and 6-8 weeks post-transplant mice sacrificed for measure of CRU numbers using limiting dilution assay in secondary recipients. Levels of regeneration may be compared to those achievable with unmanipulated cord blood and control GFP transduced cord blood. Additionally, whether growth factor administration (SF, IL-3, GM-CSF and Epo 3× wk. for last 2 wks. before sacrifice) during the repopulating phase is either necessary or can enhance Hoxb4 effects may be explored. These studies may be further extended to analysis of CRU expansion from adult sources.
[0067] Together, these studies provide new insights into the potential and conditions for HSC expansion and help to identify and characterize mediators of the Hoxb4 effect and harnessing it through alternative methods to achieve the effect by transient exposure to Hoxb4 (adenoviral or protein based) or drug-inducible expression systems.
EXAMPLE III
Identification of the Minimal Domain(s) of the HOXB4 Protein Necessary to Regulate Expansion of HSCs
[0068] Rat-1 fibroblasts overexpressing Hoxb4 proliferate in low concentrations of serum, show a reduction in G 1 phase of the cell cycle and can form colonies in soft agar (so-called anchorage independent growth). A structure-function study was performed to identify region(s) of the HOXB4 protein that may be important for these effects. The results from these experiments suggest that both the DNA-binding and the PBX-interacting domains of the HOXB4 protein are necessary. The NH 2 -terminal region of the protein seemed, however, dispensable for the effect of Hoxb4 on Rat-1 cells.
[0069] Preliminary experiments performed with BM cells indicate that the NH 2 -terminal region of Hoxb4 is required for the enhanced expansion in Hoxb4-transduced primitive bone marrow cells. This suggests that Hoxb4induced proliferation of certain types of hematopoietic cells may involve the NH 2 -terminal region of Hoxb4 in addition to the DNA-binding homeodomain and the PBX-interaction motif.
[0070] Construction of Mutants
[0071] The experimental procedures for these studies parallel those described above (retroviral gene transfer to primary bone marrow cells). The Hoxb4 mutants may be overexpressed in mouse bone marrow (BM) cells and quantification of the effects produced by these mutant forms may be measured using the CRU assay. The “CRU-expanding activity” of the N-terminal deletion mutant was tested and compared to that of full-length Hoxb4. The results from this experiment (n=2 mice only) clearly indicated that CRU numbers were increased to pre-transplantation levels for Hoxb4-transduced cells whereas CRU numbers were similar to neo-controls (reduced by ˜30-fold) in recipients of bone marrow cells transduced with the N-terminal deletion mutant (domain C to F mutant of Hoxb4). This clearly indicated that this N-terminal domain is necessary for the proliferative activity of Hoxb4 on HSC.
[0072] In order to define the minimal “active” region in the N-terminal domain of Hoxb4, we sought for conserved subdomains within this region were sought for by comparing the amino acid sequence between insect Hoxb4 (Deformed, Dfd) to that of the other Hox gene products of the 4 th paralog derived from various species (Hoxa4, Hoxd4 and Hoxc4). 2 domains were identified (A and B). Domain A (amino acid 3 to 23 of Hoxb4) contains 20 highly conserved (from insect to human) amino acids which include two conserved tyrosine residues that are flanked by acidic residues, suggesting that these motives may represent substrates for tyrosine-related kinases. Domain B is poorly conserved but contains a proline stretch and several potential serine/theronine residues, one of which is a consensus site for casein kinase II (CKII), a kinase recently shown to associate and modulate the function of insect Hox proteins.
[0073] Hoxb4 mutants lacking domain A alone or domain B alone (A+C+D+E+F) were generated and tested as indicated above. In addition, 3 point mutants which include the two tyrosine residues in domain A and the site for CKII in domain B were generated and tested at the same time because the readout for these experiments (CRU assay) was too long. Prior to making these tyrosine “mutants” (Y>F), whether any of the tyrosine residues in Hoxb4 are phosphorylated in vivo were evaluated. To do this, the anti-phosphotyrosine 4G10 antibody was used on HOXB4 protein immuno-precipitated from different hematopoietic cell lines (K562 and FDC-P1 cells) and in Rat-1 cells engineered to overexpress Hoxb4. Finally, a mutant lacking the proline-rich region (amino acid # 61 to 79) was constructed and tested.
[0074] Prior to bone marrow transduction experiments, each mutant was tested in Rat-1 fibroblast in order to determine whether a nuclear protein of the expected size is produced using western blot analysis. If not, a nuclear localization sequence (NLS) derived from c-myc was added. An antibody to both the N-terminal and C-terminal domains of Hoxb4 (VA Medical Center, USF, Calif.) was used to detect HOXB4 proteins in Rat-1 cells.
[0075] Once the minimal domain(s) of Hoxb4 that are required for CRU expansion are know, Hoxb4-interacting proteins may be isolated by using a yeast-two-hybrid screen. Alternatively, depending on the results obtained (the serine mutant for CKII binding is dysfunctional), the importance of candidate protein partners may be tested (CKII in this example).
EXAMPLE IV
Identification of Effectors of Hoxb4-Induced Proliferative Effects
[0076] This example uses an approach similar to a yeast-two-hybrid screen to isolate a novel interacting partner to PBX1 from a cDNA library prepared from human fetal liver cells at a time of active hemopoiesis to isolate Hoxb4-interacting protein(s) to identify proteins that specifically interact with Hoxb4.
[0077] Preliminary studies with various Hoxb4 mutant constructs have suggested that both the DNA-binding and Pbx-interaction motives of Hoxb4 are required for its proliferative activity on Rat-1 fibroblasts and day 12 CFU-S cells (and thus likely on CRU). The N-terminal domain of the protein is also required for its activity in primary bone marrow cells (d12 CFU-S and CRU). Since PBX1 (a Hoxb4 DNA-binding co-factor) interacts with the conserved hexapeptide and homeodomain and since primitive bone marrow cells express PBXL (also PBX2 and 3), a screen for Hoxb4-interacting proteins could exclude these 2 domains (high likelihood of picking up PBX which has been shown to interact with other Hox proteins in yeast-two-hybrid screens and which appears to be required for the proliferative activity of Hoxb4 on Rat-1 cells).
[0078] The specific requirement of the N-terminal domain of Hoxb4 for the proliferation of hematopoietic cells (but not for Rat-1 fibroblasts) suggests the presence of a unique co-factor in hematopoietic cells. The goal of this example is to isolate a protein partner to this N-terminal region of Hoxb4.
[0079] Yeast-two-hybrid systems are based on the “conditional expression of a nutritional reporter gene (HIS3 or LacZ) to screen large numbers of yeast transformed with a specially constructed fusion library for interacting proteins”. This conditional expression of reporter genes is induced by the in vivo reconstitution of a functional Gal4 transcription factor resulting from the interaction between two fusion proteins (one which contains the DNA-binding domain (DBD) and, the other, the activation domain (AD) of Gal4). In this case, a fusion protein between Hoxb4 (specific subdomains of the N-terminal region depending on the results of the previous section) and the DBD of Gal4 (Hoxb4-Gal4 DBD would be used to screen for a Hoxb4-interacting protein fused as an expression library to the AD domain of Gal4.
[0080] Once a partner to Hoxb4 is identified, its capacity to specifically interact with Hoxb4 may be demonstrated. To this end, this new protein may be tagged (HA, MYC and FLAG tags and antibodies are currently in our possession) and co-immunoprecipitation studies and mammalian two hybrids may be performed to determine whether this protein is part of a protein complex with Hoxb4.
[0081] cDNA Library
[0082] The Matchmaker Gal4 two-hybrid system III (Clontech) may be used. A series of expression libraries fused to the cDNA encoding the activation domain of Gal4 (herein called “library protein AD”) are commercially available. A library made from E14.5dpc mouse fetal liver may be used because fetal livers of that age contain significant numbers of HSC.
[0083] To Engineer a Functional TAT-HOXB4 Protein and Test the Incorporation and Persistence (Half-Life) of This Protein in Primitive Hematopoietic Cells
[0084] Using the PTAT-HA plasmid developed by Nagahara et al. (1998), we will subclone a full-length Hoxb4 cDNA in frame and downstream to the His6-TAT-HA tag. The protein will be produced in bacteria and purified exactly as described by Nagahara (1998).
[0085] The specificity of interaction between Hoxb4 and the identified partner(s) may be tested using standard co-immunoprecipitation assays and mammalian two hybrid system. Direct interaction between the 2 proteins may then be determined using classical pull down experiments. Whether this partner alters the DNA-binding specificity of the Hoxb4 (or Hoxb4-PBX)may also be investigated using EMSA studies. Finally, the involvement of this protein in mediating the proliferative effect of Hoxb4 on CRU may be tested using functional biological studies (retroviral gene transfer, knock out, etc. . .).
EXAMPLE V
Approaches to Achieve Enhanced HSC Expansion Based on Transient Exposure to Hoxb4
[0086] The effect of Hoxb4 on CRU expansion appears to occur very early (days) after retroviral gene transfer. Transient (approx. 1-2 wk.) gene transfer into primitive bone marrow cells can be achieved with high efficiency using adenoviral vectors and possibly with TAT-fusion proteins which allow the direct uptake of extracellular proteins into most cell types tested to date (including HSC). HSC which transiently express Hoxb4 (by either adenoviral gene transfer or by exposure to TAT-HOXB4 fusion protein) may benefit from the same repopulation advantage observed with HSC engineered by retroviral gene transfer to overexpress Hoxb4. This experiment tests the feasibility of this approach using the HOXB4 protein as a stem cell expanding factor.
[0087] Transient Expression of Hoxb4 in Primitive Bone Marrow Cells Using Adenoviral Gene Transfer
[0088] Conditions for high efficiency adenoviral gene transfer to primitive bone marrow cells have recently been defined. Hoxb4 adenoviral vectors may be produced to effect adenoviral gene transfer to primitive mouse and human bone marrow cells using a high titer adenovirus encoding the bacterial β-galactosidase gene. If quiescent freshly isolated Sca1 + Lin − bone marrow cells can not be infected with this β-galactosidase virus (MOI of 200), an infection efficiency of 45-60% of the same cells exposed for 2-3 days to IL-3 (6 ng/ml), IL-6 (10 ng/ml) and steel (100 ng/ml) may be obtained.
[0089] Transduction of Proteins into Mammalian Cells
[0090] It was surprisingly discovered that most of the Hoxb4 stem cell expanding effect was present at 2 weeks post transplantation (and possibly earlier). It was also surprisingly discovered that TAT-HOXB4 protein delivery to stem cells could be done in vitro before bone marrow transplantation and also in viva during the early phase of reconstitution if required.
[0091] Use of TAT-GFP and TAT-Hoxb4 to Determine Whether Primitive Mouse and Human Bone Marrow (BM) Cells Have the Capacity to Uptake TAT-Fusion Proteins
[0092] TAT-GFP and TAT-HOXB4 proteins were generated and purified. Results show that these proteins are readily incorporated in a dose-dependent manner into Ba/F3 cells with maximal uptake at 60 minutes.
[0093] The following experiment determines whether primitive BM cells (Sca1 + Lin − ) can also uptake these proteins. This may be measured using FACS analysis. The intensity of protein uptake in Sca1 + Lin − cells may be compared to that of mature mononuclear (lin + ) BM cells. Similarly, primitive human BM cells (CD34 + CD38 − and CD34 − Lin − ) may be tested for their capacity to incorporate TAT-GFP and TAT-Hoxb4. The concentration of TAT-proteins to be tested may vary between 10 to 500 nM as reported by Nagahara et al. (1998).
[0094] Once studies with TAT-GFP and TAT-Hoxb4 are optimized (protein transfer to primitive bone marrow cells), the internalized TAT-HOXB4 protein as being localized in the nucleus and functional may be demonstrated.
[0095] Once optimal conditions are defined with TAT-Hoxb4-FITC, cells may be exposed to non-FITC HOXB4 (TAT- or not) proteins and western blot analysis may be done on cellular extracts (both nuclear and cytoplasmic) at various time points in order to estimate the half-life of the incorporated proteins. The protein levels obtained may be compared to those normally achieved with cells transduced with “Hoxb4 expressing retrovirus”, to adjust the dose of protein necessary to mimic the effect observed with cells engineered to overexpress Hoxb4 using retroviral gene transfer. With these data, the functional capacity of this HOXB4 protein may be tested.
[0096] As mentioned above, the HOXB4 protein may have the inherent capacity to penetrate through the cytoplasmic membrane. This may obviate the need for the TAT fusion peptide. In a parallel experiment, a His-tag HOXB4 protein may be produced (without a TAT). For these, the PET24 vector may be used. Briefly, Hoxb4 cDNA may be subcloned in frame with the His-tag in PET24 using standard procedures. Once subcloning is finished (in DH5), the plasmid is then transferred in BL21 bacteria for protein production. The recombinant protein is then purified such as on a nickel column.
[0097] Biological Activity of the Fusion TAT-Hoxb4 or the HOXB4 Protein Using a Quick Screening in vitro Culture System Where Hoxb4 Was Previously Reported to Exert a 200-500 Fold Effect in less than 7 Days (Delta CFU-S Assay)
[0098] The biological activity of the recombinant (TAT-HOXB4 or His-HOXB4) proteins may be tested first using a surrogate assay, the delta CFU-S assay, as described previously. In this assay, it is possible to directly test in 19 days (7 days of in vitro culture+12 days of in vivo assay) whether a protein is functional. In these experiments, cells may be exposed during the 7 day culture to a concentration of TAT-HOXB4 protein which allows equal or higher levels of intracellular Hoxb4 molecules than achieved with retroviral gene transfer.
[0099] Capacity of TAT-HOXB4 Protein to Induce Expansion of Mouse and Human HSC
[0100] In the event that CFU-S expansion is achieved with the recombinant HOXB4 proteins, CRU expansion may be tested. In these experiments, the TAT-HOXB4 or the His-HOXB4 recombinant protein may be added to cultures of mouse bone marrow (BM) cells exposed 4 days earlier to 150 mg/kg of 5-FU (in vivo) and prestimulated in vitro for 2 days in the presence of growth factors (IL-3, IL-6 and steel) as mentioned above for retrovirally-transduced cells. The cells may then be exposed to “optimal” concentrations of the TAT-HOXB4 protein during 4 days in medium which includes the growth factors mentioned above. Longer periods of exposure to HOXB4 protein may also be obtained by in vivo administration of the protein (TAT-HOXB4) as recently described by Schwarze et al. (Schwarze, S. R. et al., Science 285, 1569-1572. 1999).
[0101] Once optimization is achieved with mouse bone marrow cells, these experiments may be repeated with human (cord blood CD34 + lin − CD38 − ) cells that are injected into NOD/SCID mice at limiting dilution to measure CRU.
[0102] This experiment used adenoviral gene transfer and direct protein delivery to test the possibility that Hoxb4 or TAT-Hoxb4 represents a genuine stem cell expanding factor.
EXAMPLE VI
[0103] Development of a Dominant, Drug-Inducible System for Hoxb4 Enhanced HSC Expansion
[0104] Hox proteins are highly modular with well-recognized DNA-binding homeodomain (HD) and PBX-interacting hexapeptide flanking this HD. The Hox-PBX-DNA interaction was recently solved by crystallography where it was shown that the N-terminal region of Hox proteins is dispensable for DNA-binding activity. Using principles extensively exploited in the mammalian two hybrid system, a Hoxb4 DNA-binding domain (mutant C-F) and Hoxb4 N-terminal domain (mutant A+B) were expressed, each linked to the FK506 binding protein (FKBP12) in mouse primary bone marrow cells. These hybrid proteins thereafter called [FKBP-Hoxb4 C−F] and [FKBP-Hoxb4 A+B] respectively, can undergo in vivo dimerization via the intracellular “dimerizing” agent FK1012 to generate a functional HOXB4 protein.
[0105] FKBP12 as a Dimerization Partner
[0106] The most studied system for inducible heterologous dimerization of fusion proteins is the rapamycin FKBP-FRAP (FKBP-rapamycin binding protein). In this system solved by crystallography, the immunosuppressant rapamycin binds to both FKBP and FRAP fusion proteins thereby reconstituting a functional protein. This has been tested with numerous fusion proteins and shown to be very effective. However, in contrast to FK506, rapamycin was shown to be an effective inhibitor of cell cycle progression. However, this property is incompatible since Hoxb4 induces expansion and thus proliferation of CRU. Recent studies have reported a new rapamycin derivative which still effectively binds to FKBP12 but with very little antiproliferative and immunosuppressive activity. 108 Other versions of rapamycin with similar properties may also be used.
[0107] Another well described system may be used, the FK1012-FKBP. FK1012, a dimeric form of FK506, efficiently dimerizes FKBP12 and does not alter cellular proliferation (Clackson, T. et al., Proc Natl Acad Sci USA. 95, 10437-10442, 1998) This system (FKBP12 plasmids and FK1012 analog AP20187)has been used to reconstitute, in a dose-dependent fashion, the activity of transcription factors including GAL4 (DBD)-VP16 (transactivation domain) heterologous transcription factor on a reporter system using skin keratinocytes and fibroblasts. The synthetic AP20187 compound is more potent than FK1012 and is very similar to AP1903.
[0108] Use of Retroviral Vectors to Express both [FKBP12-Hoxb4 A+B] and [FKBP12-Hoxb4 C−F] Products
[0109] The structure-function studies performed with Hoxb4 clearly showed that the complementary N- and C-terminal mutants of Hoxb4 are dysfunctional (no expansion of d12 CFU-S). A functional HOXB4 protein may be reconstituted in vivo using retroviral gene transfer and the FKBP-Hoxb4 fusion constructs mentioned in the previous paragraph. For these studies, [FKBP-Hoxb4 C−F] and [FKBP-Hoxb4 A+B] cDNAs may be introduced downstream to the retroviral LTR thus generating 2 different retroviruses with 2 distinct markers for selection (GFP and YFP for [FKBP-Hoxb4 C−F] and [FKBP-Hoxb4 A+B], respectively). Following retroviral gene transfer, transduced bone marrow cells may be sorted based on GFP and YFP expression and tested, in the presence of AP20187, to induce CRU expansion. Cells transduced with each retrovirus alone and the combination of both may be tested in parallel experiments. With VSV virus, “double-gene transfer” to mouse BM cells may be obtained in the range of 50%. After sorting, the cells may be tested first for CFU-S activity and, if functional, in CRU assays as described above. These experiments generate a drug-inducible system to build a model for dominant clonal selection of transduced HSC.
[0110] Before functionally testing the reconstituted Hoxb4 partners in vivo, whether the 2 proteins dimerize in the presence of AP20187 (in hematopoietic cells lines) may be tested by electromobility gel shift (EMSA). This may be done by incubating the cellular lysates (from cells treated or not with AP20187) with an antibody specific to the N-terminal (non DNA-binding) domain. The presence of a supershifted large complex would be the signature for hetero-dimerization between the carboxy (domains C−F) and the amino-terminal (domains A+B) region of Hoxb4.
[0111] There is a potential problem for homodimers to functionally interfere with the reconstituted full-length (heterodimerized) Hoxb4. Co-expression of deletion mutants together with (full-length) Hoxb4 may be tested to ensure that none of the mutants behaves as a competitor (dominant negative). Interference of homodimers of dysfunctional domains of Hoxb4 with the function of full-length Hoxb4 is not expected since (i) in preliminary short-term reconstitution experiments, detrimental effects on hematopoietic reconstitution were not seen with any of the (monomeric) deletion mutants (integrated proviruses were easily detected by Southern blot analysis in BM, spleen and thymus of primary recipients) and (ii) Hoxb4 does not homodimerize and cannot bind DNA as a homodimer. However, if one of these mutants (as a homo-dimer or a monomer) is problematic, different complementary mutants may be sought (which do not have dominant negative effects either as monomer of homodimers) The choice of these new complementary mutants may be based on the results of the (structure/function)studies mentioned above. Using the retrovirus, the relative expression levels of each mutant may also be changed (under a ribosomal reentry site or not). This may minimize the presence of deleterious homodimers and force the formation of heterodimers. Alternatively, if the formation of homodimers remain functionally problematic, the modified rapamycin system may be used.
[0112] Use of Retroviral Vectors to Express [FKBP12-Hoxb4 A+B] and Direct Protein Delivery of [TAT-FKBP12-Hoxb4 C−F] to Selectively Expand Retrovirally-Transduced HSC
[0113] In this experiment, retrovirally transduced HSC (which contain only one of the FKBP-Hoxb4 mutant) are exposed transiently to the complementary FKPB-Hoxb4 mutant through either direct protein delivery (TAT-fusion) or through adenoviral gene transfer.
[0114] This represents a dominant clonal selection system for HSC transduced with a retrovirus containing a dysfunctional Hoxb4 which should give a very significant (up to 55-fold under current conditions) expansion of retrovirally transduced stem cells. With this system, a retroviral gene transfer efficiency of 5% to primitive BM cells (as can be achieved with human BM cells) may translate to ˜75% of the reconstitution originating from retrovirally-transduced cells. In addition to obvious clinical possibilities, this system also represents an important tool to refine our understanding of the biology of Hoxb4 expressing HSC. The recent description of in vivo delivery of TAT proteins combined with the possibility of injecting FK1012 analogs to mice further increases the possibility to manipulate retrovirally-transduced HSC.
[0115] The above-mentioned examples improve our understanding of the molecular mechanisms utilized by the HOXB4 protein in order to expand HSC in a transplantation context in view of developing tools to manipulate the in vivo and in vitro expansion of these cells. Ultimately, these studies help identify partners and point to targets to Hoxb4. In addition, the findings derived from these studies help understand the normal mechanisms involved in the regulation of mouse and human HSC. Finally, the above examples clearly indicate that the so-called “Hoxb4 effect” occurs very early after viral transduction, which may lead to clinical studies where Hoxb4 (or downstream effectors) could ultimately be utilized as a stem cell expanding (growth) factor.
[0116] While the invention has been described in connection with specific embodiments thereof, it were understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth, and as follows in the scope of the appended claims. | The present invention relates to a hematopoietic stem cell expansion factor, and to a method for enhancing hematopoietic stem cell expansion by direct delivery of a protein in the cell. The method comprises directly delivering in a HSC an amino acid sequence having the activity of a peptide encoded by a Hoxb4 nucleotide sequence. Once delivered, the amino acid sequence is functionally active in the hematopoietic stem cell and enhances expansion thereof. The amino acid sequence may consist of a HOXB4 peptide. | 2 |
RELATED APPLICATION
This application claims the priority and benefits of Swedish patent application No. 0800008-5, filed on 2 Jan. 2008, whose entire technical content is incorporated here as a reference.
TECHNICAL FIELD
The present invention concerns a device for use in sewing, especially a thread removal tool, i.e., a remover of loose thread pieces, “thread tails”, thread ends and thread fragments.
BACKGROUND
After one has stitched a seam in a cloth or a fabric and then has unstitched the seam, e.g., when the seam was defective in some way or because the seam was only needed during a preliminary stage of the sewing of an article of clothing, thread tails will remain in the fabric. Of course, these must be removed. But it is often difficult and time-consuming to remove such thread tails with one's fingers.
DESCRIPTION OF THE INVENTION
One aim of the invention is to specify an effective remover to get rid of the thread pieces and remnants, e.g., after ripping a stitch open.
One thread remover for help in removal of thread ends and the like, such as after ripping open a stitch, contains a thread removal head which is designed to take hold of or become attached to the loose thread pieces when the thread remover is moved along the surface of a textile item, a piece of cloth, or the like, so that the surface of the thread removal head is in contact with the surface of the textile item or piece of cloth. The engaging with the surface shall be such that the thread removal head itself is not attached to the textile item, piece of cloth, or the like. In particular, the thread removal head can have a geometrical shape adapted to this purpose and/or be made of a material specially chosen for this purpose. The thread removal head can have a geometrical shape with a surface having prominences or irregularities and inner regions lying within these, which can help in the grasping of the thread pieces. The irregularities can be, for example, grooves or bumps. Alternatively, or at the same time as such a configuration, the thread removal head can be made of a material such as a plastic material, which can somehow attach to thread ends without the thread sticking or adhering to the head or, on the other hand, without the thread removal head sticking or attaching to the cloth.
A thread remover of this kind makes it quick and easy to remove the thread pieces, e.g., after ripping open a seam already stitched.
The thread remover can comprise a shaft, at whose first end is situated a thread removal head. The other opposite end can have a pointed shape for removal of certain more firmly anchored thread tails or to lead the cloth along during the stitching instead of a person having to have their fingers in proximity to the needle when he or she is sewing at the machine. This can be used, for example, when sewing patchwork quilts, where it is often necessary to sew rather small pieces of cloth and short stretches, and the person doing the sewing must be especially careful not to injure their fingers.
The thread remover can be used both in the home and the factory.
In addition or instead, there can be a tool at the other end of the shaft, such as an unstitching tool. The unstitcher can be protected by a protective cap designed with a pointed end to be used in the same way as the second end with pointed shape per the above.
FIGURE DESCRIPTION
The invention shall now be described as a nonlimiting sample embodiment with regard to the enclosed drawings, where:
FIG. 1 is a picture of a thread remover in a basic design with totally level or flat thread removal head,
FIG. 2 is a picture similar to FIG. 1 of a thread remover with a thread removal head having bumps,
FIG. 3 is a picture similar to FIG. 1 of a thread remover with a flattened thread removal head,
FIG. 4 is a picture similar to FIG. 1 of a thread remover with a thread removal head having grooves and with an unstitching tool that can be protected by a removable cap,
FIG. 5 is a picture similar to FIG. 1 but with a removable cap with pointed end,
FIG. 6 is a picture of a thread remover similar to FIGS. 4 and 5 but without cap and having a thread removal head with slanted grooves,
FIG. 7 is a picture similar to FIG. 6 but with a thread removal head having bumps,
FIG. 8 is a picture similar to FIG. 6 but with a thread removal head having lengthwise grooves,
FIG. 9 is a picture similar to FIG. 6 but with a thread removal head having two groups of slanted grooves,
FIG. 10 is a side view of one practical embodiment of a thread remover,
FIG. 11 is a schematic picture of a thread remover with rotatable, motor-driven thread removal head,
FIG. 12 is a picture of a thread remover with a thread removal head designed to be firmly attached to a protective cap, and
FIGS. 13 a , 13 b and 13 c are side views of a thread remover designed as a set of various parts.
DETAILED DESCRIPTION
FIG. 1 shows a thread remover. It contains, as its basic parts, a shaft 1 and a thread removal head 3 . The thread removal head is situated at one end of the shaft and in the embodiment shown it has a generally round shape or a shape with rotational symmetry and in particular the shape of an ellipsoid, whose main axis, also being the major axis of the corresponding ellipse, also lies on the axis of the shaft. Thus, the axis of the rotationally symmetrical shape coincides with the lengthwise axis of the shaft. The mathematical ratio between the minor axis and the major axis of said ellipsoid can be in the range of 1:1 to 1:3 and especially around 1:2. The shaft 1 can be designed as a round stick with diameter somewhat less than the minor axis of the ellipse, so that the thread removal head juts out from the shaft, viewed in the lengthwise direction of the shaft.
The thread removal head 3 can be made of a material which can “take hold of” or attach to loose thread ends and thread fragments without them becoming firmly stuck to the surface of the thread removal head and without the thread removal head becoming firmly stuck to the cloth. Such material can be a polymer or elastomer. For example, plastics of brand TP/U (thermoplastic of polyurethane type) or TP/E (thermoplastic of elastomer type) or general high-friction plastics can be used. Alternatively, only the surface layer of the thread removal head 3 need be made of such material.
In the embodiment per FIG. 1 , the thread removal head 3 has a totally flat or totally level surface. Alternatively, the surface can be provided with irregularities, as shown in FIGS. 2 and 4 - 9 . Such irregularities can make it easier for the thread removal head to make direct contact with the thread ends and also give the thread removal head a larger total surface area and thus larger working surface for the material in the thread removal head in the case when it is made from a material that “grips”, as above. For example, the surface can be configured as a bumpy surface, see FIGS. 2 and 7 , or as a grooved surface, see FIGS. 4 , 5 , 6 , 8 and 9 . The bumps 5 , the space between them, the grooves or slots 7 and the space between them can have adapted characteristic dimensions, typically being in the range of 1-5 mm. The grooves or slots as shown in FIGS. 4 and 5 can lie in the circumferential direction about the common lengthwise axis of the shaft 1 and thread removal head 3 , i.e., each groove or slot will lie in a plan perpendicular to the lengthwise axis. The grooves can also have a different orientation, such as in the lengthwise direction of the shaft 1 , i.e., strictly speaking, lying in a plane passing through the lengthwise axis of the shaft, see FIG. 8 , or they can also extend in helical manner over the thread removal head's surface with a suitable pitch angle, e.g., in the range between 45° and 60°, in relation to the lengthwise axis of the shaft, see FIG. 6 . The grooves per FIGS. 4 and 5 can then be said to have a pitch angle of and the grooves per FIG. 8 a pitch angle of 90°. There can also be two groups of grooves 7 ′, 7 ″, see FIG. 9 , so that grooves within each group extend basically parallel to each other and the grooves in one group make an angle, e.g., in the range between 75° and 105°, such as 90°, with the grooves of the other group. The thread removal head 3 can then have a diamond pattern of prominences with general rhomboid profile, which can correspond to bumps with, for example, an essentially square shape.
The end of the shaft 1 not carrying the thread removal head 3 can be shaped as a point 9 , which can have a somewhat blunt outer end, see FIGS. 1 , 2 and 3 . The pointed part has basically the shape of a circular pyramid or cone. Such a tip can be used, for example, when not completely cut through thread ends have to be removed or when guiding and feeding cloth to a sewing machine head while sewing.
One practical embodiment is shown in FIG. 10 . The thread removal head 3 has peripherally running grooves and slots 7 , i.e., grooves and slots having a pitch angle of 0° per the above. The thread removal head's total length can be around 140 mm here, while the shaft part 1 has a diameter of 12 mm and the thread removal head 3 has a length of 35 mm and a maximum diameter of 21 mm. The number of slots 7 here is seven with a mutual spacing of around 5 mm, but of course a different number and spacing than that described can be used. Also, thread removal heads with substantially larger maximum diameter can often be suitable, e.g., with a maximum diameter around 30-35 mm.
When the thread removal head 3 has a basically rotationally symmetrical shape, as shown in, e.g., FIG. 1-2 , a motor 17 can be arranged to rotate the thread removal head, see FIG. 11 . The motor can then drive at relatively low speed about an axle 19 , on which the thread removal head 3 is mounted. The motor is energised from a dry cell or battery 21 , which is placed along with the motor 17 inside the shaft 1 .
In the alternative configuration of thread removal head 3 shown in FIG. 3 , it is not rotationally symmetrical but instead flattened and can have basically the shape of a somewhat elongated rectangular block terminating in a pointed edge 11 . A cross section of the thread removal head in a plane through the lengthwise axis of the shaft 1 then corresponds to a rectangle, adjoined at one end by a triangle, i.e., one side of the triangle coincides with one side of the rectangle. For example, the triangle can be equilateral and then its base side can coincide with one side of the rectangle.
The end of the shaft 1 where the thread removal head 3 is not situated can alternatively be configured with some tool which can be used for unstitching. Thus, it is shown in FIGS. 4-9 that the other end of the shaft 1 bears a conventional unstitching tool (having a knife) 13 , which can be concealed by a protective cap 15 . The protective cap can have a point in the same way for the shaft itself per FIG. 1-3 , as shown in FIG. 5 , for example, in order to remove stubborn thread ends and guide the cloth per above. The protective cap 15 can be shaped such that when secured to the shaft 1 it constitutes an extension of the shaft itself.
The thread removal head 3 can also itself sit on the protective cap 15 , see FIG. 12 , while the shaft 1 is a self-standing unit, at whose first end a tool such as an unstitching tool 13 can be found, while its other opposite end can be shaped as a point 9 per the above. The unstitching tool can, as above, be concealed by the protective cap with thread removal head when this is placed at the first end of the shaft and be freely exposed when the protective cap is placed at the other end.
Moreover, it is possible to fashion the thread removal tool as a set of various parts, which can be put together and taken apart so that one can work as effectively as possible with the tool in every given situation. As is shown in FIGS. 13 a - 13 c , the thread removal head 3 is a loose part having a projecting part or dowel 23 . The dowel can be introduced into a corresponding cavity 25 in the entire end of the protective cap 15 and in one end of the shaft 1 , so that the thread removal head is constantly present on the respective part. The shaft at its other end can have an unstitching tool 13 . Instead of the thread removal head 3 , a pointed part 9 ′ or a thicker terminating part 9 ″ with similar dowel 23 is removably fastened to the protective cap or shaft. If the thread removal head is then placed on the protective cap 15 and the terminating part 9 ″ on the shaft 1 , one obtains a tool per FIG. 12 . If, instead, the thread removal head 3 is placed on the shaft 1 and the pointed part 9 ′ on the protective cap, one obtains a tool per FIG. 5 . The dowel 23 and cavities 25 are fashioned for a firm and constant connection, such as a snap connection or a bayonet connection.
We have described above a thread removal tool comprising combinations of a thread removal head and a shaft and in some cases a protective cap, with various configurations of thread removal head and shaft and protective cap. However, the invention will not be limited to these, but rather a person skilled in the art will see that many other combinations of configurations of and with different parts can easily be produced and therefore come within the scope of the invention. | A thread removal tool for getting rid of loose thread pieces, thread ends, etc. from textiles, fabric, cloth and the like, for example, after ripping open a previously produced seam, contains a thread removal head ( 3 ). The thread removal head can be located at one end of a shaft or a handle part ( 1 ) and is configured to take hold of loose thread pieces or thread fragments, without itself becoming attached to an underlying textile item, a piece of cloth or the like. The thread removal head can have an uneven surface, e.g., contain bumps ( 5 ), to grasp loose thread pieces and thread fragments. Furthermore, or alternatively, it can be made of or have a surface layer made of a material which has a certain sticking or fastening action on such loose thread pieces and thread fragments. | 3 |
BACKGROUND OF THE INVENTION
The invention relates to a stereo receiver circuit for progressing a multiplex signal comprising a pilot signal by means of a pilot signal detector which detects frequency components in the multiplex signal at the frequency of the pilot signal and which controls a Schmitt trigger for influencing the mono/stereo operation, said circuit also comprising a control circuit capturing the noise components in the multiplex signal and acting on the Schmitt trigger.
Such a circuit, which is essentially known from DE-AS No. 27 53 199 may be used in an FM stereo radio receiver but also in a television receiver which can receive stereophonic audio signals, for example, in accordance with the U.S. standard.
At small reception field strengths the output signal of the pilot signal detector is subject to fluctuations due to the noise which is superimposed on the multiplex signal, which fluctuations may lead to a constant switching between mono and stereo operation and to flickering of a stereo indicator coupled to the output of the Schmitt trigger. To avoid these disturbing effects, a control circuit is arranged in the known stereo receiver, which circuit captures the noise components in the multiplex signal and which controls the threshold value and the hysteresis of the Schmitt trigger accordingly. A Schmitt trigger is herein understood to mean a switching amplifier with hysteresis, i.e. a circuit which may assume two switching states, dependent on the input signal, the transition from one state to the other being effected at a different level of the input signal than the transition in the opposite direction. In the known circuit the pilot signal detector comprises a bandpass filter tuned to the frequency of the pilot signal and succeeding a rectifier. The voltage at the rectifier output fluctuates to a proportionally small extent at small field strengths so that the constant switching of the Schmitt trigger can be substantially suppressed by causing the switching threshold and the hysteresis to follow.
In a pilot signal detector in which the output signal fluctuates to a consirderably stronger extent than in the known pilot signal detector, the known circuit principle cannot be used. For example, pilot signal detectors cooperating with a PLL circuit can supply output signals which may be both clearly above and clearly below the output level which is obtained in the case of undisturbed stereo reception.
It is an object of the invention to provide a circuit of the type desribed in the opening paragraph in which switching of the Schmitt trigger is substantially prevented, even at a strongly fluctuating output signal of the pilot signal detector.
SUMMARY OF THE INVENTION
According of the invention this object is solved in that the control circuit is only active in mono operation and influences the input signal of the Schmitt trigger in the case of reception of sufficiently strong noise components to such an extent that said Schmitt trigger remains in its switching state for mono operation.
According to the invention the control circuit is only active in mono operation. In the case of strong mono transmitter signals the noise components in the multiplex signal are so weak that the control circuit cannot influence the input signal of the Schmitt trigger. In the case of a decreasing level of the received mono transmitter signals the noise components will be stronger--also those in the frequency range of the pilot signal--but the control circuit then influences the input signal of the Schmitt trigger in such a way that it remains in its mono operating state. When receiving a strong stereo transmitter signal the control circuit is inoperative and the output level of the pilot signal detector is sufficiently large to switch the Schmitt trigger to the stereo operating state. If the level of this transmitter decreases, the fluctuations of the output signal of the pilot detector increase in response to the noise until they come below a minimum value and the Schmitt trigger reaches the mono-operating state. This switching state activates the control circuit and the noise components, which are then sufficiently strong, cause the control circuit to maintain the Schmitt trigger in its mono-operating switching state.
BRIEF DESCRIPTION OF THE DRAWING
The invention will now be described in greater detail with reference to the accompanying drawing showing the block-schematic diagram of a part of the stereo decoder of a stereo receiver.
DETAILED DESCRIPTION OF THE INVENTION
A multiplex signal in the case of stereo operation and an audio signal in the case of mono operation, possibly accompanied by noise components, are present at an input terminal 1 which is arranged in a signal path in which the input terminal is preceded by an RF input circuit, an IF stage and an FM demodulator (all these components not shown). This signal is applied to various stages of the stereo decoder.
The signal at the input 1 is compared with a signal originated from a voltage-controlled oscillator 4 in a phase comparison circuit 2, which supplies an output signal which is proportional to the product of its input signals. The oscillator 4 oscillates at the n-fold value of the pilot signal frequency, preferably at its four-fold value; therefore the output signal is applied to a further input of the phase comparison circuit 2 via a frequency divider 3 which divides the frequency of this signal by the factor n. The compensation signal of the phase comparator is applied to the voltage-controlled oscillator 4 via a low-pass filter 5. If the signal at the input 1 comprises a pilot signal, the PLL circuit (2 . . . 5) thus formed will lock in at the frequency of the pilot signal, with a phase shift of 90° existing between the output signal of the frequency divider 3, which signal is active at the input of the phase comparator 2, and the pilot signal.
Moreover, the signal at the input 1 is applied to an input of a multiplier stage 6 in which it is multiplied with an output signal of the frequency divider 3 which is 90° shifted in phase with respect to the signal at the other output of the frequency divider 3. The multiplier circuit 6 supplies a voltage at its high-ohmic output, which voltage is proportional to the product of the input signals. This voltage thus comprises a component at twice the frequency of the pilot signal, as well as a DC component. The DC component charges a capacitor 7 connected to the output of the multiplier circuit 6, which capacitor 7 constitutes a pilot signal detector together with the multiplier circuit 6 and suppresses components of the double pilot signal frequency.
Thus, a direct voltage which is applied to a Schmitt trigger 8 is obtained at the capacitor 7. This trigger is constructed in such a way that it changes from a switching state for mono operation to a switching state for stereo operation when a pilot signal with a sufficient level is present. In its stereo operation the Schmitt trigger 8 turns on, i.e. switches into a conducting state a switching transistor 9 which controls an optical indicator, for example, in the form of a light-emitting diode 10 and which also controls over a mono/stereo switch which is not further shown, resulting in stereo reception when receiving a sufficiently strong stereo transmitter signal.
The circuit 1 . . . 10 described so far is known (compare, for example, the integrated circuit TDA 1578A of Valvo/Phillips). When weak mono transmitter signals are received, the PLL decoder 2 . . . 5 may lock in at frequency components of the noise in the input signal, which components fall within the lock-in range of the PLL circuit. The pilot signal detector 6, 7 may then relatively often supply an output signal which suffices to bring the Schmitt trigger 8 to its stereo switching state for a short time. Likewise, when a weak stereo transmitter is received, the ocsillator may lock in at frequency components which are present in the noise, which components deviate from the frequency of the pilot signal. The resultant phase variations lead to considerable fluctuations of the output voltage of the pilot detector 6, 7 so that the Schmitt trigger relatively often changes over to the mono switching state for a short time. The consequent continual variation of the indicator (light-emitting diode 10) and of the reception state (mono reception or stereo reception) is very disturbing to the user. It is substantially prevented by a control circuit 11.
In the case of a weak reception field strength this circuit ensures that the voltage at the pilot detector is decreased and that the Schmitt trigger is switched to or remains switched in the state for mono operation. It is controlled by the output signal of the Schmitt trigger 8 in such a way that it only becomes active when the Schmitt trigger 8 is in its state for mono operation and it evaluates the noise above the useful frequency range in the signal at the terminal 1.
The circuit comprises a DC source 12 whose direct current is directly applied to the emitter of a transistor 13 and to the emitter of a transistor 14 via a resistor 15. The bases of transistors 13 and 14 are connected to the input 1 via equal resistors 16 and 17, a capacitor 18 connected to the base of the transistor 14 constituting, together with the resistor 17, a low-pass filter which has a time constant of about 400 ns. The collector of a transistor 13 is connected to the input and the collector of the transistor 14 is connected to the output of a current mirror 19. The output of the current mirror is also connected to a transistor switch 20 which, in series with a limiter resistor 21, is arranged parallel to the capacitor 7. The terminal of the DC source 12 at the differential amplifier 13 . . . 15 is connected to the collector-emitter path of a switching transistor 22 whose base is connected to the output of the Schmitt trigger 8 via a limiter resistor 23.
If the Schmitt trigger 8 is in its switching state for mono operation, its output voltage, likewise as its input voltage is low, so that the transistor 22 is turned off and the current of the DC source 12 only flows via the transistors 13 and 14. However, if the Schmitt trigger is in its switching state for stereo operation, its output voltage is so large that the switching transistor 22 is turned on and the entire current of the DC source 12 is shunted to earth via this transistor. In this switching state for stereo operation the circuit 11 is inactive.
In the case of mono operation the base of transistor 14 receives the low frequencies, i.e. the entire useful frequency range of the multiplex signal. These frequencies naturally also appear at the base of transistor 13; but components of higher frequencies originating from the noise above the useful frequency range are additionally obtained. As long as the reception circumstances are satisfactory, the noise components are small and the bases of the transistors 13 and 14 essentially receive the same signal. Due to the DC voltage drop at the resistor 15 the base-emitter voltage of the transistor 14 is smaller than that of the transistor 13 and consequently the collector current of the transistor 13 is larger than that of the transistor 14. As a result, the current at the output of the current mirror 19 is larger than the collector current of the transistor 14 and the transistor switch 20 connected to the output of the current mirror 19 is blocked.
Relatively large noise signals in the range above the useful frequency are obtained in the case of weak transmitted. If the amplitudes of these noise components of the frequency f exceed a threshold value U, for which the relation holds that
U=0.5IR(1+(f.sub.g /f).sup.2).sup.1/2
in which I is the direct current supplied by the source 12, R is the value of resistor 15 and f g is the 3 dB cut-off frequency of the low-pass filter 17, 18, the current supplied by transistor 14 may become larger than the current of the transistor 13 for a short time. In fact, the noise components at the base of transistor 13 are then larger than the DC voltage drop at resistor 15 so that the positive noise voltage peaks can render the base-emitter voltage of the transistor 13 smaller than the base-emitter voltage of the transistor 14 for a short time. During these peaks the collector current of the transistor 14 is larger than the output current of the current mirror 19 and the switching transistor 20 is switched in its conducting mode, i.e. it is turned on. With respect to transistor 20 the circuit 12 . . . 19 thus operates as a high-pass filter succeeded by a rectifier.
If the transistor 20 is turned on, the capacitor 7 is discharged via the series arrangement of the limiter resistor 21 and the transistor 20, the discharge current being essentially larger than the current which the multiplier stage 6 can supply for charging the capacitor.
The control circuit 11 cooperates with the stages 6 to 8 of the stereo decoder in the following manner:
In the case of strong mono signals the signal at the input 1 comprises at most very small components in the frequency range of the pilot signal. Consequently, the voltage at the capacitor 7 is only small and the Schmitt trigger 8 is in its switching state for mono operation so that the switching transistor 22 is turned off, or in other words blocked. The circuit 11 is then active, but the noise having a higher frequency is so weak that the collector current of the transistor 13 is always larger than that of the transistor 14. The transistor switch 20 is thus blocked and the voltage at the capacitor 7 only depends on the input signals of the multiplier stage 6.
If the reception field strength of a transmitter transmitting mono signals becomes weaker, the noise components will become larger, both in the frequency range of the pilot signal and above the useful frequency range. The increase of noise components in the frequency range of the pilot signal results in a fluctuation of the signal supplied by the multiplier stage 6, which fluctuation may become so large that the voltage at capacitor 7 could switch over the Schmitt trigger 8 for a short time if there were no control circuit 11. However, since the peaks of the noise components having a higher frequency turn on the switch 20 in this state of reception, the capacitor 7 is discharged so that such a switch-over is prevented.
When receiving a strong stereo transmitter, the mutliplex signal at the input 1 continually comprises a relatively strong pilot signal component at which the PLL circuit 2 . . . 5 locks in so that the capacitor 7 is charged to a voltage which exceeds the threshold value of the Schmitt trigger 8 so that this Schmitt trigger changes over to the switching state for stereo operation. As a result, the transistor 22 is turned on and the circuit 11 becomes inactive. When receiving stereo transmitters having a small field strength, the pilot signal amplitude decreases and the noise increases. The output signal of the multiplier stage 6 than fluctuates to a considerable extent and may become so small for a short period that the Schmitt trigger 8 switches over. As a result, the transistor 22 is turned off and the control circuit 11 becomes active. The noise components having a higher frequency then ensure that the transistor 20 is turned on so that the capacitor 7 is discharged to such an extent that the Schmitt trigger constantly remains in its switching state for mono operation at this field strength or at field strengths which are still small. If the reception field strength subsequently increases again--and the noise components accordingly decrease again--to such an extent that the transistor 20 is substantially no longer turned on, the capacitor 7 may be charged to a value at which the Schmitt trigger swtiches over to stereo. However, this field strength is larger than that at which it necessarily changes over from stereo operation to mono operation. The circuit 11 therefore also has a hysteresis effect.
The pilot signal detector may be replaced by another circuit which is responsive to components in the input signal at the frequency of the pilot signal and which generates an output signal which is dependent on their amplitude. It is only essential that the control circuit influences this output signal or the input signal of the Schmitt trigger in such a way that the Schmitt trigger remains in the state for mono operation in the case of strong noise. | Stereo receiver circuit for processing a multiplex signal comprising a pilot signal by means of a pilot signal detector which detects frequency components in the multiplex signal at the frequency of the pilot signal and which controls a Schmitt trigger for influencing the mono/stereo operation, said circuit also comprising a control circuit capturing the noise components in the multiplex signal and acting on the Schmitt trigger. To prevent the Schmitt trigger from switching between the state for mono operation and the state for stereo operation in the case of weak reception field strengths, the control circuit is only active in mono operation and influences the input signal of the Schmitt trigger in the case of reception of sufficiently strong noise components to such an extent that the Schmitt trigger remains in its switching state for mono operation. | 7 |
BACKGROUND
The present invention relates to systems for transporting and delivering ice particles at high velocity onto a workpiece for cleaning or other treatment of the workpiece.
It is commonly known to blast a workpiece with a particulate abrasive that either melts or sublimes at room temperature for cleanly dissipating the abrasive subsequent to its use, thereby avoiding contamination of the workpiece or its environment. The abrasive can be frozen water, typically called "ice", solid carbon dioxide, typically called "dry ice", or combinations comprising one or both of these materials. One well known process for forming the particulate as dry ice is disclosed in U.S. Pat. No. 4,389,820 to Fong et al, wherein liquid CO 2 is dispensed and frozen in a snow chamber, the snow falling into a planetary extruder die mechanism where it is compacted into pellets by being forced through radial holes of a ring-shaped die, the length of the pellets being defined by structure that fractures the material by partially blocking the exit paths from the die. The pellets can be dispensed directly upon formation or they can be stored and/or transported for use upon demand in a hopper or the like. Among the problems in this art are the following:
1. The size of the particles greatly affects blasting quality and efficiency, large particles being desirable for breaking through crusty contamination of the workpiece, smaller particles being needed for reaching small features of the workpiece, and different mixes of sizes are needed for many jobs;
2. It is more difficult to make small pellets than big ones;
3. It is difficult and expensive to adjust the particle size by changing the diameter of the pellets, in that the die is difficult to replace and the multiplicity of radial holes are expensive to produce;
4. Although some adjustment in particle size is possible by changing the length between fractures of the emerging material, the length must be maintained at near twice the diameter for uniform particle size-shortening the distance between the fractures produces greater relative variation in the length of the pellets, and attempts to make the length very short seriously degrades the integrity of the particles while subjecting the die to clogging;
5. The particles are subject to degradation by subliming, by melting, and by abrasion or pulverization during transport to the workpiece, these mechanisms having increasingly adverse effects as the particle size is reduced; and
6. The delivery of particles at very low temperatures rapidly cools the workpiece, often with undesirable effects. For example, when the workpiece is cooled below the dew-point, moisture collects thereon subsequent to the treatment, the moisture tending to attract other contaminants and thereby defeating the purpose of the treatment.
Thus there is a need for a delivery system for hygroscopic or deliquescent particulate that delivers the material at high velocity and low temperature with precise control of particle size distribution. There is a further need for such a blasting system that avoids excessive cooling of the workpiece without degrading the particulate.
SUMMARY
The present invention meets this need by providing an apparatus for treatment of a workpiece by blasting same with sublimable particles. In one aspect of the invention, the apparatus includes a source of the particles; a nozzle unit spaced from the source and having a gas inlet for receiving a high pressure gas, and a particulate inlet for receiving the particles and in fluid communication with a material outlet, a nozzle outlet in fluid communication with the gas inlet being located downstream of the material outlet; transport means for transporting the particles from the source to the particulate inlet of the nozzle unit; divider means proximate the particulate inlet of the nozzle unit for splitting at least a portion of the particles, whereby the average volume of the particles is reduced from an incoming first average volume per particle to a second average volume per particle, the second average volume being less than approximately the first average volume; and accelerator means in the nozzle unit for accelerating the particles to high velocity in response to the high pressure gas.
In another aspect of the invention, the apparatus includes the source of the particles, the nozzle unit, the transport means, the accelerator means, and heater means for heating the high pressure gas, whereby the particles are delivered from the nozzle in a stream of outlet gas, the outlet gas having a gas temperature at the nozzle outlet, the gas temperature being at least 20° C. above the particle temperature for limiting heat removal from the workpiece.
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 pictorial diagram of a particulate delivery system according to the present invention;
FIG. 2 is a plan view of a test workpiece for the system of FIG. 1;
FIG. 3 is a graph showing the temperature drop of the workpiece of FIG. 2 when subjected to blasting by the system of FIG. 1 in alternative modes of operation, and at different rates of progression of the blasting;
FIG. 4 is a lateral sectional view of a portion of the system of FIG. 1;
FIG. 5 is an axial sectional view of the system of FIG. 1 on line 5--5 of FIG. 4;
FIG. 6 is a lateral sectional detail view of the system of FIG. 1 on line 6--6 of FIG. 4;
FIG. 7 is a graph showing test results relating particle size and velocity at constant blasting pressure;
FIG. 8 is a pictorial diagram in the orientation of FIG. 5 showing an alternative configuration of the system of FIG. 1;
FIG. 9 is a pictorial diagram as in FIG. 8, showing another alternative configuration of the system of FIG. 1; and
FIG. 10 is a detail pictorial diagram showing an alternative configuration of a nozzle portion of the delivery system of FIG. 1.
DESCRIPTION
The present invention is directed to a system for controlled discharge and delivery of a particulate medium at low temperature and high velocity for treating a workpiece. With reference to FIG. 1 of the drawings, a particulate blasting system 10 includes a hopper 12 for receiving a quantity of a particulate media 14, the hopper 12 having a bottom hopper outlet 16 that is connected through a hopper valve 17 to a closed, downwardly directed hopper passage 18. The passage 18 leads to a material inlet 20 of feeder means 22 for controllably feeding the media 14 from the hopper 12 in response to gas pressure at a gas inlet 24 of the feeder means 22, the media 14 being transported along with the gas through a material conduit 26 for producing a particulate stream 28 from nozzle means 30, the nozzle means 30 accelerating the media 14 as further described below. A main passage 32 connects the gas inlet 24 of the feeder means 22 through a main or feed valve 33 to a suitable source of compressed air or other gas (not shown). A pressure regulator or adjustment valve 34 is interposed between the feed valve 33 and the source of gas for providing a suitable gas pressure at the gas inlet 24 and a corresponding rate of flow of the media 14.
Also shown in FIG. 1, is a bypass passage 36 having a bypass valve 38 for selectively pressurizing the hopper passage 18 as more fully described U.S. Pat. No. 5,071,289 which is assigned to the assignee of this application and incorporated herein by this reference, whereby gas momentarily flows upwardly through the hopper outlet 16 into the hopper 12, and downwardly into the material inlet 20 of the feeder means 22 for avoiding blockages of the media 14. It will be understood that the details of the feeder means 22, and the means for supplying the pelletized media 14 are not critical, being outside the scope of the present invention.
The feed valve 33 is connected for selectively opening the main passage 32 to the gas inlet 24 of the feeder means 22 in response to a transport signal 40 from suitable control means 42, the control means 42 being responsive to a dispenser signal 44 from a dispenser switch 46, the dispenser switch 46 being located for convenient operator control on the nozzle means 30, as described further in the above-referenced copending patent application.
According to one aspect of the present invention, a blast conduit 48 is fluid-connected between the main passage 32 and the nozzle means as further described below, and having heater means 50 series-connected therein for heating gas that flows therethrough to the nozzle means 30, the gas from the blast conduit 48 accelerating to high velocity the particulate media 14 that is delivered to the nozzle means 30 through the material conduit 26. The use of a blast conduit separate from the material conduit 26 for accelerating the media 14 is known in the art and further described in the above-referenced U.S. Pat. No. 4,389,820 to Fong et al. The heater means 50 is particularly effective in highly concentrated blasting of very cold particulate for reduced cooling of the workpiece, without producing excessive heating of the media 14. In an exemplary configuration of the apparatus 10, a 9 kW circulation heater suitable for use as the heater means 50 and having conventional male 21/2 NPT inlet and outlet passage connections is available as Model CBLNA47Gnn from Watlow, Inc. of St. Louis, Mo., wherein nn is a voltage code (10 is 240 volt/1 phase; 3 is 240 volt/3 phase).
As more particularly shown in FIG. 1, the nozzle means 30 includes a material inlet 30a and a material outlet 30b for receiving and passing the particles 14 from the material conduit 26 to a nozzle outlet 30c, a gas inlet 30d for receiving high pressure gas from the blast conduit 48, a venturi member 30e together with the high pressure gas accelerating the particles between the material outlet 30b and the nozzle outlet 30c.
As further shown in FIG. 1, an exemplary configuration of the apparatus 10 includes a comminutor 52 for fracturing a controllable portion of the pelletized media 14, thereby delivering a greater number of smaller particles to the nozzle means than are transmitted by the feeder means, as further described below, the comminutor 52 is connected by a short coupling 54 to the material inlet 30a of the nozzle means 30. The present invention provides the advantages of cold particulate delivery in the presence of heated gas for reduced cooling of the workpiece, but without the harmful effects of excessive heating of the media 14, because the heated gas comes into contact with the media 14 only during the final acceleration of the media 14 from the nozzle means 30.
With further reference to FIGS. 2 and 3, preliminary testing of the apparatus 10 as shown in FIG. 1 but without the comminutor 52, has been conducted, the nozzle means 30 being directed onto a test workpiece 60 having a temperature sensor 62 centrally located thereon. The workpiece 60 was formed from a sheet of 2219 T87 aluminum alloy having a thickness of 0.080 inch, a length PL of 12 inches and a width PW of 12 inches. The stream 28 was advanced at constant rates of 1, 2, and 3 inches per second lengthwise across a laterally centrally located blasting path 64 opposite the sensor 62, the path 64 having path width BW of approximately 4 inches, the temperature drop ΔT being measured at the sensor 62 by suitable means (not shown), the results being presented in FIG. 9 by sets of plotted curves 64.
The testing was done at a constant pressure of approximately 240 psi at the main passage 32, with a flow rate of the dry ice media 14 between approximately 475 and approximately 500 pounds per hour. As shown in FIG. 9, a first set of the curves 64x, designated 64ax and 64bx, represents the cooling of the workpiece 60 with the heater means 50 inoperative, a second set of the curves 64o, designated 64ao and 64bo, representing the cooling with the heater means 50 operating at 9 kW input and raising the temperature of the gas from the blast passage 48 by approximately 80° F., from about 85° F. to about 165° F. Of the curves 64x and 64o, a pair 64ax and 64ao represent a maximum depression in the temperature of the workpiece 60 at the sensor 62, data points being indicated by "x" for the curve 64ax and by "◯" for the curve 64ao. The remaining pair of the curves, designated 64bx and 64bo, represent the time history of the measured temperature from a start of the blasting at one edge of the workpiece 60 until after an end or stop of the blasting at the opposite edge of the workpiece 60.
As shown in FIG. 9 by the curves 64ax and 64ao, operation of the apparatus 10 with the heating means 50 activated significantly limits the maximum temperature drop ΔT of the workpiece 60. In particular, the maximum temperature drop ΔT was nearly 75° F. with the heater means 50 inactive at the 1 inch per second blasting rate, but ΔT was limited to approximately 35° F. with the heater means 50 activated as described above. Further, the maximum temperature drop ΔT was cut to approximately half or less at each of the rates 1, 2, and 3 inches per second when the heater means 50 was activated. In these tests, no significant degradation of the effectiveness of the blasting for cleaning the workpiece 60 was observed.
According to the test results, activation of the heater means 50 was effective for preventing or severely limiting the collection of moisture on the workpiece, in that the workpiece was kept well above the dew-point temperature (which is reached at ΔT ≧about 32° F.) at the blast rates of 3 and 2 inches per second. Even at the 1 inch per second rate, the temperature only momentarily approached or reached the dew-point, as compared with a period of several seconds during which the sensor 62 recorded temperatures significantly below the dew point when the heater means 50 was inactive.
With further reference to FIGS. 4-6, an exemplary and preferred configuration of the comminutor 52 includes a cylindrically tubular housing 70 having a plurality of blade members 72 transversely supported therein in an axially spaced, angularly staggered relation, each of the blade members 72 protruding opposite sides of the housing 70, opposite end portions thereof being clinched over as indicated at 74 for anchoring the blade members 72 in place. As shown in FIG. 4, the blade members 72 are axially spaced by a longitudinal spacing S and a corresponding center distance C. As also shown in FIG. 5, the blade members 72 are uniformly angularly spaced by an angle φ about a centrally located comminutor axis 76 of the housing 70. In the exemplary configuration of FIGS. 4-6, adjacent ones of the blade members 72 are angularly offset by the angle φ.
As best shown in FIG. 6, a preferred cross-sectional configuration of the blade members 72 is longitudinally elongated to a length L, having a reduced lateral thickness T between front and rear wedge-shaped extremities 78, designated front extremity 78a and rear extremity 78b. The front extremity 78a is configured for cleanly slicing or fracturing incoming pellets of the media 14, each of the extremities 78 also being configured for minimally affecting the flow of gas through the housing 70. As further shown in FIG. 6, the front extremity 78a forms a leading apex angle A that is preferably less than about 30°. A particularly advantageous configuration of the front extremity 78a is provided by conventional stainless steel razor blade inserts, the angle A being approximately 10°.
The conventional razor blade technology can be utilized by shearing or breaking long hardened and sharpened strips of the stainless steel to an appropriate length for protruding the housing 70. Rather than by bending the end extremities 74 as shown in FIGS. 4-6, the blade members 72 can be retained by a suitable epoxy, or by a ring member that is slipped over the housing 70.
The number of the blade members 72 and the angle φ by which the blade members 72 are uniformly spaced about the comminutor axis 76 is selected for concentrating the particle size of the media 14 that is delivered to the nozzle means 30 in a desired range. More importantly, a desired mix of the particle sizes is obtained by first forming the pelletized media relatively large, such as having a diameter of approximately 0.125 inch and a length of approximately 0.31 inch. When it is desired to have all of the particles be smaller, the housing 70 is provided with a full complement of the blade members 72. When a concentration of the small particles is to be mixed with a proportion of the larger undivided pellets, some of the blade members are removed from the housing 70 (or another of the comminutors 52 so configured is substituted), two or more of the blade members 72 being adjacently spaced by the angle φ. Thus a greater number of the full complement of the blade members produces a mix having a smaller proportion of the full-sized pellets, and vice-versa. Moreover, the size of the smaller particles is controlled by selecting the angle φ. One way to do this is by omitting alternate ones of the blade members 72, thereby doubling the angle φ. Another way is by substituting for the housing 70 another that is made for the desired angle φ.
As discussed above, it is believed that the net blasting effectivity at a given flow rate of the media 14 is enhanced by having a greater number of smaller particles. Tests have been conducted for confirming the advantages of utilizing reduced particle size, using a Laser Grey Probe System from Particle Measurement Systems of Boulder, Col. The tests were conducted for the purpose of correlating the particle size with the velocity of the delivered particles, in an effort to relate the total momentum of the delivered particles with the particle size at constant delivery rate and blast pressure.
Silhouette images of the particles as they crossed the instrument view area were measured: the width to represent particle size and length to represent particle velocity. Approximately 70 images of CO 2 pellets were measured. From these measurements, a pellet size was developed by multiplying the image length by the width, the product being taken to the 1.5 power for representing a 3-dimensional volume. The length measurement was also multiplied by 300 (a nominal maximum velocity setting of the instrument), this product being divided by the width. A calculation was then made for predicting the pellet velocity for various pellet sizes, at a drive pressure of 73 psia for comparison with the test data, the calculated data being presented below in Table 1. Table 1 includes calculated values of kinetic energy per particle size, the number of particles in a given total volume of the media 14, and the cumulative energy for that number of particles of each size. As shown in Table 1, the cumulative kinetic energy (which is believed to be a measure of blasting effectiveness for some coatings or contaminants) increases as the particle size decreases, according to the calculations. The velocity data from the measurements was averaged, within size increments, and is tabulated below in Table 2, a scale factor of 1.28 being used for providing an equivalent pellet size, the data being plotted in FIG. 7.
TABLE 1______________________________________Calculated Cumulative Nozzle Impact Energy Kin. En.Length Velocity Mass Per No. of Cumulative(in.) (ft./sec.) (× 10.sup.-6) Particle Particles Kin. En.______________________________________0.025 505.4 0.517 .066 4009 264.590.050 405.4 1.033 .085 2005 170.430.075 355.2 1.550 .098 1336 130.930.100 319.3 2.067 .105 1002 105.210.125 296.0 2.583 .113 802 90.630.150 275.5 3.100 .118 668 78.820.175 260.2 3.617 .122 573 69.910.200 248.2 4.133 .127 501 63.630.225 237.1 4.650 .131 445 58.30______________________________________
TABLE 2______________________________________Reduced DataSize Equivalent Average(L × W) 1.5 Length Velocity______________________________________.000-.010 .006 476.010-.020 .019 459.020-.030 .032 453.030-.040 .045 417.040-.050 .058 382.050-.060 .070 365.060-.070 .083 346.070-.080 .096 268.080-.090 -- --.090-.100 .122 355.100-.110 .134 280.110-.120 -- --.120-.130 .160 262______________________________________
As shown in FIG. 7, there is good correlation between the calculated values and the reduced data for particle sizes between 0.03 and 0.15 inches. An experimental prototype of the comminutor 52 has been built in the configuration of FIGS. 4 and 5, but substituting 0.045 inch diameter stainless steel wire for the blade members 72, the spacing C being approximately 0.125 inch, the angle φ being approximately 22.5°. In preliminary testing of the apparatus 10 having the experimental comminutor 52, significantly improved blasting effectiveness was observed with certain coatings of the workpiece, particularly enamels.
Thus the comminutor 52 of the experimental configuration provides improved blasting effectiveness in the system 10. Greater improvement is expected with use of the blade members 72 configured as shown and described above in FIG. 6.
With further reference to FIGS. 8 and 9, alternative configurations of the comminutor 52 have at least some of the blade members 72 laterally displaced from the comminutor axis 76. As shown in FIG. 8, the blade members 72 form a five-sided star-shaped pattern when viewed from one end of the housing 70. Alternatively, and as shown in FIG. 9, the blade members 72 form an eight-sided star-shaped pattern.
The comminutor 52 can be coupled to the nozzle means 30 by a conventional quick-release coupling. Alternatively, the comminutor 52 can be built into the nozzle means 30 as shown in FIG. 10.
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. For example, other heater power ratings and power settings can be used. Therefore, the spirit and scope of the appended claims should not necessarily be limited to the description of the preferred versions contained herein. | A system (10) for delivering a cold particulate material (14) has a closed storage hopper (12) for the material, the hopper having a bottom hopper outlet (16); a venturi feeder (22) having a material inlet (20) for feeding the material, a material conduit (26) to a remote nozzle (30), and a gas inlet (24); a hopper passage (18) connecting the hopper outlet to the feeder material inlet; a gas feed valve (33), the gas feed valve being openable in response to a feed signal (40) for activating the feeder and a blast conduit to the nozzle; a heater (50) in the blast conduit for limiting cooling of a workpiece without adversely heating the material; and a comminutor (52) in the material line proximate the nozzle for delivery of the material at reduced particle size to the nozzle for increased blasting effectiveness. | 1 |
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